Worcester Greenstar Ri User manual

THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS: 24Ri GC NUMBER 41-311-65
18Ri GC NUMBER 41-311-77
15Ri GC NUMBER 41-311-75
12Ri GC NUMBER 41-311-63
LIQUID PETROLEUM GAS: 24Ri GC NUMBER 41-311-66
18Ri GC NUMBER 41-311-78
15Ri GC NUMBER 41-311-76
12Ri GC NUMBER 41-311-64
GB/IE
CHECKLIST & service
interval record is printed at the rear of
this manual

INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
8 716 109 699a (05/05)
1
WORCESTER BOSCH:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARD:
TOWER FLUE COMPONENTS
VALE RISE
TONBRIDGE
TN9 1TB
TEL: [phone]
www.tfc-group.co.uk
PLEASE READ THESE 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 THE WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER
BOSCH.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED BENCHMARK CHECK-
LIST (OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813 EIRE ONLY) AND USER
GUIDE WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR
SERVICING.
NOTE: THE BENCHMARK CHECKLIST & SERVICE INTERVAL RECORD CAN BE FOUND
AT THE REAR OF THESE INSTRUCTIONS.
ABBREVIATIONS USED IN THIS MANUAL:
Ø 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
CONTACT INFORMATION INSTALLATION & SERVICING INSTRUCTIONS
SYMBOLS USED IN THIS MANUAL:
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
• When lifting the boiler, bend the knees,
and keep the back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry the boiler close to the body
• Wear protective clothing and gloves to
protect from any sharp edges
STORE THE APPLIANCE IN A DRY
AREA PRIOR TO INSTALLATION.

SAFETY & REGULATIONS
SAFETY PRECAUTIONS & SYMBOLS 3
INSTALLATION REGULATIONS 3
APPLIANCE INFORMATION
GENERAL INFORMATION 4
TECHNICAL DATA 5
LAYOUT & COMPONENTS 6
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 7
MAINS SUPPLY 8
WATER SYSTEMS & PIPEWORK 9
CONDENSATE PIPEWORK 10
BOILER LOCATION & CLEARANCES 11-12
PLUMBING MANIFOLD 13
FLUE TERMINAL POSITIONS 14
FLUE OPTIONS 15
INSTALLATION
UNPACKING THE BOILER 16
WALL MOUNTING PLATE / FLUE OPENING 17
OUTER CASE REMOVAL 18
BOILER CONNECTIONS (GAS/WATER) 19
FLUE INSTALLATION 20-22
CONDENSATE CONNECTIONS 23
ELECTRICS 24
POSITION OF WIRED COMPONENTS 25
COMMISSIONING
PRE-COMMISSIONING CHECKS 26
FILLING THE SYSTEM 27
STARTING THE APPLIANCE 28
WATER TREATMENT 29
COMMISSIONING 30
FINISHING COMMISSIONING 31
SERVICING & SPARES
INSPECTION AND SERVICE 32-37
SETTING THE GAS / AIR RATIO 38-39
REPLACEMENT OF PARTS 40-44
SHORT PARTS LIST 45
CONVERSION KITS
GAS. CONVERSION 46
FAULT FINDING & DIAGNOSIS
ELECTRICAL WIRING DIAGRAM 47
FAULT FINDING 48
MAIN FUNCTION 49
BENCHMARK CHECKLIST & SERVICE RECORD SHEET PRINTED AT THE REAR OF THE
MANUAL
CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
FAULT FINDING
& DIAGRAMS

SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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SAFETY &
REGULATIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
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
A Benchmark Checklist 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).
COMBUSTIBLE 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, 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 current Gas Safety (Installation and Use)
Regulations.
Flue systems must not be modified in any way other than as described in the fitting
instructions. Any misuse or unauthorised modifications to the appliance, flue or
associated components and systems could invalidate the warranty. The manufacturer
accepts no liability arising from any such actions, excluding statutory rights.
SERVICING
Advise the user to have the system serviced annually by a competent, qualified
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 on the
Benchmark Checklist after each service.
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, 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) 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
pipework up to 28mm (R1)
BS5546 : Installation of gas hot water supplies for
domestic purposes
EN:12828 : Central heating for domestic premises
BS5440:1 : Flues and ventilation for gas appli-
ances of rated heating not exceeding 70kW (net) :
Flues
BS5440:2 : Flues and ventilation for gas appli-
ances of rated heating not exceeding 70kW (net) :
Air Supply
BS7593 : Treatment of water in domestic hot
water central heating systems
BS 6798 : 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 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 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.
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.

GENERAL INFORMATION
STANDARD PACKAGE:
A - Wall hung gas fired condensing boiler for
central heating and indirect domestic hot water
B - Wall plate
C -Hardware literature pack
D - Tail pipes - water
E - Bottom Panel
SPECIFICATIONS:
Pre-wired and pre-plumbed
Galvanised steel inner frame
Digital 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
External pump anti-seizure protection
Flue gas temperature limiter
Condensate trap & syphon
600mm
390mm
A
B
C
D
E
270mm
GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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APPLIANCE
INFORMATION

TECHNICAL DATA
Central Heating
Max. rated heat output net 40/30°C KW 12.85 16.06 19.28 25.67 12.85 16.06 19.28 25.67
Max. rated heat output net 50/30°C KW 12.74 15.92 19.11 25.45 24.74 15.92 19.11 25.45
Max. rated heat output net 80/60°C KW 12.0 15.0 18.0 24.0 12.0 15.0 18.0 24.0
Max. rated heat input net KW 12.32 15.40 18.48 24.62 12.32 15.40 18.48 24.62
Max. flow temperature °C 82 82 82 82 82 82 82 82
Max. permissable operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m3/h 1.3 1.63 1.96 2.6 - - - -
Propane Gas (LPG) kg/h - - - - 0.96 1.20 1.44 1.91
Flue
Flue Gas Temp. 80/60°C, rated min. load °C 62/56 66/58 70/60 78/63 62/57 66/59 71/61 79/64
Flue Gas Temp. 40/30°C, rated min. load °C 41/33 44/33 48/34 54/35 43/35 46/36 49/37 55/38
CO2level at max. rated heat output % 9.8 9.8 9.8 9.8 11.0 11.0 11.0 11.0
CO2level at min. rated heat output % 9.2 9.2 9.2 9.2 10.5 10.5 10.5 10.5
NOx - class 5 5 4 5 5 5 4 5
Condensate
Max. condensation rate l/h 0.93 1.2 1.5 2.0 0.7 0.9 1.2 1.5
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 50+pump 50 + pump 50 + pump 50 + pump 50 + pump 50 + pump 50 + pump 50 + pump
General Data
SEDBUK band A A A A A A A A
Appliance protection rating IP 20 20 20 20 20 20 20 20
Permissable ambient temperatures °C 0-50 0-50 0-50 0-50 0-50 0-50 0-50 0-50
Nominal capacity of appliance I 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1
Noise output level dB(A) 39 42.7 43.7 41 39 42.7 43.7 41
Packaged boiler weight kg 31 31 31 31 31 31 31 31
Total boiler weight kg 27.4 27.4 27.4 27.4 27.4 27.4 27.4 27.4
Lift weight kg 22.6 22.6 22.6 22.6 22.6 22.6 22.6 22.6
SEDBUK % 90.1 90.1 90.1 90.2 91.4 91.4 91.4 92.0
NATURAL GAS L.P.G.
DESCRIPTION UNITS 12Ri 15Ri 18Ri 24Ri 12Ri 15Ri 18Ri 24Ri
TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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APPLIANCE
INFORMATION

LAYOUT & COMPONENTS
The diagram opposite shows the controls in the
servicing position and excludes the outer case,
inner covers and fascia panel.
1 AIR / GAS MANIFOLD
2FAN
3 AIR / GAS ADJUSTMENT SCREW
4GASVALVE
5 INLET PRESSURE TEST POINT
6 BOILER POWER SWITCH
7 FLAME INDICATOR (GREEN)
8 COVER FOR EXTERNAL WIRING
CONNECTIONS
9 POWER AND FAULT INDICATOR (BLUE)
10 BOILER THERMOSTAT AND RESET KNOB
11 FLUE PRESSURE SWITCH
12 FAN PRESSURE TEST POINT
13 MANUAL VENT POINT
14 IGNITION AND FLAME SENSE ELECTRODES
15 OVER-HEAT THERMOSTAT
16 FLAME VIEWING MIRROR
17 SECURING NUT, AIR /
GAS MANIFOLD CLAMP
18 SENSOR - BOILER FLOW
19 FLUE AIR PRESSURE SWITCH
CONNECTION
20 FLUE OVERHEAT THERMOSTAT
21 ACCESS POINT FOR CLEANING HEAT
EXCHANGER
22 REMOVABLE TOP CASE PANEL FOR
SERVICING
23 GAS INLET CONNECTION 22mm
COMPRESSION
24 TRAP / SYPHON
25 TRAP / SYPHON OUTLET
CONNECTION ( 3/4”PLASTIC PIPE)
26 FLOW CONNECTION 22mm
COMPRESSION
27 DRAIN POINT
28 RETURN CONNECTION 22mm
COMPRESSION
29 HEAT EXCHANGER
30 GAS COCK (ACCESS POINT)
31 SILICONE TUBE (USE TO VENT AIR
FROM HEAT EXCHANGER)
LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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APPLIANCE
INFORMATION

CLEANING PRIMARY SYSTEMS
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:
1 Fill the system with cold water and check for
leaks.
2 Open all drain cocks and drain the system.
3 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.
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
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.
1
2
3
4
5
KEY
Valve
Flushing
Agent
CLEANING PRIMARY SYSTEMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION

MAINS SUPPLY
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz, 50 watts not including
pump.
• Cable: PVC insulated 0.75mm2(24 x 0.2mm)
temperature rated to 90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• All pipes to the boiler must be cross-bonded.
• Mains supply to the boiler and system wiring
centre must be through one common fused
double pole isolator situated adjacent to the
appliance.
• Wiring must comply with IEE wiring regulations
and any local regulations which may apply to
fixed wiring to a stationary appliance.
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 size of
the gas supply pipe be less than that of the
appliance inlet connection.
• The meter or regulator and pipework to the
meter 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. This does
not include the pipework from the meter to
the boiler.
MAINS SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION

WATER SYSTEMS & PIPEWORK
PLASTIC PIPEWORK & UNDER FLOOR
HEATING:
• Any plastic pipework must have a polymeric
barrier with 600mm (minimum) length of
copper or steel 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.
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.
• On new installations TRV’s must be used on
all radiators except where a room thermostat
is sited. On all installations they should at
least be fitted in the sleeping areas. See note
below on open radiator/bypass
• A drain cock is required at the lowest point
on the system.
• An air vent is required at the highest point on
the system.
S and Y PLAN SYSTEM:
• NB Generally a bypass is not nesessary on
a Y plan system as one of the ports is open
to flow.
A Static Head - Minimum static head 250mm
measured from the highest point in the heating
system (top surface of the appliance or highest
point in the heating system) to the water level in
the feed and expansion tank.
B Heating Vent (22mm minimum)
C Primary Cold Feed (15mm minimum)
D Diverter Valve and Zone Valves
E Pump
F Automatic Bypass
G Radiator Valve (Flow)
H Lockshield Valve (Return)
• NB A drain cock should be fitted at the
lowest point of the heating circuit and
beneath the appliance.
FULLY PUMPED SEALED SYSTEM:
• The CH sealed system must be filled using a
WRAS approved filling loop or comply with
the diagram opposite for System fill
• Do not use galvanised pipes or radiators.
I Expansion Vessel
J Pressure Guage
K Relief Valve
L Stop Valve Fixed Cylinder Type or sealed
systems approved connection
• NB A drain cock should be fitted at the
lowest point of the heating circuit and
beneath the appliance.
H
G
WATER SYSTEMS & PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING

CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION
CONDENSATE PIPEWORK
CONDENSATE PIPEWORK:
• The condensate pipe must be a minimum of
22mmØ plastic pipe.
•The condensate pipework must fall at
least 50mm per metre towards the outlet
and should take the shortest practicable
route.
• The pipework must follow one of the options
shown opposite into an internal serviceable
trap (min. 75mm) such as a sink/washing
machine waste or discharge direct into a vent
stack (E) 450mm min. above pipe invert, or
into a gulley (D) below ground but above the
water level.
•Use waterproof pipe insulation in exposed
positions and for external pipework.
1 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
B - Sink
C - 22mmØ plastic condensate pipe
D - Gulley
E - Internal soil and vent stack
F - Serviceable waste trap (75mm min)
G - 300mm x 100mmØ sealed plastic tube
H - Ground level
J - Drainage holes 50mm from base of tube
(12mmØ at 25mm centres) facing away from
building
K - Limestone chippings
IMPORTANT: Ensure there are no
blockages in the pipe run.

BOILER LOCATION & CLEARANCES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION
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 support-
ing 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 ancilliary
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 minimum
space required to install and service the boiler.
If a boiler is installed in a compartment with
clearances less than shown in the diagrams A
and B, ventilation is required. Refer to tables
below for ventilation requirements.
BOILER CLEARANCES - UNVENTILATED
COMPARTMENTS:
The diagrams (A and B) opposite show two
options for the minimum space required to
install and service the boiler inside an unventi-
lated compartment.
*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.
Ri
Vent To room or Direct to
position internal space outside
High Minimum free Minimum
level area 122 cm2free area
61 cm2
Low Minimum free Minimum
level area 122 cm2free area
61cm2
SERVICING CLEARANCES
VENTED COMPARTMENT
VENTILATION FREE
COMPARTMENTS
INSTALLATION CLEARANCES
Using 100mm flue kit
1080mm
Using 125mm flue kit
- 1110mm
A
B

BOILER LOCATION & CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION
BATHROOMS:
The boiler can be installed outside the shaded
areas shown opposite. (Zone 3 according to
IEE Wiring Regulations).
(See Technical Data for IP ratings.)
BOILER LOCATION &
CLEARANCES
IMPORTANT: any switch or appliance
control using 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.
11
23
2
3
11
23

PLUMBING MANIFOLD
CONNECTIONS:
Heating System: 22mm compression fittings*
Gas: 22mm
*Use the 22mm copper pipes provided with
the appliance.
Use the fittings supplied in the Lit/Hardware
pack.
• If the flow and return pipes are to be run
behind the appliance it maybe an advantage
to connect the pipes before hanging on the
wall especially if space is limited.
**
Return
Flow
Return
Flow
PLUMBING MANIFOLD INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION

FLUE TERMINAL POSITIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
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PRE -
INSTALLATION
FLUE TERMINAL POSITIONS
• 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. This could be a nuisance, for example,
near security lighting.
• 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 (minimum
50mm) around the flue and fixed to the wall
with plated screws.
See Contact Information (inside front cover).
Minimum dimensions of flue terminal positions for balanced room sealed flues with
fanned draught:
DRWG. TERMINAL POSITION DISTANCE
REF:
A1Directly below an opening, air brick, opening windows, etc. 300mm
B1Above an opening, air brick, opening window, etc. 300 mm
C1 Horizontally to an opening, air brick, opening window, etc. 300 mm
D Below gutters, soil pipes or drain pipes 75mm
E Below eaves 200mm
F2Below balconies or car port roof (lowest point) 200mm
G From a vertical drain pipe or soil pipe 150mm
H From internal or external corner or to a boundry alongside the terminal 300mm
I Above ground, roof or balcony 300mm
J From a surface or boundry facing the terminal 600mm
K From a terminal facing the terminal 1200mm
L2From 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 Horizontally from a terminal on the same wall 300mm
O From a non combustible vertical structure on the roof
P Above intersection with the roof
1 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 flue kits.
Care should be taken to ensure terminal siting
does not cause a nuisance to adjacent properties.
*
*
*
**
**
**

PRE -
INSTALLATION
FLUE OPTIONS
• The diagrams (opposite) show the
components used and the maximum flue
length for each configuration of 100mm and
125mm flues.
• Shaded flue components indicate the
standard 100mm 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 extension
kits.
• Horizontal 125mm and Vertical 100mm and
125mm flue kits are available with separate
instructions. Contact your supplier or
Worcester Bosch.
A - Standard horizontal flue (100mm diameter
shown)
B - Straight flue extension
C - Flue bend 90°
D - Flue bend, 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 60/100mm: 4600mm
Horizontal 80/125mm: 13000mm
Vertical 60/100mm: 6400mm
Vertical 80/125mm: 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 60/100mm: 960mm
Horizontal & Vertical 80/125mm: 1000mm
Flue Terminal lengths:
Horizontal 60/100mm: 800mm including terminal
Horizontal 80/125mm: 1200mm
Vertical 60/100mm: 1140mm to top of terminal
Vertical 80/125mm: 1365mm to top of terminal
STANDARD FLUE HORIZONTAL
Ø100
MAX 686 A x 1
MIN 250 A x 1*
Ø125
MAX 1070 A x 1
MIN 250 A x 1*
* Requires cutting
MAXIMUM FLUE HORIZONTAL
Ø100 - 4600mm
A x 1 + B x 5
Ø125 - 13000mm
A x 1 + B x 13
MAXIMUM FLUE VERTICAL START + 1 BEND
Ø100 - 4600mm
A x 1 + C x 1 + B x 5 +
Fx1
Ø125 - 13000mm
A x 1 + C x 1 + B x 13 +
Fx1
Ø100 - 2600mm
A x 1 + B x 3 + C x 1
Ø125 - 11000mm
A x 1 + B x 11 + C x 1
MAXIMUM FLUE HORIZONTAL + 1 BEND
MAXIMUM FLUE VERTICAL
START + 2 BENDS
Ø100 - 2600mm
A x 1 + C x 2 + B x 4 +
Fx1
Ø125 - 11000mm
A x 1 + C x 2 + B x 13 +
Fx1
Ø100 - N/A
Ø125 - 9000mm
A x 1 + C x 3 + B x 11 +
Fx1
MAXIMUM FLUE VERTICAL
WITH 2 x 45° BENDS
Ø100 - 4400mm
(including terminal)
B x 5 + D x 2 + E x 1
Ø125 - 13000mm
(including terminal)
B x 13 + D X 2 + E x 1
Ø100 - 2400mm
(including terminal)
B x 4 + C x 2 + E x 1
Ø125 - 11000mm
(including terminal)
B x 13 + C x 2 + E x 1
VERTICAL FLUE WITH
2 x 90° BENDS
A
A
B
A
B
F
C
A
B
C
F
B
C
A
F
B
C
A
E
B
D
E
B
C
MAXIMUM FLUE VERTICAL
START + 3 BENDS
FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
8 716 109 699a (05/05)
15

A - Straps
B - Outer carton
C - Base tray
D - Inner wrap and wall template
E - Wall mounting plate
F - Installer pack
G - Base Panel
H - 22mm pipes (2) (system flow and return)
IMPORTANT HANDLING INSTRUCTIONS
• It is advised that two people are used to carry
the carton from the van to the point of delivery.
• Once the carton has been delivered , the outer
carton is removed first. Care should be taken
when releasing the straps. If a sharp impliment
is used make sure the outer carton is not
peirced and that the impliment is used in such a
way so that it may not cause personal injury. All
sharp objects must be covered or the blade
retracted after use and put away in a safe
place. The wall mounting plate, the 2 X 22mm
pipes and the Lit/Hardware pack are now
removed making sure that no damage occurs to
the internal wrap which doubles as the Wall
Template. Care should be taken when lifting the
boiler from the base and the proper technique
for safe lifting of any heavy object should be
strictly observed.
Additional requirements for roof space
installation:
• The boiler should be first unpacked before
ascending ladder to loft space.
• Two sets of steps should be used.
• Two people should share the lifting of the
boiler up to the loft hatch, where the boiler is
entered into the loft space tilted and slid on its
back into the loft.
Once the appliance is removed from its
packaging check the contents against the
packing list.
Before installing appliance ensure system has
been cleaned as explained on page 8.
UNPACKING THE BOILER
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
• When lifting or putting things down, bend
the knees, and keep the back straight
and feet apart.
• Do not lift and twist at the same time.
• Lift and carry objects close to the body
IIMPORTANT: All the previous Pre-Installation sections must be read
and requirements met before starting boiler or flue installation.
E
F
NOTE:
Cardboard
inner wrap is
also the wall
template.
NOTE: Carefully cut along perferated line to
release wall template.
A
B
C
D
C
D
G
H
UNPACKING THE BOILER
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
8 716 109 699a (05/05)
16
INSTALLATION

SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
FIXING THE MOUNTING FRAME:
• The boiler template shows the relative
positions of the flue and pipes to the boiler.
Also clearances around the appliance.
Fix the template to the wall in the desired
position ( A).
Mark the clearance around the boiler and the
position of gas and system pipes ( 2) and
( 3).
Drill 4 holes for the wall mounting plate
through the template.
Drill 2 holes for bottom fixing screws.
Drill hole for flue duct through the wall.
NOTE: The template has been sized to allow for
minimum clearances of 5mm sides, 200mm
base and 30mm above a Ø100 flue elbow.
REAR FLUE OUTLET
• The drawing ( B ) opposite shows the boiler
template with the flue centre lines of both the
100mm and 125mm flue systems.
Mark centreline of flue to be used ( 1 ).
• If a Ø100mm diameter flue is to be used,
a125mm diameter hole is required. However, if
using the weather sealing collar by pushing it
through from inside the property, then a
150mm diameter hole is required to
accommodate this.
• The terminal section of the 100mm flue has an
inbuilt 3° angle.
If extensions are to be added then the complete
flue must rise at an angle of 3°.
• The 125mm Ø flue system will require the flue
to rise at an angle of 3°.
Drill hole using a core drill or similar.
SIDE OUTLET:
Mark from the centre line of the wall template
to the wall which the flue will pass through
( 4).
Allow for a rise of 52mm per metre length of
flue, to give a 3° angle.
Clear any debris from the site.
CAUTION: Ensure there are no pipes,
electric cables, damp proof courses or
other hazards before drilling.
X 6
X 6
10mm Ø
WALL MOUNTING PLATE
FLUE OPENING
127m m
WALL MOUNTING PLATE FLUE OPENING INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
8 716 109 699a (05/05)
17
INSTALLATIONCOMMISSIONING
A
B

1
2
3
4
B
A
OUTER CASE REMOVAL
REMOVING OUTER CASE
1. Undo and remove 2 screws (A) securing
boiler casing at the top of the appliance.
2. Undo the 2 captive screws (B) securing
boiler casing at the bottom of the appliance.
3. Pull case upwards.
4. Remove cardboard packing piece from
appliance.
With the outer case removed the
appliance is suitable for a 1 man lift (<25kg).
OUTER CASE REMOVAL
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
8 716 109 699a (05/05)
18
INSTALLATION

GAS AND WATER CONNECTIONS:
Remove template and secure the wall
mounting plate to the wall with the fixings
supplied.
• If there is greater than 600mm clearance
below the appliance it is possible to fit the flow
and return pipes, supplied, with the boiler
installed on the wall.
If clearance is less than 600mm below the
appliance it may be necessary to fit the flow
and return pipes before hanging the appliance.
A - flow (22mm)
B - return (22mm)
C - Gas inlet (22mm)
NOTE: The boiler is best lifted using the
handling holes either side of the unit. Do not
lift the boiler by the air gas manifold or control
box.
System pipes may be run vertically upwards
behind the boiler or below it.
NOTE: If pipes require reducing in length this
is best done before they are fitted to the
boiler.
Lift the boiler onto the wall plate and level
using the feet (D) at the bottom rear of the
boiler casing.
Fit retaining screws through the boiler frame
(E).
Make connections to the heating system
pipes.
Connect the gas supply to the boiler gas
cock 22mm compression fitting (pipe not
supplied).
BOILER CONNECTIONS
CAUTION: ISOLATE THE MAINS GAS
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
22mm Ø
22mm Ø
22mm Ø (Not supplied)
5mm
Pipes in alternative
position
A
B
AB
D
E
C
E
BOILER CONNECTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR Ri
8 716 109 699a (05/05)
19
INSTALLATION
Handling Holes
Do not lift by the
air gas manifold
Condensate outlet 112mm
A, B and C 18mm