WORCESTER GR2301iW Greenstar 2000 Combi Gas Boiler

Product Information

Specifications

• Product Name: Gas-fired condensing combi appliance Greenstar 2000 GR2301iW
• Model Number: 6721839340 (2023/06) UK

Explanation of symbols and safety instructions

Explanation of symbols

Warnings: In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing danger are not taken. The following signal words are defined and can be used in this document:

• DANGER: Indicates that severe or life-threatening personal injury will occur.
• WARNING: Indicates that severe to life-threatening personal injury may occur.
• CAUTION: Indicates that minor to medium personal injury may occur.
• NOTICE: Indicates that material damage may occur.

General safety instructions
Please read these instructions carefully before starting installation of this Installation manual.

Notices for the target group: These installation instructions are intended for gas, plumbing, heating, and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life. Read the installation, service, and commissioning instructions (heat source, heating controller, pumps, etc.) before installation. Observe the safety instructions and warnings. Follow national and regional regulations, technical regulations, and guidelines. Record all work carried out.

Intended use

The appliance may only be used for heating water or domestic hot water in domestic properties. Observe the details on the data plate and the specifications (installation manual) to ensure correct use of this appliance.

Product Usage Instructions

Installation and Maintenance Instructions
To install and maintain the Gas-fired condensing combi appliance Greenstar 2000 GR2301iW, please follow these steps:

1. Read the installation, service, and commissioning instructions provided in the manual.
2. Observe the safety instructions and warnings mentioned in the manual.
3. Follow national and regional regulations, technical regulations, and guidelines.
4. Record all work carried out during installation and maintenance.

Shutdown

To shut down the appliance, follow these steps:

1. Set frost protection to ensure the appliance is protected during cold temperatures.
2. Enable anti-seize protection to prevent any seizing issues with the appliance.

Fault Finding and Diagnosis
If you encounter any faults with the appliance, use the following information for diagnosis:

• Refer to the general information provided in the manual.
• Consult the fault code table for troubleshooting.
• Understand pump operation and diagnosis for further assistance.
• Note that some faults may not be displayed, so refer to the relevant section in the manual for guidance.

Environmental Protection and Disposal
Follow proper environmental protection and disposal procedures as outlined in the manual.

Data Protection Notice
Please refer to the Data Protection Notice section in the manual for relevant information.

FAQ

Q: What is the intended use of the Greenstar 2000 GR2301iW appliance?
A: The appliance is intended for heating water or domestic hot water in domestic properties.

Q: Who are the target audience for the installation instructions?
A: The installation instructions are intended for gas, plumbing, heating, and electrical contractors.

Q: What should I do if I encounter a fault with the appliance?
A: Refer to the fault finding and diagnosis section in the manual for troubleshooting guidance.

Installation and Maintenance Instructions
Gas-fired condensing combi appliance Greenstar 2000
GR2301iW
bar

Explanation of symbols and safety instructions

1 Explanation of symbols and safety instructions
1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken. The following signal words are defined and can be used in this document:
DANGER DANGER indicates that severe or life-threatening personal injury will occur.
WARNING WARNING indicates that severe to life-threatening personal injury may occur.
CAUTION CAUTION indicates that minor to medium personal injury may occur.
NOTICE NOTICE indicates that material damage may occur.
Important information

The info symbol indicates important information where there is no risk to people or property.

Additional symbols

Symbol · ­
Table 1

Meaning a step in an action sequence a reference to a related part in the document a list entry a list entry (second level)

1.2 General safety instructions
H Please read these instructions carefully before starting installation.
· 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 only and must be followed except for any statutory obligations.
· This appliance must be installed by a competent registered gas engineer, such as a Gas Safe registered engineer including a British Gas engineer. Failure to install correctly could lead to prosecution.
· If you are in any doubt, contact the Worcester, Bosch Group help line (0330 123 3366).
· Distance learning and training courses are available from Worcester. · The BENCHMARK Commissioning Checklist can be found on page 98
of this Installation manual.
HNotices for the target group These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life. Read the installation, service and commissioning instructions (heat
source, heating controller, pumps, etc.) before installation. Observe the safety instructions and warnings. Follow national and regional regulations, technical regulations and
guidelines. Record all work carried out.
H Intended use The appliance may only be used for heating water or domestic hot water in domestic properties.
Observe the details on the data plate and the specifications (installation manual) to ensure correct use of this appliance.
Worcester, Bosch Group offer flue gas systems which are suitable for use with the appliance. It is the responsibility of the installer of the flue to ensure this flue gas system operates correctly and in a safe manner.
HMisuse Appliance must be used as per the intended use statement. Operation outside the parameters of the intended use is considered misuse and could cause harm to people and damage to property.
Accessories should be as per accessories list. Minimum operational parameters are included in this document.
Using the appliance outside of its intended use may also invalidate the manufacturer’s guarantee.
HIf 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 or regulator. Open windows and doors. Warn your neighbours and leave the building. Prevent anyone from entering the building. Move well away from the building: call the National Gas Emergency
Service on 0800 111 999. L.P.G. boilers: Call the supplier’s number on the side of the gas tank.

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Greenstar 2000 ­ 6721839340 (2023/06)

H Risk to life from carbon monoxide poisoning.
There is a risk to life from escaping flue gases Do not modify the flue gas system. Ensure that flue pipes and gaskets are undamaged.
If flue pipes are damaged or leaking: Turn off and isolate the appliance. Open windows and doors. If necessary, leave the building and warn your neighbours. Prevent anyone from entering the building. Rectify any damage to the flue system immediately.
HInstallation and maintenance Installation and maintenance must only be carried out by a competent registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.
Carry out a gas tightness test after completing work on gas-carrying components.
Only use original spares.
HElectrical work Electrical work must only be carried out by a qualified electrician:
Before starting electrical work; ­ Ensure that the electricity supply is safely Isolated and secured to prevent inadvertent re-connection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85. ­ Using test equipment approved to GS38 to confirm that the electricity supply is disconnected. ­ Before touching live parts: Wait at least five minutes to discharge the capacitors.
Refer to the manufacturer’s information when installing non Worcester components and systems to the Worcester appliance.
HHandover to the user When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions.
Explain how to operate the heating system and draw the user’s attention to any safety relevant action.
In particular: ­ Advise that alterations, servicing and repairs must only be carried out by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. ­ Advise the user to have the appliance and system serviced annually to help ensure economy, safety and reliability. ­ The heat generator may only be operated with the casing fitted and closed.
Point out the possible consequences (including personal injury, danger to life and material damage) of improper or inadequate inspection, cleaning and maintenance.
Point out the dangers of carbon monoxide (CO) and recommend the use of CO detectors.
Leave the installation instructions with the completed Benchmark Checklist and the operating instructions with the user or at the gas meter.
HServicing Advise the user to have the appliance and heating system thoroughly serviced annually by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.
Approved spares must be used to help maintain the efficiency, safety and reliability of the appliance.

Explanation of symbols and safety instructions
HBenchmark Service Record The service engineer must complete the Benchmark Service Record at the back of this manual after each service.
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 manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit hhic.org.uk for more information.
HHealth 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).
HCombustion 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 warranty.
HFitting and modification 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.
H General manual handling guidelines Only remove packaging at the time of the final installation. Always use Health and Safety guidance for manual handling of an
appliance. ­ Never lift or carry more than the safe guidance limit on your own. ­ Always use appropriate methods and equipment when lifting/
carrying an appliance. Never lift or carry packages by the shipping straps. During handling and unpacking, wear safety gloves to prevent injuries
to your hands. Dispose of packing materials appropriately.
H Important handling instructions Care should be taken when transporting, lifting and carrying the appliance. Use a means of transport suitable for handling appliances (e.g. sack
truck with strap, stair climbing or step trolley). When handling appliances, secure them against a fall. Let only trained personnel undertake the handling. The correct method for handling heavy objects should be strictly
observed, at all times.

Greenstar 2000 ­ 6721839340 (2023/06)

5

Regulations

2 Regulations
Installation regulations Current Gas Safety (Installation and Use) Regulations:
All gas appliances must be installed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer in accordance with the current 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 Regulations (Wales) Building Standards (Scotland) (Consolidation) Health and Safety Document 635 (The Electricity at Work
Regulations 1989) and any other local requirements EU Regulations No. 2017/1369 – Energy Labelling (as retained in UK
law and amended) EU Regulations No. 811/2013 – Energy Labelling (as retained in UK
law and amended)
Building Regulations Part L1A (Current version) – new dwellings If the installation is in a new build property or it is a first time installation in an existing property, the heating systems must conform to current building regulations Part L1A.
The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling can be controlled as one zone.
An alternative would be individual electronically controlled TRVs. For dwellings with a floor area over 150m2, separate time and temperature control for each zone is required. It is best practice to fit Thermostatic Radiator Valves (TRV’s) to all radiators except the area where the room thermostat is sited.
Building Regulations Part L1B (Current version) – existing dwellings For appliance replacements on an existing system, it is not necessary to zone the upstairs and downstairs separately, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat.
While the system is drained down, it is best practice to fit Thermostatic Radiator Valves (TRV’s) to all radiators except the area where the room thermostat is sited.

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 pipework up to 28mm (R1) · BS5546
­ Installation of gas hot water supplies for domestic purposes · EN12828
­ Central heating for domestic premises · BS5440:1
­ Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net): Flues
· BS5440:2 ­ Flues and ventilation for gas appliances of rated heating not exceeding 70kW (net): Air Supply
· BS7593 ­ Treatment of water in domestic hot water central heating systems
· BS6798 ­ Installation of gas fired boilers of rated input up to 70kW (net)
· BS7671 ­ IET Wiring Regulations
LPG Installations An appliance using LPG must not be installed in a room or internal spacebelow ground level unless one side of the building is open to the ground.
Timber framed buildings Where the appliance 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.
Water supply: All seals joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must meet the requirements of the WRC and hold approval by a notified body, e.g. WRAS. The installation must also comply with the requirements of Part G of the Building Regulations.

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Greenstar 2000 ­ 6721839340 (2023/06)

Product Information

3 Product Information
Appliance features · Aluminium-silicon heat exchanger. · NOx emissions 40mg/kWh. · Direct burner ignition. · Zero pressure governor gas valve with fully modulating fan. · Display for appliance status and access to diagnostics, system and
commissioning parameters. · 1 hour memory retention after power interruption. · Low electrical power consumption in operation and stand-by modes. · Low energy modulating pump. · Condensing in CH and DHW modes. · DHW Eco mode, to use gas on demand. · Galvanised steel wall mounting bracket. · Compatible with Worcester standard and intelligent controls.
­ See accessories list for available controls. · Condensfit II flue systems 60/100 and 80/125 mm allows plume re-
direction. · Condensfit II flue systems 60/100 allows the ability to attach plume
management kit. · Front accessible components for maintenance. · Quick Tap water saving function.
CH Water Salt based artificially softened water must not be used to fill the central heating system.

3.1 Scope of delivery
1
2
3
4
5
6
7
8
9
10
11
0010043701-001
Fig. 1 [1] Wall mounted gas-fired condensing combi appliance. [2] Wall mounting bracket. [3] Fittings pack. [4] Condensate hose connector. [5] Valves set. [6] Compression fittings set. [7] Literature pack:
­ Installation and Maintenance Instructions, ­ User Instructions, ­ Wall mounting template. [8] Guarantee card. [9] ErP label. [10] PRV compression elbow. [11] Side panel infills.
3.2 Declaration of Conformity The design and operating characteristics of this product comply with the British, European and supplementary national requirements.
The UKCA and CE markings declare that the product complies with all the applicable British and European legislation, which is stipulated by attaching these markings. You can request the complete text of the Declaration of Conformity from the UK address indicated in this document.
3.3 Simplified UK/EU Declaration of conformity regarding radio equipment
Bosch Thermotechnik GmbH hereby declares, that the product Greenstar 2000 described in these instructions complies with the Directive UK S.I. 2017/1206 (UK) 2014/53/EU. You can request the complete text of the UK/EU Declaration of Conformity from the UK address indicated in this document.

Greenstar 2000 ­ 6721839340 (2023/06)

7

Product Information

3.4 Regulations In order to ensure installation and operation of the product in accordance with the regulations, please observe all the applicable national and regional regulations as well as all technical rules and guidelines.
You can find a list of the most relevant British and European directives and regulations in the table below.

EU legislation

UK legislation

Electromagnetic Compatibility – Electromagnetic Compatibility

Directive 2014/30/EU

Regulations 2016

Low Voltage Directive 2014/35 Electrical Equipment (Safety) Regulations 2016

Radio Equipment Directive 2014/53/EU

Radio Equipment Regulations 2017

Pressure Equipment Directive 2014/68/EU

Pressure Equipment (Safety) Regulations 2016

Gas Appliances Regulation (EU) 2016/426

Regulation 2016/426 on gas appliances as brought into UK law and amended

Machinery Directive 2006/42/EC Supply of Machinery (Safety) Regulations 2008

Ecodesign Directive 2009/125/ The Ecodesign for Energy-Related

EC

Products Regulations 2010

Energy Labelling Regulation (EU) Energy Labelling Regulation (EU)

2017/1369

2017/1369 (as retained in UK law

and amended)

Restriction of the Use of certain The Restriction of the Use of

Hazardous Substances in Eletrical Certain Hazardous Substances in

and Electronic Equipment (RoHS) Eletrical and Electronic Equipment

– Directive 2002/95/EC

Regulations 2012

European Directive 2012/19/EC (UK) Waste Electrical and

on old electronic and electrical Electronic Equipment Regulations

appliances

2013 (as amended)

Table 2

3.5 Appliance type overview These appliances are for use with: · Natural Gas or LPG (Cat.II 2H3P type C13, C33 & C53)
This document refers to the following appliance types:

Appliance type GR2301iW 25 C NG GR2301iW 30 C NG GR2301iW 25 C LPG GR2301iW 30 C LPG

Part number 7 736 902 326 7 736 902 325 7736 902 328 7736 902 327

Gas Council number 47-800-34 47-800-36 47-800-35 47-800-37

Table 3 Type overview

The name of the appliance consists of the following parts: · GR2301iW : Type name · 25 or 30: Hot water output in kW · C: Combi appliance · NG: Gas type (Natural Gas) · LPG: Gas type (Liquid Petroleum Gas)

3.6 Product identification
Data plate The data plate contains performance data, approval data and the serial number of the product. The position of the data plate can be found in the product overview in this chapter.
Additional type plate The additional type plate contains information on the product name and the most important product data. It is located in an easily accessible place on the outside of the product.

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Greenstar 2000 ­ 6721839340 (2023/06)

3.7 Pipe work positions and flue outlet

Product Information

Function 5 PRV Outlet 6 DCW Inlet

From left case edge 189 mm
265 mm

7 CH Return

330 mm

Table 5 Pipe dimensions

Diameter of pipe
15 mm · Compression elbow 15 mm · Compression fitting (via
isolation valve) 22 mm · Compression fitting (via
isolation valve)

For servicing purposes, keep condensate and pressure release valve discharge pipes away from other hydraulic components.

23 4 6 7

1

5

0010043702-001

Fig. 2 Pipe and flue outlet dimensions

Description X Appliance width Y Appliance height Z Appliance depth W Flue centre from appliance left side D Flue centre from rear of appliance

1. Side panel height = 710mm

Dimensions (mm) 400 724 1) 300 200 125

Table 4 Appliance and flue outlet dimensions

Function

From left Diameter of pipe case edge

1 Condensate Hose 33 mm Outlet

21,5 mm · Rubber push fit connection

2 CH Flow

70 mm 22 mm

· Compression fitting (via isolation valve)

3 DHW Outlet

135 mm 15 mm

· Compression fitting (via adaptor)

4 Gas

200 mm 22 mm

· Compression fitting (via isolation valve)

Greenstar 2000 ­ 6721839340 (2023/06)

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Product Information 3.8 Product overview
20
19
18 17
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1
Fig. 3 Product overview
10

21 22 23 24 25 26 27 28 29
30 31 32 33
34 35 36
37 38
0010043703-002
Greenstar 2000 ­ 6721839340 (2023/06)

Legend to figure 3:
[1] Control unit [2] Fuse (replacement) [3] KEY accessory housing (wireless gateway) [4] Condensate trap [5] DHW temperature sensor [6] Data plate [7] Plate heat exchanger [8] Pressure relief valve (heating circuit) [9] Condensate trap locking mechanism [10] Gas supply pressure test point [11] Flue gas temperature limiter [12] Heating flow [13] Expansion vessel [14] Fan [15] Schrader valve [16] Flow temperature sensor [17] Air-gas manifold with non-return valve [18] Zero flow sensor [19] Automatic air vent [20] Combustion air intake [21] Flue connection [22] Inspection/Heat exchanger cleaning access [23] Front cover bracket [24] Heat exchanger temperature limit sensor [25] Ignition transformer [26] Electrode [27] Fan pressure test point [28] Gas-air mixing chamber [29] Primary Heat Exchanger [30] Condensate sump [31] Gas valve [32] Heat exchanger sump cover [33] System pressure sensor [34] Diverter valve [35] Heating pump [36] Flow turbine [37] Pressure gauge [38] Position for code plug (not supplied)
3.9 Product data for energy consumption
The product data on energy consumption can be found in the operating instructions for the user.

Product Information

3.10 Standard accessories 3.10.1 Appliance accessories

Part number 7 733 600 266 7 733 600 236 7 733 600 237 7 733 600 476 7 716 192 746 7 716 192 610 7 733 600 091 7 736 902 357 7 736 902 355 7 736 902 372 7 736 900 525 7 736 902 361 7 736 902 512

Description Greenstar System filter (22mm mini) Greenstar System filter (22mm) Greenstar System filter (28mm) Greenstar System filter brass (22mm) Worcester CondenseSure Keyless filling link Heat exchanger cleaning kit Low NOx code plug kit 25kW Low NOx code plug kit 30kW DHW pre-heat kit Greenstar Xtra FGHR Spacer Frame (70mm) Vertical piping kit

Table 6 Appliance accessories

3.10.2 Programmer/timer accessories
The programmers/timers listed can be used with the appliances stated on the front of this manual.

Part number 7 733 600 332 7 733 600 333 7 738 110 054 7 738 111 064 7 738 112 324 7 738 112 338

Description
MT20 mechanical timer
MT20RF mechanical thermostat
Sense I Sense II (including weather sensor)1) Comfort+ II RF 1) Comfort+ stat RF 2)

1. Preheat time control available. 2) Must be used with an external proprietary 230V timer.

Table 7 Control accessories Bosch EasyControl smart control system

Part number 7 736 701 341 7 736 701 392 7 738 112 351 7 736 701 555 7 736 701 556 8 750 000 270

Description EasyControl (white) 1) EasyControl (black) 1) EasyControl RF Key
EasyControl TRV set (white)
EasyControl TRV set (black) EasyConstrol smart TRV (individual)

1. Preheat time control available.

Table 8 EasyControl accessories
Basic weather compensation sensor Outdoor weather sensor (to activate on-board simple Weather Compensation).

Part number 7 716 192 764

Description Outdoor weather sensor

Table 9 Control accessories

Greenstar 2000 ­ 6721839340 (2023/06)

The outdoor weather sensor is supplied with the Sense II. It is optional with the Comfort+ II RF. Weather compensation is available with the EasyControl without the need for a physical outdoor sensor, however, it can improve control accuracy for installations in isolated micro-climates or highly sheltered locations such as valleys.
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Pre-Installation

4 Pre-Installation
NOTICE
Risk of damage to system or appliance! Before installation All the following Pre-Installation sections must be read and
requirements met before starting appliance or flue installations.
4.1 System preparation
4.1.1 Artificially softened water The heating system must not be filled with water which has been treated using an ion exchange (salt based) water softener. Where these water softeners are installed, a permanent untreated water supply should be provided to maintain pressure in the heating system. A bypass must be provided at the water softener to comply with BS:14743. Where a permanent untreated supply cannot be provided, the system must be initially filled using the bypass provided at the water softener. Occasional topping up of the system with artificially softened water is acceptable. Inhibitor must be added to the system. The pH levels must be between 6.5 and 8.0 at the time of commissioning. When a permanent untreated supply is not provided to the heating system filling point, the pH levels must be checked annually and recorded in the service record.
NOTICE
Risk of damage to appliance! The heating system must not be filled with water which has been
treated using an ion exchange water softener. If the system is partially drained for maintenance or repair work, the
system must be refilled by utilising the bypass valve at the water softener. The pH and inhibitor levels should be checked.
4.1.2 Water systems and pipework
Primary system plastic pipework: · Any plastic pipework must have a polymeric barrier, complying with
BS 7921 and installed to BS 5955 with 600mm (minimum) length of copper connected to the appliance. · Plastic pipework used for under-floor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50°C with 1000mm (minimum) length of copper or steel pipe connected to the appliance.
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 BS 2767:10. · All other valves should conform to BS 1010. · It is best practice to fit Thermostatic Radiator Valves (TRV’s) to all
radiators, except the area where the room thermostat is sited which must be fitted with lockshield valves that are left open. · The circulating pump speed is fixed therefore as system circulation can be significantly adjusted or stopped by TRV’s or zone valves, a system bypass must be installed to give at least a 3 metre circuit when activated. · Drain cocks are required at all the lowest points on the system. · Air vents are required at all high points on 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.
Hot water: · Taps and mixing valves must be capable of sustaining a pressure up to
10 bar. · Hot water temperature and flow rate are affected by the size and
insulation of pipework making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent temperature setting is required. · If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets. · Thermostatic mixing valves (TMVs) must be fitted at the point of use as specified in G3 of the building regulations and if specific, accurate temperature control is required by the user.
Primary system considerations – Combi & System appliances
Sealed system
· The CH sealed system must be filled using a WRAS approved filling loop or comply with examples in section 4.1.4 “System fill”.
· Where the system volume is more than 100 litres or exceeds 2.5 bar at maximum heating temperature an additional 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 value as the built-in expansion vessel [1] (default pre-charge pressure is 0.75 bar).

1 2
3 Fig. 4 Additional expansion vessel [1] Appliance expansion vessel [2] Additional expansion vessel [3] Pressure relief discharge [4] Heating return [5] Heating flow

4 5
0010021117-001

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Greenstar 2000 ­ 6721839340 (2023/06)

To determine whether an additional expansion vessel is required: Follow the steps below:
Calculate the total system volume (litres). ­ Plot a line vertically on the chart ( Fig. 5).
Determine the central heating maximum operating flow temperature. ­ Plot a line horizontally on the chart ( Fig. 5).
Determine the pre-charge in the expansion vessel based on static head, 1 metre = 0.1 bar. ­ Static head should be measured between the expansion vessel and the highest point on the system (top of the highest radiator).
Select a curve from the key below (1-5). System pressure should be set at 0.1 – 0.25 bar higher than the
vessel pre-charge. ­ It must be at least to the minimum on appliances with an analogue
gauge. ­ Minimum pressure settings may need to be adjusted to suit on,
appliances with a digital gauge, in the applicable menu function. ­ Intelligent filling settings may need to be adjusted to suit on,
appliances with the automatic filling accessory, in the applicable menu function.
If the dissected lines are in area A then no additional expansion is required.
If the dissected line is in are B then an additional expansion vessel must be installed ( Fig. 4).

T[°C] 90

80

70
60
50
A
40

5 4

B

3

2

1

30 0

100 200 300 400 500 600 700
V[l] 0010016558-002

Fig. 5 Curves for the expansion vessel
1 Pre-charge pressure 0.5 bar (minimum) 2 Pre-charge pressure 0.75 bar 3 Pre- charge pressure 1.0 bar 4 Pre-charge pressure 1.2 bar 5 Pre-charge pressure 1.3 bar A Operational capacity of the expansion vessel (left of the relevant
curve) B Additional expansion vessel required (right of the relevant curve) T Maximum operating temperature [ °C] V Total System Volume [l]

Pre-Installation 4.1.3 System layouts examples Sealed primary system – Single central heating circuit: Typical primary system example
1 Fig. 6 Single central heating circuit example [1] Appliance Sealed primary system – 2 x central heating zones: · Requirement for new builds if the floor area of a property is over
150m2. 2
2
7
1 Fig. 7 Separated heating zones [1] Appliance [2] Zone valves [7] Auto bypass across flow and return to be at least 1.5m away from
the appliance (3m loop of pipe)

0010021228-003

0010021227-002

The default pre-charge pressure for the expansion vessel is 0.75 bar

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13

Pre-Installation
4.1.4 System fill
Integral filling link · An optional filling link accessory is available to fill the system.
­ Refer to filling link instructions for fitting and operation.
Filling primary sealed systems
NOTICE
Filling the primary sealed system The system must not be filled with salt based softened water. Ensure the primary water filling point uses an untreated cold water
connection from the mains supply, before a water softener.
· Filling the system must comply with one of the following methods shown.
· The filling point must be at low level and must never be a permanent connection to the mains water supply.
· Filling loops must be WRAS approved. · If the external filling link is sited away from the appliance, then a
pressure gauge should be installed at the filling point.

The pressure shown on the gauge may differ from that shown on the digital display. Final system pressure adjustments must be made whilst referencing the digital display.

External filling loop

1

6

33

5

2

2

4

4.2 Mains supply
4.2.1 Electrical supply · Supply: 230V AC – 50 Hz · This appliance must not be connected to a three phase supply. · The wiring between the appliance and the electrical supply must
comply with the latest IET wiring regulations that apply to wiring a fixed appliance for Class 1 equipment. · The correct type of RCD must be employed where additional protection is required that is suitable for a low energy DC modulating pump according to IET wiring regulations. · External 3 A fuse to BS1362. · The appliance must be earthed. · Cable: PVC insulated 0.75mm2 (24 x 0.2mm) temperature rated to 90 °C, to BS EN50525. · Any additional components that are connected to the appliance with mains electrical supply must not have a separate supply. · Additional equipment wired to the appliance must comply with the latest IET wiring regulations.
· Appliance protection rating – IPX4D
4.2.2 Gas supply · Appliances using Natural Gas (NG) must be connected to a governed
meter. · Appliances using Liquid Petroleum Gas (LPG) must be connected to
a regulator. · Installation and connection of the gas supply to the appliance must
be in accordance with the latest version of BS6891. · Gas pipe sizing should be calculated to ensure no more than the
permitted mbar drop between the meter to the appliance inlet. ( chapter 6). · The meter 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.
Pipe sizing (NG & LPG)

0010012942-001

Fig. 8 External filling loop system fill example
[1] Cold mains inlet pipe [2] Stop valve [3] Check valve [4] Test point [5] Hose union [6] Central heating flow pipe

Gas pipe work: Gas installation pipe work must be designed to ensure the pressure
loss between the meter outlet (NG) or storage and regulator (LPG) and the inlet to each appliance does not exceed 1mbar (NG) or 2.5mbar (LPG) table 25 “Allowed mbar pressure drop”.
Basic pipe sizing calculation

Basic pipe sizing calculation.
This method is only a guide – for more complex design please refer to latest version of BS6891 and training given in ACS.

14

Greenstar 2000 ­ 6721839340 (2023/06)

Natural Gas (NG):
Discharge rates for copper tube with 1mbar differential pressure between the ends for Natural Gas.

Discharge rates for Natural Gas (m3/hr)

with straight horizontal copper tube

Pipe

Pipe Size (mm)

Length (m)

15

22

28

35

3

2.9

8.7

18

32

6

1.9

5.8

12

22

9

1.5

4.6

9.4

17

12

Discharge 1.3

3.9

8

15

15

m3/hr

1.1

3.4

7

13

20

0.95 2.9

5.9

11

25

0.92 2.5

5.2

9.5

30

0.88 2.3

4.7

8.5

Table 10 Natural Gas

Natural Gas:
When using this table to estimate the gas flow rate in pipe work of a known length, the effective length will be increased by 0.5m for each 90° elbow and tee fitted and by 0.3m for each 45° bend.

Liquid Petroleum Gas (LPG)::
Discharge rates for copper tube with 2.5mbar differential pressure between the ends for LPG.

Tubing length (m)
3 6 9 12 15 18 21 24

Discharge rates for LPG (m3/hr) with straight horizontal copper tube

Outside diameter

15mm

22mm

28mm

kW m³/hr kW m³/hr kW m³/hr

38.4 1.49 207 8.01 412 15.92

26.1 1.01 135 5.21 230 8.86

20.5 0.79 108 4.19 215 8.33

17.9 0.70 94 3.62 187 7.25

15.5 0.60 82 3.20 168 6.51

13.5 0.53 74 2.86 145 5.61

12.9 0.50 67 2.58 135 5.24

12.0 0.47 61 2.58 126 4,87

Table 11 Liquid Petroleum Gas (LPG)

Liquid Petroleum Gas (LPG):
When using this table to estimate the gas flow rate in pipework of a known length, the effective length will be increased by 0.6m for each 90° elbow or tee used and by 0.3m for each 45° bend or straight coupler used.

Pre-Installation
4.2.3 Gas supply · Appliances using Natural Gas (NG) must be connected to a governed
meter. · Installation and connection of the gas supply to the appliance must
be in accordance with the latest version of BS6891. · Gas pipe sizing should be calculated to ensure no more than the
permitted mbar drop between the meter to the appliance inlet. ( chapter 6). · The meter 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.
Pipe sizing (NG)

Gas pipe work: Gas installation pipe work must be designed to ensure the pressure
loss between the meter outlet (NG) table 25 “Allowed mbar pressure drop”.
Basic pipe sizing calculation

Basic pipe sizing calculation.
This method is only a guide – for more complex design please refer to latest version of BS6891 and training given in ACS.

Natural Gas (NG): Discharge rates for copper tube with 1mbar differential pressure between the ends for Natural Gas.

Discharge rates for Natural Gas (m3/hr) with straight horizontal copper tube

Pipe

Pipe Size (mm)

Length (m)

15

22

28

35

3

2.9

8.7

18

32

6

1.9

5.8

12

22

9

1.5

4.6

9.4

17

12

Discharge 1.3

3.9

8

15

15

m3/hr

1.1

3.4

7

13

20

0.95 2.9

5.9

11

25

0.92 2.5

5.2

9.5

30

0.88 2.3

4.7

8.5

Table 12 Natural Gas

Natural Gas:
When using this table to estimate the gas flow rate in pipe work of a known length, the effective length will be increased by 0.5m for each 90° elbow and tee fitted and by 0.3m for each 45° bend.

Greenstar 2000 ­ 6721839340 (2023/06)

15

Pre-Installation
4.2.4 Water supply
Use in hard water areas: Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the DHW heat exchanger is limited by the electronic control. In areas where temporary water hardness exceeds 200ppm, 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.
Keyless filling link accessory

Minimum static pressure. A minimum static cold water mains pressure of 1.75bar is
recommended for correct operation of the Keyless filling link.
Water mains pressure: · Minimum mains water pressure, for maximum performance refer to
section 13.1 “Technical data”. · Maximum mains fed water static pressure is 10 bar.
If necessary fit a pressure reducing valve.
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.

NOTICE
Non-return valves in the cold water feed system.
If a non-return valve is fitted on the mains inlet, then pressure can increase significantly over normal standing pressure when the appliance carries out a DHW preheat or due to fast acting valves closing on other appliances/outlets.
To ensure water pressure stays at a level that will not damage the boiler or other household appliances, we would recommend on installations where standing pressure exceeds 3bar, that a 3 bar pressure reducing valve and mini expansion vessel are fitted.
· Where the mains water supply has a non-return, back flow prevention valve fitted, a mini expansion vessel [3] should be connected to the mains water inlet pipe [1] between the non-return valve [2] and the appliance[4] as shown below.

3

4

4.3 Appliance location and clearances
4.3.1 Appliance location · Follow local regulations for the location within the property that the
appliance is to be installed. · This appliance is only suitable for installing internally within a
property at a suitable location onto a flat, fixed rigid surface capable of supporting the appliance weight. · The appliance is not suitable for external installation. · Protect installation area against dust and moisture.
No surface protection is required against heat transfer from the appliance.
DANGER Danger from explosive and flammable materials: Storage of explosive and flammable materials. Do not store flammable materials (paper, curtains, clothing, primer,
paint, …) in proximity to the appliance.
WARNING Risk of injury due to damage to the appliance The appliance must not be sited in such a position that some or all of
the underside of the appliance is closer than 760mm above a permanently fixed hob. Reasonable care should be taken to ensure the appliance is not installed directly above where other heat-producing kitchen appliances such as portable hot plates, toasters and kettles are likely to be sited.
NOTICE
Damage to appliance: Contaminated combustion air. Do not use any cleaners containing chlorine or hydrogen halide (i.e.
spray cans, primers, cleaners, paint and glue). Do not store or use these substances in the appliance or room. Avoid the build-up of dust.
NOTICE
Damage to appliance: Extreme temperatures may cause damage to the heating system. Ensure the appliance location’s ambient temperature is above 0 °C
and below 50°C.

12
0010015563-001
Fig. 9 Mini expansion vessel location [1] Mains water inlet pipe [2] Non- return valve [3] Mini expansion vessel – part no. 7 716 192 105 [4] Appliance

16

Greenstar 2000 ­ 6721839340 (2023/06)

NOTICE
Damage to system:
The heating system pipe work can be damaged by frost if installed in an internal unheated area, such as a loft, basement or garage. The appliance internal frost protection only monitors the system water temperature within the appliance to provide protection for the appliance.
System frost protection can be achieved when using either Worcester weather- compensating controls or via a hard-wired thermostat when using external 230v controls (refer to figure 60, page 45).
The system pipe work in the internal unheated area should be insulated.
If the appliance is to be shut down for an extended period, drain the central heating system.
The appliance must be installed where:
The area is well lit, allowing users to clearly see the appliance to carry out any work or checks.
An engineer can gain clear and safe access to work on the product or component, including making adequate provision for visual inspection of flues in voids.
The homeowner can gain clear and safe access to the controls or to check, top up or reset the appliance.
Roof space installations must fully conform to BS 6798: roof space installations.
Products in roof spaces must have permanent fixed lighting, a permanent fixed retractable ladder and a fixed floor area sufficient to allow access for normal use and servicing around the product and between the product and the access hatch. We would also recommend that a remote pressure gauge and filling loop are sited where the customer can gain easy access to assist with checking and topping up.

Pre-Installation

4.3.2 Rooms containing a bath or shower
CAUTION
Risk of electric shock Any switch or appliance control using mains electricity must not be
within reach of a person using the bath or shower.
· In all cases the installation must be in accordance with the latest amendments to the latest edition of the IET Wiring Regulations (BS7671).
· Check the IP rating of any control units to be used on this appliance. · Circuit breaking devices should be used in accordance with the
regulations. · Figure 10 is for guidance only.

600mm

600mm

11

2 2*

2

600mm

600mm

212

2250mm 2250mm

A A
A 0010052067-001
Fig. 10 Bathroom installations
[1] Zone 1 [2] Zone 2 [2*] Without the end wall, zone 2 must extend 600mm from the bath [A] 600mm radius from the bath or shower · Appliance protection rating – IPX4D

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Pre-Installation
4.3.3 Appliance clearances · The following details cover the installation, service and maintenance
clearances for the appliance.
CAUTION Risk of damage to appliance or property The appliance will overheat if the clearance space around the appliance is restricted by objects. Do not restrict this space with the addition of cupboards, shelves etc.
next to or around the appliance. Do not store any combustible materials on or next to the appliance,
such as clothes, towels, paper or plastic bags.

Reduced front maintenance minimum clearances The front servicing clearance for this appliance can be reduced to 450mm.
For installations with a front servicing clearance less than 600mm (minimum of 450mm), the following additional criteria must be achieved.
· The bottom of the appliance case must be between 1000mm and 1500mm from the floor.
· There must be at least 450mm clearance in front of the appliance to floor level. Anything sited below the appliance must not protrude into this clear space.
· There must be at least 200mm clearance to any structure which is sited below the appliance.
· There must be at least 300mm clear space to either the left hand or right hand side of the appliance. This clear space must be from the required clear height above the appliance to floor level. ­ This clearance will not apply if the appliance is sited within 300mm of a door way and the door frame is the only obstruction.

Minimum clearances must be observed to any obstruction/ surface, (dark shaded areas, figures 12 and 13).

0010012940-002
0010031674-001

1

Fig. 11 Appliance minimum clearances

Minimum clearances

Description

Dimensions (mm)

X

Appliance width

Y

Appliance height

400 724 1)

Z

Appliance depth

300

Installation/Maintenance

1

Overall clearance height

1094/1134 2)

2

Overall clearance depth

900 3)

3

In front of appliance

600 3)

4

Overall clearance width

5

Above the appliance

410 170/210 2)

6

Either side of appliance

5

7

Below the appliance

8

Compartment depth

200 320 4)

9

Appliance to removable door

20

1. Side panel height = 710mm 2) Height for either 60/100 flue or 80/125 flue
2. This can be reduced (refer to Reduced front maintenance minimum clearances). 4) Clearance to a combustible material

Table 13 Appliance minimum clearances

A 2
4 3
2
Fig. 12 Reduced front maintenance clearances – Side view [A] Appliance. [1] Above appliance – Same clearance required as for standard
clearances of 60/100 flue or 80/125mm flue. [2] In front of appliance – Minimum 450mm. [3] Bottom of appliance to the floor – 1,000 – 1,500mm. [4] Below appliance – 200mm.

18

Greenstar 2000 ­ 6721839340 (2023/06)

1

6

5

A

Pre-Installation
4.4 Flue systems considerations
WARNING Flue systems Possible flue gas escape Use Worcester, Bosch Group approved Condensfit II flue systems
only, no other manufacturer’s flue have been tested or approved for use with Worcester, Bosch Group appliances.

4
3 5

CAUTION
Concealed flue systems:
Where a flue system is going to be concealed, provision must be made for service and inspection.
Voids containing concealed flues must have at least one inspection hatch no less than 300mm square.
Flue joints within the void must not be more than 1.5 metres from the edge of the inspection hatch.
Inspection hatches should be located at changes of direction. If this is not possible, bends should be viewable from both directions.

0010031673-001

Fig. 13 Reduced front maintenance clearances – Front view
[A] Appliance. [1] Above appliance – Same clearance required as for standard
clearances of 60/100 flue or 80/125mm flue. [3] Bottom of appliance to the floor – 1,000 – 1,500mm. [4] Below appliance – 200mm. [5] One side of appliance – Minimum 300mm. [6] One side of appliance – Minimum 5mm.
Appliances in compartments Follow the latest requirements of BS6798 and BS5440 and note: · Minimum clearances must be maintained. · An access door is required to install, service and maintain the
appliance and any ancillary equipment. · If the appliance is installed in an unventilated airing/storage
cupboard, there is no requirement to make a partition between the appliance and the storage space as long as the minimum clearances around the appliance are maintained.

Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions.

Flue kit part numbers

Part number Flue Ø 7 716 191 082 60/100 7 716 191 171 60/100 7 733 600 048 60/100 7 733 600 298 60/100 7 719 003 702 80/125 7 719 002 430 60/100 7 719 002 431 80/125

Description Telescopic horizontal flue kit Extended telescopic horizontal flue kit Horizontal high level telescopic flue kit 1050mm horizontal fixed flue kit Telescopic horizontal flue kit Vertical balanced flue kit Vertical balanced flue kit

Table 14 Flue kit assembly part numbers

Greenstar 2000 ­ 6721839340 (2023/06)

19

0010015191-001

Pre-Installation

4.4.1 Flue length Horizontal maximum flue lengths

Appliance GR2301iW 25 C GR2301iW 30 C

Flue length [L] 60/100
12,000mm 12,000mm

Table 15 Maximum flue lengths – Horizontal flues

Flue length [L] 80/125
21,000mm 21,000mm

Vertical maximum flue lengths

Appliance GR2301iW 25 C GR2301iW 30 C

Flue length [L] 60/100
12,000mm 12,000mm

Table 16 Maximum flue lengths – Vertical flues

Flue length [L] 80/125
21,000mm 21,000mm

Flue system bends

NOTICE
Effective flue lengths of bends: Each bend used has an equivalent straight flue length. Refer to table 17.

Bend 45° 90°

Effective flue length

60/100

80/125

0.5m

0.5m

1.5m

1.5m

Table 17 Effective length of bends

4.4.2 Flue options
The systems have different maximum flue lengths, refer to the following example flue options for those maximum flue lengths.

Horizontal high level flue assembly

60/100 mm
383 mm – 603 mm

130 mm Min

Telescopic horizontal flue assembly 60/100 mm
[A] 350 mm – 570 mm [B] 570 mm – 790 mm
130 mm Min
Fig. 15 Horizontal flue option Telescopic horizontal flue assembly [A] · Flue length [L] (adaptor bend included in length calculation)
­ 60/100 = 180 – 570mm ­ 80/125 = 405 – 600mm Extended telescopic horizontal flue assembly [B] · Flue length [L] (adaptor bend included in length calculation) ­ 60/100 = 570 – 790mm ­ 80/125 = N/A Horizontal fixed length flue assembly
1050 mm
330 mm Min
Fig. 16 Horizontal flue option · Flue length [L] (adaptor bend included in length calculation)
­ 60/100 = 330 – 1,050mm ­ 80/125 = N/A Extended horizontal flue

0010015190-001

0010015193-001

Fig. 14 Horizontal flue option
· Flue length [L] (initial bend included in length calculation) ­ 60/100 = 202 – 603mm ­ 80/125 = N/A

Fig. 17 Horizontal flue option
· Flue length [L] (adaptor bend included in length calculation) ­ Maximum flue length as stated in “Horizontal maximum flue lengths”.

0010015192-001

20

Greenstar 2000 ­ 6721839340 (2023/06)

Horizontal flue with additional 90° elbow

Pre-Installation High level horizontal flue with additional 90° elbows

0010015194-001

0010015198-001

Fig. 18 Horizontal flue option
· Flue length [L] (adaptor bend included in length calculation) ­ Maximum flue length as stated in “Horizontal maximum flue lengths” minus the 90° bend equivalent straight flue length as stated in Table 17 “Effective length of bends”.
Horizontal flue with additional 90° elbows

Fig. 22 Horizontal flue option
· Flue length [L] (initial bend included in length calculation) ­ Maximum flue length as stated in “Horizontal maximum flue lengths” minus 2 x 90° bends equivalent straight flue length as stated in Table 17 “Effective length of bends”.
Vertical balanced flue assembly

0010015195-001

0010015199-001

Fig. 19 Horizontal flue option
· Flue length [L] (adaptor bend included in length calculation) ­ Maximum flue length as stated in “Horizontal maximum flue lengths” minus 2 x 90° bends equivalent straight flue length as stated in Table 17 “Effective length of bends”.
High level horizontal flue

A = 300 mm B = 500 mm
Fig. 23 Vertical flue option · Flue length [L] ­ Maximum flue length as stated in “Vertical maximum flue lengths”.
Vertical balanced flue with 90° elbow offset

0010015196-001

Fig. 20 Horizontal flue option
· Flue length [L] (initial bend included in length calculation) ­ Maximum flue length as stated in “Horizontal maximum flue lengths”.
High level horizontal flue with additional 90° elbow

A = 300 mm B = 500 mm
Fig. 24 Vertical flue option · Flue length [L] ­ Maximum flue length as stated in “Vertical maximum flue lengths” minus 2 x 90° bends equivalent straight flue length as stated in Table 17 “Effective length of bends”.

0010015200-001

0010015197-001

Fig. 21 Horizontal flue option
· Flue length [L] (initial bend included in length calculation) ­ Maximum flue length as stated in “Horizontal maximum flue lengths” minus the 90° bend equivalent straight flue length as stated in Table 17 “Effective length of bends”.

Greenstar 2000 ­ 6721839340 (2023/06)

21

Pre-Installation Vertical balanced flue with 45° elbow offset
A = 300 mm B = 500 mm

100mm

140mm 500mm

3° X

0010015201-001

Fig. 25 Vertical flue option · Flue length [L] ­ Maximum flue length as stated in “Vertical maximum flue lengths” minus 2 x 45° bends equivalent straight flue length as stated in Table 17 “Effective length of bends”.
4.4.3 Plume management system
NOTICE
Plume management terminal: The plume management terminal must not be sited within 500mm of
the air intake, and must not exceed the maximum straight length for a horizontal Ø 60/100mm flue with a 60mm plume management system.
Horizontal plume management runs The initial horizontal run from the terminal elbow must have a
minimum 10° fall back, (stop tabs in the elbow prevent less than 10°) to the appliance for proper disposal of condensate. Any further horizontal runs after an elbow can be 3°.
WARNING Minimum plume management length: The minimum distance of 500mm must be maintained between air inlet and exhaust. Do not terminate the plume management inside the terminal
exclusion zone (shaded area) shown in figure 26.

500mm

500mm

500mm

±80°

Fig. 26 Terminal exclusion zone

0010013548-003

NOTICE
Cutting the 500mm pipe The Plume management extension kit contains the components
required for such a configuration.

Plume management bends
NOTICE Effective plume management lengths of bends: Each bend used has an equivalent straight plume management length. Refer to the table 18.

Bend 45° 90°

Effective plume managnement length 0.75 metres 1.5 metres

Table 18 Effective length of bends

The maximum flue length allowed for 0.5 m of plume is 9 m, each additional 1 m of plume reduces the flue length by 750 mm, up to a maximum of 4.5 m of plume management with 6 m of flue.

22

Greenstar 2000 ­ 6721839340 (2023/06)

5000

4500

4000

3500

3000
2
2500
[mm] 2000

1500

1000

500

0

0

2000 4000 6000 8000 10000 12000

1

[mm]

0010036485-001

Fig. 27 Plume length to flue length graph
[1] Flue length [mm] (maximum 12,000 mm with minimum 500 mm plume)
[2] Plume length [mm] (maximum plume length 4,500 mm)

Pre-Installation

Greenstar 2000 ­ 6721839340 (2023/06)

23

Pre-Installation

4.4.4 Flue terminal positions
CAUTION
Flue terminal positions All measurements are the minimum clearances required. Terminals must be positioned so to avoid combustion products
entering the building.

Vertical flue terminal positions

RIDGE VENT

1 RIDGE FLUE

2

1500

1500

2 1500

300

2 600
7 400 300

6

600

600

600

2000

1500

1500 600

8 5 500 1200
3 300 300

10

4

1500

600 500 5

7 400
500 5

BOUNDARY LINE

1/2

9 B O U N D A R I E S

1/2

0010021441-002

Fig. 28 Vertical flue terminal positions
Key to figure 28:
[1] 1,500mm measured between a vertical flue terminal and an opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.
[2] Minimum clearance to an additional flue, 600mm to a room sealed flue or 1,500mm to an open flue.
[3] 300mm clearance from a vertical flue terminal adjacent to a boundary line, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting a terminal in relation to boundary lines.
[4] 600mm minimum clearance measured from an opening or vented skylight to a vertical flue terminal. If the terminal is within 1,500mm of the opening or vented skylight then it must be at least 300mm above the opening.
[5] 500mm clearance measured horizontally from a vertical flue to a vertical structure. Not required if the terminal is 300mm above the structure.
[6] The flue must not penetrate the roof in the shaded area. The terminal must be at least 1,500mm from the opening or vent

when sited below the window or 600mm when sited to either side or above. [7] 400mm measured diagonally from a pitched roof or 500mm in regions with heavy snow fall. 300mm measured vertically from the air intake to the closest intersection with the roof. [8] 1,200mm separation measured between a vertical flue and a horizontal flue terminal. [9] For the purpose of determining suitable flue terminal positions for gas appliances, the boundary can be considered to extend to the centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways. [10] 1,500mm measured between a vertical flue terminal and an opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.

24

Greenstar 2000 ­ 6721839340 (2023/06)

Pre-Installation

Note:
Where a vertical flue terminates in an area that is enclosed on 3 sides, the flue must be no more than 1,000mm below the lowest roof line. You must ensure that all clearances are maintained and that products of combustion disperse safely from the area.

Horizontal flue terminal positions

10

BOUNDARY LINE

DORMER

SKYLIGHT

6

6

OPENING OPPOSITE

300
3

600

600

TOP
14

600

300 2000

TOP

600

600

600

5

1500

3
300
11
300 1500
18

1200 4

300
11
300

8
1200 300
17

5 600
300 1000
13

300 300
11

1
200
7
600
10 25
300 300

BOUNDARY LINE

200
1 10 300

5
600
10
300

1
200
1/2 1/2

2
100 25
9 B O U N D A R I E S

75 25

1
200
75 25

12 BELOW GROUND OPEN LIGHT WELL

<1000

300

300

600

300

2

25

100

150

25 25 100

25 25 100

15
300

Fig. 29 Horizontal flue terminal positions

16
100 25
10
300
0010021442-004

Greenstar 2000 ­ 6721839340 (2023/06)

25

Pre-Installation
Key to figure 29: [1] 200mm below eaves and 75mm below gutters, pipe and drains. [2] The dimension below eaves, gutters, pipes and drains can be
reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building. [3] 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 surfaces or boundary lines. [4] 1,200mm separation measured between terminals facing each other. [5] 600mm distance to a surface or boundary line facing a terminal, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines. [6] The terminal must be at least 1,500mm from the opening or vent when sited below the window or 600mm when sited to either side or above. [7] 600mm diagonally to an opening door, air vent or opening window. If the flue terminal is at least 300mm above the adjacent opening door, air vent or opening window, then the diagonal measurement does not apply. [8] 1,200mm separation measured between a vertical flue and a horizontal flue terminal. [9] For the purpose of determining suitable flue terminal positions for gas appliances, the boundary can be considered to extend to the centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways. [10] 300mm to an internal or external corner. 300mm above a surface, such as the ground/ floor level or roof surface. * If the terminal section is less than 150mm and has two screws securing it to the elbow, the terminal section will not require a supporting bracket. [11] 300mm above, below and either side of an opening door, air vent or opening window. [12] Below ground level in an open lightwell. The flue must be at least 600mm from the opposing surface and have at least 300mm clearance either side and below. The flue terminal must be no more than 1,000mm from the top of the lightwell. [13] Flues should clear any LPG storage by 1,000mm horizontally and 300mm above. [14] Proximity of flue duct outlet to boundaries, 2,000mm distance to an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines. [15] 300mm from an opening or vented window, 150mm to a fixed unvented window. [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. The telescopic flue joint of the terminal must be sealed with suitable silicon sealant if it is external to the building. [17] 300mm Horizontally from a terminal on the same wall. [18] 1500mm Vertically from a terminal on the same wall.
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. A flue terminal guard shall be fitted whenever a terminal or air inlet is
fitted less than 2,000mm above ground, above a balcony or above a flat roof to which people have access.
26

Greenstar 2000 ­ 6721839340 (2023/06)

Pre-Installation

4.4.5 Plume re-direct and plume management terminal positions
Maximum and minimum plume management lengths: A minimum distance of 500mm must be maintained between the
plume management outlet and the flue air intake. The maximum plume management length is 4.5 metres for the
appliances detailed on the front of this manual. The 45° bend is equivalent to 0.75 metres of straight plume
management and the 90° bend is equivalent to 1.5 metres.

NOTICE
All measurements are the minimum clearances required. Refer to “Horizontal flue terminal positions” for all concentric flue
terminal positions unless the flue position is specified in figure 30″Plume re-direct and plume management terminal positions”. Terminals must be positioned so to avoid combustion products entering the building. Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.

1
180°
±80°

±45°

500 500

500 ±80°

EXCLUSION ZONE

4
1,500

100 600
140 500
EXCLUSION ZONE

6
100 600
500 EXCLUSION ZONE

200
300 2

200 11

200 300 9 150

150 1200 12

BOUNDARY LINE

600 300
8 300

300 10
150

10

300

300 150 7

1500

14

300

300

25

200

13

25

15

150

5 600

BOUNDARY LINE 0010021676-001

300

2
TOP

2000 6

OPENING OPPOSITE
BOUNDARY LINE

600

3

600

150 300

TOP

300

TOP
300

5

TOP 7

8

9 150

Fig. 30 Plume re-direct and plume management terminal positions

10 300

FLUE TERMINAL GUARD 7 716 191 176

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27

Pre-Installation
Key to figure 30
– Plume re-direct terminal positions: [1] This feature allows some basic plume re-direction options on a
standard telescopic horizontal flue terminal. 300mm minimum clearances to a opening e.g. window. However the minimum clearances to an opening in the direction that the plume management is facing, must be increased to 1,500mm. Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the drainpipe. [2] 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 surfaces or boundary lines. [3] Where the flow of products of combustion is not at right angles to the boundary, the 600mm dimension may be measured in the direction of flow as long as the terminal is not less than 300mm from the boundary. [4] When redirecting the flue discharge the terminal end must be at least 1,500mm from any opening in the direction of the discharge to prevent combustion products from entering the building.
Key to figure 30
– Plume management terminal positions: [5] 600mm distance facing a surface or a boundary line, unless it will
cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting a terminal in relation to surfaces or boundary lines. [6] Proximity of flue duct outlet to boundaries, 2000mm distance to an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines. [7] 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 surfaces or boundary lines. [8] 300mm distance from a boundary line to the air intake as long as the exhaust terminal faces away from the boundary line. The exhaust terminal must have a minimum 300mm clearance to a surface below and there must be at least 600mm clearance when measured horizontally in a straight line from the exhaust terminal to any other surface. [9] Plume Management kit air intake can be reduced to 150mm providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line. [10] Above, below and either side of an opening door, air vent or opening window. Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance. [11] Below balcony or overhang. The air intake clearance can be reduced to 150mm providing the flue exhaust outlet has a 200mm clearance. [12] 1,200mm between terminals facing each other1). [13] Internal/external corners. The air intake clearance can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance. [14] Clearances no less than 200mm from the lowest point of the balcony or overhang. [15] If a plume management kit is installed within the confines of a carport or other covered, partially enclosed extension, then the exhaust terminal must be positioned at least 1200mm away from any opening into the building which is sited within the footprint of

1. 600mm in case two plume management kits are used on opposing terminals. Each terminal should use a minimum length of 500mm plume management.

the carport. If the exhaust terminal is extended at least 300mm beyond the footprint of the carport then the distance from the terminal to an opening within the carport can be reduced to 600mm. The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue pipe to any flammable material and that it extends at least 300mm above the roof. The air intake must have a minimum 150mm clearance to any opening in the building in order to ensure the integrity of the structure is maintained. If the exhaust terminates within the footprint of the carport then the carport must have at least 2 sides completely open. If the exhaust terminates at least 300mm beyond the footprint of the carport then the carport must have at least one completely open side. The exhaust terminal must be positioned to ensure that plume will not cause nuisance or damage to vehicles and that minimum clear distances in front of the terminal will not be impeded by vehicles.
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. Plume kits running horizontally must have at least a 3° fall back to the
appliance for proper disposal of condensate, except or the initial horizontal run from the terminal. The initial plume kit horizontal run will have at least a 10° fall back to the appliance, due to the terminal elbow design, for proper disposal of the condensate.

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Greenstar 2000 ­ 6721839340 (2023/06)

4.5 Condensate discharge
Full details on condensate discharge.
Follow the latest version of BS6798 and HHIC guidance.
For correct installation and trouble free operation of the appliance the following advice should be followed: 1. To minimise the risk of freezing, wherever possible, the condensate
drain should be installed internally. 2. All condensate pipe work must `fall’ from the appliance by a minimum
of 3° (52mm per metre) to ensure adequate condensate flow. 3. The pipe work route must allow air to be supplied back to the
appliance for correct operation. 4. Connection to a rainwater down pipe must include an air break.
Also: · Assessment of the risk of the condensate pipe freezing must be
carried out and appropriate precautions taken where necessary. This must take into account the specific site conditions. · The condensate pipe work connected to the condensate drain outlet on the appliance should have a minimum internal diameter (ID) of 19mm. · Keep external pipe work as short as possible. Further precautions against freezing must be taken if external pipe runs exceed 3m. · External pipe work should have a minimum internal diameter (ID) of 30mm. · Minimise the number of bends and connectors. · Remove burrs and cutting debris after the cutting pipe. · Remove surplus solvent from the interior of the pipe. · The condensate pipe work shall be run in standard drainpipe material, e.g. polyvinyl chloride (PVC), unplasticised poly vinyl chloride (PVC-U), acrylonitrilebutadiene.styrene (ABS), polypropylene (PP) or chlorinated poly vinyl chloride (PVC.C).
4.5.1 Condensate pipework
NOTICE
General consideration
Where a new or replacement appliance is being installed, access to an internal “gravity discharge” point should be one of the factors considered in determining appliance location.
Condensate pipe connection at the appliance: The condensate pipe must have a nominally outside diameter of 22mm plastic pipe.
Ensure there are no blockages in the pipe run. Ensure that the discharge method for the installation can effectively
handle the condensate waste from the appliance.

Pre-Installation

4.5.2 Condensate production When the appliance is in operation it can produce between 1 to 2 litres of condensation per hour.
This discharge is a constant drip feed during the production of condensate and does not release in frequent large volume discharges repeatedly.
4.5.3 Internal connections

Good Practice The following guidance indicates the good practices that must be
maintained for the Installation and Maintenance of a product.
Soil stack connection Figure 31 In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted.
Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the appliance 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.

1

2

0010012746-002

3
Fig. 31 Disposal to soil vent stack [1] Condensate discharge from appliance [2] Soil and vent stack [3] Minimum 450mm and up to 3 storeys

NOTICE
Unheated internal areas.
The condensate discharge may freeze in areas during prolonged cold temperatures.
Internal pipe runs in unheated areas such as lofts, basements and garages should be treated as external runs and consideration should be given to using a CondenseSure siphon.
For additional information refer to “External Connections” (Chapter 4.5.4 page 30)

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Pre-Installation
Waste pipe connection Figure 32 Alternatively if the first option is not possible an internal kitchen, bathroom or washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of the waste trap and that the condensate drain enters into the top of the pipe using a swept tee.
1

2 1

75 mm min.

0010052046-001

75 mm

2

min.

Fig. 32 Waste pipe disposal
[1] Condensate discharge from appliance [2] 75 mm sink waste trap
Condensate pump Figure 33
Where direct connection to “gravity discharge” pipework 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 condensate pump manufacturer. · The pump outlet should discharge to a suitable “gravity discharge”
outlet. ­ The condensate then flows, by gravity, through the 22mm plastic
pipe to the condensate discharge point.

Max.

3

4

1

Min.
2

4.5.4 External connections
NOTICE
Septic tanks Untreated condensate must not be allowed into septic tanks. Connection to systems which drain into a septic tank should be
avoided due to the risk of affecting anaerobic bacteria.
NOTICE
Rainwater down pipe or external drain disposal Untreated condensate must not be allowed to flow into streams or rivers. A rainwater down pipe or an external drain shall only be used for
condensate disposal if the down pipe or external drain is connected to a combined foul and rainwater drainage system. Refer to BS 6798 for more information on condensate disposal.
NOTICE
Grey water recovery system Contamination of recovered water Condensate disposal shall not be allowed into a grey water recovery
system that is intended for re-use.
External disposal considerations
NOTICE
Freezing conditions Frozen condensate will block the condensate drain pipe and stop the appliance from running Pipe lengths should be kept to a minimum and the routed as vertically
as possible. All external pipework must be insulated using suitable waterproof
and weather resistant insulation. If external pipework exceeds 3m, a CondenseSure or trace heating
must be installed. If a CondenseSure is fitted then the guidance for a large volume
condensate trap or CondenseSure should be applied.
NOTICE
Condensate waste disposal Care should be taken when siting a soak-away to avoid causing
damage to existing services and building footings.

0010052045-001

Fig. 33 Condensate pump example [1] Condensate discharge from appliance [2] Condensate pump [3] Pipework transition [4] Gravity discharge pipework
Proprietary condensate pump Ensure minimum and maximum pump lifting heights are followed as
per condensate pump manufacturers instructions.

30

Greenstar 2000 ­ 6721839340 (2023/06)

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:
The external run be kept as short as possible and ideally should not exceed three metres. Additional precaution against freezing must be taken if the external pipe run does exceed three metres.
The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to a minimum internal diameter (ID) of 30mm before it passes through the wall to the exterior.
The hole through the wall for the condensate pipe should be sleeved and be sealed to the building fabric on the internal and external face using a suitable building material.
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 appliance, 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.
All external pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut.
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. All other guidance above and the instructions for the trace heating system, should be closely followed.
As well as trace heating, other methods for protecting pipe work that are run externally should be considered to prevent freezing during prolonged periods.
­ Insulation materials can be used, these should be of class “O” grade with an outer coating that is weather proof and have a UV resistant finish. A minimum of 19mm thick insulation is recommended for 32mm external pipes.
­ The use of a drain cover (such as those to prevent leaf blockage) may offer further protection from wind chill.

Pre-Installation
Additional protection for transition through a wall. The external pipework can be insulated to help prevent freezing during prolonged cold periods. · Where insulation is required, the entire run of external pipework [5] should be insulated with a recess in the external face allowing better insulation protection coverage [4] as it transitions to the outside of the building. · The hole through the wall must be sealed to the building fabric on the internal [1] and external [3] face using a suitable building material, (use a 40mm sleeve [2] to pass the condensate pipework through and then seal the internal and external faces).

2 1

3 4
5

0010026770-002
Fig. 34 Additional protection for transition through a wall [1] Internal face sealed (32mm pipe sealed to sleeve) [2] 40mm sleeve [3] External face sealed (32mm pipe sealed to sleeve) [4] Insulation recessed into the wall [5] Condensate discharge pipe
Good Practice The following guidance indicates the good practices that must be
maintained for the Installation and Maintenance of a product.

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31

Pre-Installation
Rain water down pipe with external air break Figure 35 · Refer to following example to dispose of condensate to a rain water
down pipe. · An air break or rain water hopper must be utilised, between the
appliance condensate outlet and the drainpipe, outside the property, to avoid flooding of the appliance should the downpipe become obstructed.

Open drain or gully with external air break Figure 36
Where the pipe terminates over an open drain or gully and there is a risk of ground flooding, then the additional requirement below is recommended: · An air break should be installed in the external pipework as shown to
avoid an airlock during ground flooding/adverse weather conditions which could prevent the condensate from discharging.

1 8
9
1 8
9

10
11 12 13 14
21 20 12 10

Fig. 35 Disposal into rain water down pipe
[1] Condensate discharge from appliance [8] Pipework transition [9] Appliances with small capacity trap without CondenseSure
accessory fitted. ( page 33) [10] External rain water pipe to foul water [11] External air break [12] Air gap [13] Strap-on fitting [14] 43mm 90° male/female bend [20] Rain water hopper [21] Increase pipe size

0010012784-003 0010012786-003

1 8

9
21 11 21

25mm min.
Fig. 36 Disposal to open drain or gully with air break
[1] Condensate discharge from appliance [8] Pipework transition [9] Additional protection for transition through a wall. ( page 31) [11] External air break [21] Increase pipe size
Condensate soak away considerations Before deciding to use a purpose-made soak away the history of the locality and the ability of the surrounding area to disperse the condensate should be taken into account, e.g. areas prone to flooding and ground with a high clay content can result in poor drainage with an increased risk of water logging or freezing causing the condensate pipe to become obstructed by water or ice and the boiler to shut down,
Although it is possible to increase the size of the soak away and the area with limestone chippings in clay soil areas, if the clay content is high and prevents effective dispersal of the condensate then a soak away may not be a suitable means of condensate disposal and an alternative method should be used.

32

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Condensate soak away with external air break Figure 37 · Refer to following example to dispose of condensate to a soak away. · The condensate soak away must be sited at least 500mm away from
building footings. · The condensate drainage pipe may be run above or below the ground
to the soak away. The following example shows drainage pipe run above ground. · The soak away must use a minimum of 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. · An air break must be installed in the external pipework as shown to avoid an airlock during ground flooding/adverse weather conditions which could prevent the condensate from discharging.
Minimum hole size for the condensate soak away must be 400mm deep by Ø 300mm.

9
1 8
15 16

400mm min. 25mm min.
500mm min.
21 11
21
15 16

19 17

18
0010012788-002

Fig. 37 Disposal to soak-away
[1] Condensate discharge from appliance [8] Pipework transition [9] Appliances with small capacity trap without CondenseSure
accessory fitted. ( page 33) [11] External air break [15] 100mm minimum Ø plastic pipe [16] Drainage holes [17] Limestone chippings [18] Bottom of sealed tube [19] Increase size of soak away size and the area with limestone
chippings if in clay soil area. Not recommended for high clay soil areas. [21] Increase pipe size

Pre-Installation
Minimum Standard The following guidance indicates the minimum standards that must
be maintained for the Installation and Maintenance of a product.
Appliances with small capacity trap without CondenseSure accessory fitted. All external pipework must be insulated using suitable waterproof and weather resistant insulation. External pipework exceeding three metres in length. One of the following must be installed: Trace heating, -or A condensate pump, -or A CondeseSure accessory. Trace heating fitted: · Check with trace heating manufactures instructions for additional
requirements. Condensate pump or CondenseSure fitted to the appliance: · Installations with increased risk of freezing due to environmental
factors: ­ Insulating the condensate pipework through the external wall [2] must be carried out. ­ The hole through the wall must be sealed to the building fabric on
the internal [1] and external [3] face using a suitable building material.
2 1
3
4

Fig. 38 Through the wall lagging example
[1] Internal face sealed [2] Insulation [3] External face sealed [4] Condensate discharge pipe

0010036808-001

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33

Pre-Installation
4.6 Pressure relief discharge
4.6.1 Pressure relief pipework
CAUTION
Scalding risk from hot water or steam!
The pressure relief valve (PRV) is an appliance safety device and may discharge hot water or steam when activated.
The outlet pipe should be sited in such a way that it does not cause a hazard or an obstruction when discharging, for example above a window, entrance door or other public access way.
The point of termination should provide a visual indicator in case the PRV discharges.
· The pressure relief discharge pipe [1 or 3] should be run in pipe which has a diameter of at least 15mm, that is made of copper or a material that will withstand PRV discharge temperatures and pressures, and which complies with BS 5254 or BS EN 1451.
· Plastic pipework must be properly supported with a maximum of 300mm between supports to prevent sagging.
· The PRV discharge pipe must run continuously downwards away from the appliance to a safe point of discharge.
· The pressure relief should discharge away from any electrical or other hazard, preferably to an external drain or soak-away.
· The pipe [1 or 3] should be finished with a partial bend, to face the external wall (as shown) to ensure safe discharge of hot water.
· In all normal circumstances a PRV discharge pipe installation as described above sufficiently meets all but the most exceptional circumstances. ­ Where the PRV discharge pipe could be susceptible to damage, vandalism, freezing etc that could cause either a blockage or restriction in the ability to discharge safely then a tundish should be considered. The tundish should be sited in a position where damage to the property or injury to occupants cannot occur from any spillage or discharge.

4.6.2 Alternative PRV connections – Combined PRV/condensate The PRV or a combined PRV/condensate discharge can be connected into a suitable internal waste system, the installer must ensure that all the pipework, including the waste pipe, is capable of withstanding PRV temperatures and pressures.
Connection to a waste water pipe is possible by using either: · A shielded tundish with non-return valve used to discharge upstream
of a trap (there must not be a trap directly in the PRV discharge pipe without a tundish). · A PRV can discharge directly into a suitable waste pipe downstream of a trap. Connections must be on top of the pipe to ensure they do not block. A Hotun (or similar) can be fitted for visual indication if desired but is not necessary.
The guidance of BS 6798 sections 6.3.5 and 6.4.3.2a must be followed.
For installations where it is not possible to run the PRV discharge pipe continuously downwards away from the appliance, the remote PRV kit can be used to remove the PRV from the appliance and relocate it to a higher position.

1 1

2

2

3

2

3

4 4

Fig. 39 Pressure relief pipework [1] Discharge pipe (turned back onto external wall example) [2] Outside wall [3] Discharge pipe (into drain or gully example) [4] External drain
34

6720818077-38.1Wo

Greenstar 2000 ­ 6721839340 (2023/06)

4.7 Cleaning primary systems
NOTICE
Risk of damage to system or appliance! Debris from the system can damage the appliance and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee and contravene the Building Regulations. It is a requirement of the Building Services Compliance Guide which
is a second tier document to the Building Regulations to flush and inhibit the primary water system in accordance with BS 7593. The Building Services Compliance Guide recommends that a primary water cleanser is fitted to the system. Worcester Bosch recommend fitting a filter that will help remove both magnetite and non-magnetic debris.
NOTICE
Risk of damage to system or appliance! Salt based, artificially softened water that adjusts the pH value MUST
NOT be used to fill the system. Alternatively there are water softening/treatment products that do
not adjust or alter the pH levels of the water. With these products it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system
NOTICE
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. Heating systems may lose small amounts of water over time. In cases
where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer.
Before cleaning the system: Ensure that the system and pipework is in good working order. Where possible keep the existing appliance/circulating pump in
place when flushing the system before installing the new appliance. Alternatively use an after market power flushing system or similar to remove magnetite and other debris from the central heating system. ­ Even new central heating systems contain contaminants that
need to be removed before treating the system with inhibitor/antifreeze. ­ When an appliance is installed onto a new system then it is possible to use the appliance whilst cleaning the system. A system filter must be fitted to the return to reduce the risk of contaminants entering the appliance. Follow the guidance of BS7593.

Pre-Installation

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.
Products approved to the BuildCert standard are deemed as compatible with the components and equipment within the appliance and system.

The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the appliance (aluminium, mild steel, stainless steel, copper and brass) and any other materials/components within the system.
The concentration level of inhibitor in the system should be checked every 12 months or sooner if system content is lost.

Water treatment products
Suitable water treatment products can be obtained from the following manufacturers:

ADEY FERNOX SENTINEL Table 19

01242 546700 www.adey.com 0330 100 7750 www.fernox.com 01928 704330 www.sentinelprotects.com/uk

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35

Pre-Installation
4.7.1 Flushing the system Flushing the system using existing appliance/circulating pump or new appliance.
Existing appliances/circulation pumps An existing appliance/circulating pump should be used to flush the
system before the new appliance is installed.
New appliances A new appliance must only be used to assist the cleaning of a newly
installed 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. Mark the position of the lockshield valves and open them fully. Fully open all TRVs. Circulate the flushing agent before the appliance is fired up. Run the appliance/system at normal operating temperature as directed by the manufacturer of the flushing agent. Drain and thoroughly flush the system to remove the flushing agent and debris. Do not drain the system through the PRV of new appliances. It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances. Close the drain cocks and manual air vents. For existing appliance/circulating pump actions. Add a suitable inhibitor to the system in accordance with the manufacturers instructions. Fill the system to between 0.8 and 1.7 bar via a WRAS approved filling loop. Vent any air from the appliance and system. For new appliance. Once the new appliance has been installed follow the guidance in Filling the appliance and adding inhibitor section.

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Installation

5 Installation
NOTICE
Risk of damage to appliance or accessories. All the previous pre-installation sections must be read and
requirements met before starting the appliance or flue installations.
CAUTION Risk of injury through incorrect lifting and carrying! Only lift a manageable weight, or ask for help. Bend the knees and keep the back straight with feet apart, when
lifting or putting down heavy objects. DO NOT lift and twist at the same time. Lift and carry object close to the body.

Removing the front casing
The front casing is secured with two screws which are critical to maintain the case seal and to prevent unauthorised removal (electrical safety). Always secure the casing with these screws.
Loosen the two screws [1] and pull the bottom of the casing forward. Lift off the casing.

Appliance on site Check contents of delivery are undamaged. Remove the appliance from its packaging and check the contents
against the scope of delivery. Once the appliance is unpacked the installation can commence.
Important handling instructions · It is advised that two people are used to carry the carton from the
vehicle to the point of delivery. · Once the carton is in the property, the outer carton is removed first.
Care should be taken when releasing the straps. If a sharp implement is used make sure the outer carton is not pierced and that the implement is used in such a way so that it may not cause personal injury. · All sharp objects must be covered or the blade retracted after use and put away in a safe place. Care should be taken when lifting the appliance from the base and the proper technique for safe lifting of any heavy object should be strictly observed.
The appliance packaging and base tray are designed so that the appliance can be tilted backwards onto the outer carton. The carton then becomes a protective mat.
Now remove the front casing and set safely aside. This is to protect the casing from damage during installation.

1
Fig. 40 Removing the front casing
Additional requirements for roof space installations · The unpacked appliance can now be moved into the loft space · Two sets of steps should be used. · Two people should share the lifting of the appliance up to the loft
hatch, tilt and slid on its back into the loft space. · Ensure that the roof space has permanent fixed lighting, a permanent
fixed retractable ladder and a fixed floor area, from the hatch to the appliance installation point. This will allow access for installation, normal use and servicing.
Before installing the appliance, ensure that the system has been cleaned.

0010029675-001

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37

Installation

5.1 Position the appliance
HRisk of explosion from escaping gas! Escaping gas can cause an explosion. Ensure the mains gas supply is isolated before starting any work and
follow all relevant safety precautions.
NOTICE
Incorrect mounting can cause material damage. If the appliance is mounted incorrectly, it may fall off the wall. Ensure the appliance is mounted onto a flat, fixed rigid surface
capable of supporting the appliance weight. Only use screws and rawl plugs that are suitable for the wall type and
weight of the appliance. Ensure all aspects of the installation are considered when positioning
the appliance, flue run and discharge, condensate disposal, PRV discharge etc.

5.1.1 Mounting bracket fixing

Wall mounting template
The wall mounting template has been sized to allow for the minimum clearances around the appliance, ( section 4.3.3 “Appliance clearances”).

1

2

3

WARNING
4
Damage to property!
Damage caused by drilling into pipes, electrical cables, damp proof course or other hazards.
Before drilling ensure that there are no obstructions or other hazards.

NOTICE
Damage to appliance! Residue, metal shavings, and contaminants in the system pipe work can damage the appliance. Flush the system pipe work thoroughly to remove all residue. Follow the instructions with respect to cleaning primary systems.
Running pipes to the appliance. · The area around a rear flue outlet must be avoided.

Fig. 41 Wall mounting template
1 Side exit flue example 2 Rear exit flue example 3 Wall mounting template 4 Primary fixing points D 125mm
The appliance wall mounting template shows the relative positions of the flue and the top fixings of the wall mounting bracket. Fix the wall mounting template [3] to the wall in the desired position. Drill the holes [4] through the template for the primary fixing points
as indicated on the template. ­ Additional fixing points for the appliance will be indicated on the
wall mounting template.

0010029478-001

38

Greenstar 2000 ­ 6721839340 (2023/06)

Flue outlet position. The appliance wall mounting template has the flue centre lines for the following flue systems: · 60/100mm · 80/125mm
Flue turret adaptor The flue turret adaptor has an in-built 3° angle giving the flue
assembly the rise from the appliance to ensure the condensate flows back to the appliance.
Rear flue outlet [2]. Mark centre line of flue to be used; the external diameter of the hole
can also be marked if required. If extensions are to be added then the complete flue must rise at an
angle of 3° from the appliance. Side flue outlet [1]. Mark from the centre line of the wall mounting template to the wall
which the flue will pass through. Allow for a rise of 52mm per metre length of flue, to give a 3° angle. Example hole size. · If a 60/100mm diameter flue is to be used, a 125mm diameter hole
is required. · If using the weather sealing collar by pushing it through from inside
the property, then a 150mm diameter hole is required to accommodate this. Flue outlet position marked and ready to drill hole. Drill hole using a core drill or similar. Clear any debris from the site. Appliance fixings and flue outlet drilled and ready. Remove the wall mounting template.
5.2 Appliance connections
WARNING
Appliance – gas connection Ensure the mains gas supply is isolated before starting any work
and follow all relevant safety precautions.
NOTICE
Appliance – hydraulic connections Ensure all water pipework, to be connected, are isolated/drained and
follow all relevant safety precautions. Be careful of plastic components when using a naked flame on
pipework.

Installing the Valve Set

Installation

Connection set fitting For ease of installation the connection sets can be connected before
the appliance is mounted on the wall bracket.
Refer to figure 42. Ensure the sealing washers are fitted in the connection sets before
installing the connection sets.

7

12 3 45

0010043782-001

Fig. 42 Fitting the connection sets (for orientation reference)

Description CH flow DHW outlet Gas DCW Inlet CH return
Table 20

From left case edge 1 70 mm 2 135 mm 3 200 mm 4 265 mm 5 330 mm

From wall 35mm 35mm 35mm 35mm 35mm

Surplus water may be present inside the appliance due to factory testing.

External condensate pipework or internal pipe runs in unheated areas such as lofts, basements and garages exposed to prolonged cold temperatures should be protected ( chapter 4.5).

Greenstar 2000 ­ 6721839340 (2023/06)

39

Installation
5.3 Hanging the appliance
NOTICE Transport protection covers Remove any internal transport packaging and protection covers from
the appliance where applicable.
NOTICE Risk of damage to casing! The front cover may be damaged whilst mounting the appliance on the wall. Remove front cover prior to hanging.
Connect PRV discharge pipe
It is recommended to fit the PRV pipework after isolation valves are fitted; to provide more tool access for compression fittings.
It is recommended to use the PRV elbow connector [2] supplied. This provides easy installation, guards against potential harmful heat transfer if soldering and allows the boiler to be removed from the wall, if needed, with PRV pipework in place.

Installing pipework
DANGER
Contaminated heating water can damage the appliance! Residue in the pipework can damage the appliance. Flush the pipework before installing the appliance.
Determine internal diameter for the gas supply. All pipe connections in the heating system must be able to withstand
a pressure of 3 bar, and 10 bar in the DHW circuit. Install isolation valves. To fill and drain the heating system, install a drain valve at the lowest
point of the system. Install the Pressure Relief Valve discharge pipe to the latest advice in
BS6798. Always route discharge pipes with a continuous fall.
Appliance connections
NOTICE
Commissioning without water damages the appliance! Only operate the appliance when filled with water.

12
Fig. 43 Connecting to the PRV tail connection [1] PRV tail connection [2] PRV elbow connector [3] Drain valve

3
0010043784-002

To allow for a neat installation and to avoid future access to the drain valve, please consider not to close access to the drain valve by making of the routing PRV pipe tail.

8
1 2 3 456 7
0010043783-001
Fig. 44 Connections on the gas and water side [1] Condensate hose connection [2] CH flow valve [3] DHW outlet connection [4] Gas isolator [5] PRV 90 degree compression (supplied) [6] Cold Mains inlet valve [7] CH return valve [8] Connections for keyless filling link Connect the gas supply, cold mains inlet, DHW outlet and central
heating flow and return.

40

Greenstar 2000 ­ 6721839340 (2023/06)

Connect condensate discharge pipe
Connect the condensate discharge pipe to the appliance condensate hose outlet connection.

Installation
Filling the siphon Pour 200 to 250 millilitres of clean water through the inner flue
opening to fill the siphon before running the appliance.

2
1
0010043785-001
Fig. 45 Connecting to the condensate outlet connection [1] Condensate discharge pipe [2] Condensate hose outlet connection Fitting the hose to the condensate trap Take the cap off the drain on the condensate trap. Fit the condensate hose on the condensate trap.

2
0010033003-001
Fig. 47 Filling the siphon 5.4 Flue turret/adaptor installation
NOTICE Flue installation Refer to the Flue Kit Installation instructions provided with your flue
kit to correctly install the flue with this appliance. Do not exceed the maximum straight length for a horizontal or vertical
flue or a 60mm plume management system (if used) as stated in the relevant Installation and Maintenance Instructions manual or addendum.
Telescopic flue Cutting the flue to an exact measurement is not required as the
telescopic flue terminal can allow for some adjustment.

0010043646-001
Fig. 46 Fitting the hose to the condensate trap
Only route the condensate hose with a slope and connect it to the drain line.
Check tightness of connection at condensate trap.

Apply silicone lubricant to sealing surfaces, to ease assembly of flue components. Refer to the manual supplied with the flue kit for complete installation instructions.
For plume management effective lengths and the effective flue lengths, chapter 4.4.
Additional notes and reminders: · Ensure that all cut lengths are square and free from burrs. · Ensure that the flue and seals are not damaged. · The flue is sealed when assembled correctly, the components are
pushed fully home and secured. · The flue rises from the appliance at an angle of 3° or 52mm per metre
length. · Support the flue at each flue extension joint and at each change of
direction, use suitable brackets and fittings: ­ Flue bracket 100mm part number: 7 716 191 177. ­ Flue brackets 100mm x 6 part number: 7 716 191 178. ­ Flue bracket 125mm part number: 7 716 191 179.
2,000mm
1,000mm

52mm

104mm

Fig. 48 Slope for condensate disposal

0010013472-001

Greenstar 2000 ­ 6721839340 (2023/06)

41

Installation
Refer to figure 49. Remove the three inner flue tube retaining screws [1].
­ The inner tube will be held in place in the appliance. Check the appliance flue seal [2] is correctly seated and apply
silicone grease. Flue turret [A] fitting Align the flue turret [A] to the appliance flue outlet with flat facing [3] to the rear of the appliance. ­ This should be pushed straight down, on to the appliance. The three inner flue tube retaining screws [1] are re-used to secure the flue turret [A]. Vertical adaptor [B] fitting Align the vertical adaptor [B] to the appliance flue outlet with flat facing [3] to the rear of the appliance. ­ This should be pushed straight down, on to the appliance. The three replacement retaining screws [4] supplied with the adaptor kit are used to secure the vertical adaptor [B].
1

3
3
Fig. 49 Flue turret/adaptor connection

2 A
1
B 4
0010023595-001

5.5 Electrical connection
DANGER
Risk of electric shock! Isolate electrical components from the power supply (230 V AC)
(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85. Check for zero potential before proceeding with work, using test equipment approved to GS38 to confirm that the electricity supply is disconnected.
Electrical considerations: All electrical work must be carried out by a competent and authorised
person. All work must comply with the current national and regional
regulations, technical regulations and guidelines for electrical installations. The isolator shall be situated next to the appliance for new systems and, where practicable, replacement appliances. The mains electrical supply to the appliance must be through a fused double pole isolator. The isolator must have contact separation of 3mm minimum between poles. Any system connected to the appliance must not have a separate electrical supply. Any additional components that are connected to the appliance that require 230 Volts must be connected to the same supply as the appliance. The correct type of RCD must be employed where additional protection is required that is suitable for a low energy DC modulating pump according to the current technical wiring regulations. External fuse 3 Amps. When stripping the wires, ensure copper strands do not fall into the control box.
NOTICE
Risk of damage from hot appliance components. Hot appliance components can damage electrical cables. Ensure all electrical cables are in the correct cable guides and away
from hot appliance components.

Cable routing:
Route cables over the valve bracket avoiding any hot components. Run power cables separately from signal cables. Interference from
power cables can induce spurious faults on signal cables, ensure that there is at least 100mm separation between power and signal cables. Ensure the cables are of sufficient length to allow the control box to be moved to the service position.
If the power cable is of insufficient length, accessing the connection terminal ( Fig. 54) Replace with the following cable types:
­ Cable: PVC insulated 0.75 mm2 (24 x 0.2mm) temperature rated to 90 °C.
­ Wiring must comply with the latest edition of BS 7671 (IET wiring regulations).
Connect the cable so that the protective conductor is longer than the other wires.

42

Greenstar 2000 ­ 6721839340 (2023/06)

5.5.1 Component access
Release catch and hinge open the control panel into the service position.

Installation
5.5.2 Installer connections
Connect external accessories Low Voltage (signal cable) accessories connections. Release the latches using a thin bladed screwdriver. Arrows on the
electrical cover indicate the position where the screw driver must be inserted to release the catches. Open the rear cover.

0010043788-002
Fig. 50 Moving control panel into service position
Mains cable routing Mains supply cable routing must be routed through the hole in the
bottom plate Figure 51.

0010043790-002
Fig. 52 Open the cover For splash protection (IP): Cut the strain relief according to the
diameter of the cable.

Care should be taken not to damage cables when cutting strain relief.

1

Fig. 51 Mains supply cable routing

0010044167-001
0010043793-001
Fig. 53 Cable feed Guide the cable through the strain relief. Connect the cable to the terminal block for external accessories. Secure the cable to the strain relief.

Greenstar 2000 ­ 6721839340 (2023/06)

43

Installation
Replaceable mains cable (power cable) and 230v external controls connections. Release the catches [1] and remove cover.

Connect the power cable to the mains connector and earth bracket.

N
230V IN

L LS N LR
230V OUT

0010043794-002
Fig. 54 Open the rear cover
Remove the cable clamp. For splash protection (IP): Cut the strain relief according to the
diameter of the cable [1]. Unscrew the cable retaining screw [2]. Guide the cable through the strain relief. Tighten the cable retaining screw [2] to secure the cable. Replace the cable clamp.

0010044510-002
Fig. 56 Connect the power cable Connect the 230V external controls to the external connector and
earth bracket.

1 3

5mm

N L LS N LR

230V IN

230V OUT

0010027249-001

2 2
Fig. 55 Cable feed The mains cable is pre-fitted, however, it can be replaced or upgraded by following these steps:

0010044516-001
Fig. 57 Connect the power cable Remove the factory-fitted jumper between LS and LR. Remove the edge connector prior to fitting the wire.
This is to remove the risk of copper strands entering the PCB and causing failures.

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Greenstar 2000 ­ 6721839340 (2023/06)

External accessories terminal strip Control unit

Symbol

Function Not used.
Only used for the domestic hot water pre-heat accessory.

Outdoor temperature sensor (accessory)

Communication BUS connection for hard-wired Worcester/Bosch EMS controls.
Low voltage power supply for hard-wired Worcester mechanical controls. 230V external controls connection. 230V feed output and switch live/demand input for external controls.
· External control switch live/demand (Live Return) to the appliance [LR] ­ Remove link between LR and LS when connecting external 230V controls.
· Live output [LS] to external controls. · Neutral output [NS] to external controls. · Earth to be connected on earth bar within the 230V
external controls interface unit.
Table 21 Terminal strip for external accessories
5.5.3 Cable preparations

The appliance is factory-fitted with a 230V mains cable. It can be replaced if a longer cable is needed or, if 230V external controls are fitted, a multi- core cable.

NOTICE
Damage to control unit! Small pieces of wire can cause shorts and damage to electronics. When stripping wires always ensure copper strands do not fall into
the control box.
230V mains cable (power cables), example figure 58 Ensure the conductors (C) can reach the appropriate terminal
connection and that the protective (earth) conductor is longer than the other wires. ­ Power cables connected to the appliance may have different
conductor lengths depending on the termination point.

6-8mm

230V
6-8mm
N

0010023711-001

L
C > C
Fig. 58 Mains voltage (power cables) preparation

Low voltage (signal cables), example figure 59

6-8mm

0-30V

Installation

0010012956-001

26-30mm
Fig. 59 Low voltage (signal cables) preparation 5.5.4 External controls – Domestic installations Appliance external control connections example

External frost protection:
Proprietary external frost protection will only be able to be used if external 230V controls are fitted (wired in parallel to the external 230V controls). Worcester weather-compensating controls have built-in external frost protection functionality ( Worcester controller Instructions manual).
The electrical power supply to the external equipment [2] is supplied from LS (Live), NS (Neutral) terminals and PE – (earth) from the earth bar.
The Switch Live from the external equipment [3]: ­ Heating (()/ zone controls connects to LR (Live Return) terminal, remove the pre-wired link.
External frost thermostat connections [4]: ­ The Live supply is terminal LS. ­ The Switch Live is terminal LR.

N

L

2

230V OUT

1
230V AC

LR

3

OUT IN

4

L LS N LR 230V OUT

5AF

N 230V
IN

5AF

LS – LR

0010042687-001

Fig. 60 External controls connections example
[1] 230V mains supply to the appliance. [2] 230V supply from the appliance to the external controls. [3] Heating (()/ zone Switch Live (Demand) from the external
controls. [4] External frost protection Live supply and Switch Live (Demand).

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45

Commissioning

6 Commissioning
6.1 Pre-Commissioning checks
DANGER
Risk of electric shock! Isolate electrical components from the power supply (230 V AC)
(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85. Check for zero potential before proceeding with work, using test equipment approved to GS38 to confirm that the electricity supply is disconnected.
Checks before commissioning: Check that the service and water pipes are connected correctly. Inspect the entire gas installation, including the meter and conduct a
tightness test in accordance to the latest gas safety technical regulations and guidelines (e.g. UK standards advice found in BS 6891). Check the gas type specified on the identification plate matches that of the gas supply and that the gas supply is properly purged. Check that the appliance is filled with water and under pressure (0.8 to 1.7 bar) and that there are no leaks. Check that the electrical connections of the appliance are correct: ­ Mains electrical supply – 230V, 50Hz ­ Compliant earth connection. ­ Correct polarities. ­ External equipment and controls are wired in correctly. Check that the flue is correctly fitted, airtight, free from any obstruction and the connections are secure. Check that the condensate pipework is connected properly and that there are no leaks.
NOTICE
If the appliance is not to be commissioned immediately then, after successfully completing all of the checks and any rectification work: Isolate the electricity supply. Isolate the gas supply. Close the water shut-off valves to the appliance. Label appropriately.

6.2 Water treatment
Primary system flushing (Central Heating) Ensure that the system has been cleaned: · Following the guidance of BS 7593:
­ Code of Practice for treatment of water in hot water central heating systems.
· Overview available in Pre-installation, Cleaning primary systems section.
Inhibitor (Central Heating): Add a suitable inhibitor that is compatible with aluminium (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.
The pH value of the system water must be between 6.5 and 8 or the appliance warranty will be invalidated.
The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the appliance (aluminium, mild steel, stainless steel, copper and brass) and any other materials/components within the system. Record the date when the inhibitor was added to the system on the
guarantee card. The concentration level of inhibitor in the system should be checked
every 12 months or sooner if system content is lost.
NOTICE
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 system micro leak have failed,
Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

46

Greenstar 2000 ­ 6721839340 (2023/06)

6.2.1 Filling the appliance and adding Inhibitor
Before pressurising the system. The appliance integral expansion vessel is pre-charged to 0.75 bar (equal to a static head of 7.5m (24.6ft)). A Schrader type valve is fitted to the expansion vessel to allow for pressure adjustment if required. If an extra expansion vessel is fitted to the central heating system,
ensure that it is set to the same pressure as the appliance internal expansion vessel, refer to separate instructions supplied with the extra expansion vessel.
Filling the system – Sealed systems
NOTICE
Salt based softened water must not be used to fill the central heating system.
Check that the drain cocks and manual air vents are closed and all radiator valves are open.
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system might be exposed to freezing conditions, to the heating system water in accordance with the manufacturers instructions.
Turn on the water main and open the system valves. Fill the system to between 0.8 and 1.7 bar via a WRAS approved
filling loop or one of the filling link accessories. ­ Refer to filling link accessory instructions for operation and use. The Automatic Air Vent will release any air trapped in the appliance. Manually vent all radiators, tighten the vent screws when completed Check the system for any leaks and correct if required. Top up the system pressure if the pressure has dropped below 0.8 bar. Isolate and remove the filling loop connections to the system. ­ Refer to Integrated filling link accessory instructions for any
further actions required after filling the system.

Commissioning

Adjusting the operating pressure of the heating system
Display on the pressure gauge
Optimal Charge Pressure Range

Minimum Charge pressure

Maximum Charge pressure

Maximum charge pressure at maximum heating water temperature must not be exceeded (pressure relief valve opens).
Table 22
If the indicator is below 1 bar when the system is cold: Top up the water until the indicator is between 1 bar and 1.5 bar
again. If pressure is not being maintained: Check tightness of expansion vessel and heating system.
Operating pressure checking of the heating system via HMI

Table 23

Displayed when system pressure is lower than 1.1 bar.
Displayed when system pressure is higher than 1.3 bar. Stop filling the system and press the ok key.

Keyless filling link
An additional 0.75bar static mains pressure is required above required system pressure to ensure the effective operation of the keyless filling link accessory.

Greenstar 2000 ­ 6721839340 (2023/06)

47

Commissioning
6.3 Circulation pump characteristic curve Self-modulated pump (based on burner load)

CH Differential Pressure [bar] 0,8

0,7

0,6
A
0,5

0,4

0,3

0,2

0,1

B

0 0 200 400 600 800 1000 1200 1400 1600

Flow Rate [l/h]

010050904-001
Fig. 61 Circulation pump characteristic curve
A Pump characteristic at maximum pump speed (100%) B Pump characteristic at minimum pump speed (40%)
In order to save as much energy as possible and the minimize the possibility of water circulation noise, pump speed minimum and maximum values can be adjusted according to the estimated system restrictions of the installation place.
Pump speed maximum and minimum values can be selected via service menu L3 section. Minimum pump speed adjustment: L3-d3 (40% 100%) Maximum pump speed adjustment: L3-d4 (40% – 100%)
Factory settings are: Maximum pump speed: 100% Minimum pump speed: 40%

6.4 Starting the appliance NOTICE
Damage to appliance or system! Running the appliance: Never run the appliance when the appliance/system is empty or
partially filled.
6.4.1 Control panel overview
1

234 5 67 8

9

0010043796-001
Fig. 62
[1] Display [2] (: Heating mode on/off, set the maximum flow temperature [3] *: Hot water mode, adjusting the hot water temperature [4] eco: Toggle economy mode (pre-heat off) [5] ok: Save settings, Chimney sweeper key: press 5 seconds for
chimney sweep mode [6] “: Return/back [7] : To navigate through menus and decrease settings [8] : To navigate through menus and increase settings [9] Pressure gauge

48

Greenstar 2000 ­ 6721839340 (2023/06)

6.4.2 Screen display

12

3

45

6

6.4.3 Switching on the device

Commissioning

The appliance is vented after initial power-up. This involves the heating pump switching on and off at intervals (for approx. 13 minutes).
and the flow temperature appear alternately in the display.
Open automatic air vent valve.

10 9
Fig. 63 Screen display

8

7

0010016015-004

Key Explanation [1] Digital display
· Displays a temperature or appliance status/diagnostic code. [2] Central heating (CH)
· ( Heating mode On · ] Heating mode Off [3] Fault indicator
· Displays during a fault condition. [4] Burner operation
· Displays when the appliance is firing during a CH/DHW mode.
[5] Internet connected (accessory)
· Displays when compatible controller is connected to the appliance (not used).
[6] Radio link connected (accessory)
· Displays when compatible controller is connected to the appliance.
[7] Chimney sweep mode
· Displays during service when the appliance is set to maximum or minimum output.
[8] Service mode
· Displays when a qualified service engineer is in the service menus.
[9] Eco mode active
· Displays when in Economy mode (DHW Pre-heat/comfort function is turned off)
[10] Domestic hot wate

References

• Welcome — Heating and Hotwater Industry Council
• New Boilers | Worcester Bosch
• Installers First
• A guide to central heating protection | boiler efficiency | Sentinel
• WEEE Electronic Waste | Bosch Home Comfort Group
• New Boilers | Worcester Bosch
• Guarantee | Worcester Bosch
• Guarantee Terms And Conditions | Worcester Bosch
• Worcester Spare Parts | Worcester, Bosch Group | Worcester Bosch

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