GREENSTAR CDi

WALL HUNG RSF GAS-FIRED CONDENSING COMBINATION BOILER

FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER

THE APPLIANCE IS FOR USE WITH

NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13 & C33)

NATURAL GAS:
WORCESTER GREENSTAR 25CDi GC NUMBER 47-311-92
WORCESTER GREENSTAR 30CDi GC NUMBER 47-311-93
WORCESTER GREENSTAR 37CDi GC NUMBER 47-406-08
WORCESTER GREENSTAR 42CDi GC NUMBER 47-406-10

LIQUID PETROLEUM GAS:

WORCESTER GREENSTAR 25CDi GC NUMBER 47-311-96
WORCESTER GREENSTAR 30CDi GC NUMBER 47-311-97
WORCESTER GREENSTAR 37CDi GC NUMBER 47-406- 09
WORCESTER GREENSTAR 42CDi GC NUMBER 47-406-11

INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
&SERVICING
(}enchmarf)
CONTACT INFORMATION INSTALLATION & SERVICING INSTRUCTIONS

WORCESTER BOSCH: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

TECHNICAL: 08705 266241 THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER BOSCH APPLIANCE
SERVICE: 08457 256206 MODEL(S) STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE
SPARES: 01905 752571 USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE.
LITERATURE: 01905 752556
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
TRAINING: 01905 752526
STATUTORY OBLIGATION.
SALES: 01905 752640
WEBSITE: [Link]
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.

IF YOU ARE IN ANY DOUBT CONTACT WORCESTER BOSCH TECHNICAL HELPLINE.

WATER TREATMENT:
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER
FERN OX 01799 550811 BOSCH.
[Link]
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813
SENTINEL 0151 420 9595
(EIRE ONLY) WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR SERVIC-
[Link]/sentinel
ING.

ABBREVIATIONS USED IN THIS MANUAL:

0 Diameter
FLUE TERMINAL GUARD: NG Natural Gas
LPG Liquid Petroleum Gas
TOWER FLUE COMPONENTS CH Central Heating
VALE RISE DHW Domestic Hot Water
TONBRIDGE IP Ingress Protection
TN9 1TB SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom

STORE THE APPLIANCE IN A DRY AREA

PRIOR TO INSTALLATION.
SYMBOLS USED IN THIS MANUAL:

Domestic hot water Time clock C H only

• Central heating

Cold water main supply

Programmer/timer

Room thermostat

Electricity supply Wait time period

LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
• When lifting the boiler, bend the knees,
Gas supply
and keep the back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry the boiler close to the body
• Wear protective clothing and gloves to
protect from any sharp edges

INSTALLATION &
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11) Bosch Group
SERVICING INSTRUCTIONS
CONTENTS

SAFETY & REGULATIONS

SAFETY PRECAUTIONS 4
INSTALLATION REGULATIONS 4

APPLIANCE INFORMATION
GENERAL INFORMATION 5
TECHNICAL DATA 6
LAYOUT & COMPONENTS 7-8

PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 9
MAINS SUPPLIES 10
WATER SYSTEMS & PIPEWORK 11
CONDENSATE PIPEWORK 12
BOILER LOCATION & CLEARANCES 13-14
PLUMBING MANIFOLD 15
FLUE TERMINAL POSITIONS 16
FLUE OPTIONS 17-20

INSTALLATION
UNPACKING WALL FRAME AND ANCILLARY ITEMS 21
WALL MOUNTING PLATE I FLUE OPENING 22
CHARGING LINK (FILLING LOOP) 23
UNPACKING THE APPLIANCE 24
FITTING THE APPLIANCE I BOILER CONNECTIONS 25
FLUE INSTALLATION 26-28
CONDENSATE CONNECTION 29
ELECTRICAL 30
POSITION OF WIRED COMPONENTS 31

COMMISSIONING
PRE-COMMISSIONING CHECKS 32
FILLING THE SYSTEM 33
STARTING THE APPLIANCE 34
WATER TREATMENT 35
COMMISSIONING 36
FINISHING COMMISSIONING 37

SERVICING & SPARES

INSPECTION AND SERVICE 38-42
REPLACEMENT OF PARTS 43-52
SETTING THE GAS/AIR RATIO 53
SHORT PARTS LIST 54

CONVERSION KITS
L.P.G. CONVERSION 55

FAULT FINDING & DIAGNOSIS

FAULT FINDING 56
CENTRAL HEATING FUNCTION 57
PREHEAT AND DHW FUNCTION 58
PROTECTION FUNCTION 59

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CDI

6 720 613 700a (2006/11)

CONTENTS
Bosch Group
SAFETY PRECAUTIONS INSTALLATION REGULATIONS

IF YOU SMELL GAS: Gas Safety (Installation & Use) Regulations:

All gas appliances must be installed by a
X DON'T SMOKE OR STRIKE MATCHES competent person in accordance with the above

X DON'T TURN ELECTRICAL SWITCHES ON OR OFF regulations. Failure to install appliances correctly
could lead to prosecution.

V' DO PUT OUT NAKED FLAMES

V' DO OPEN DOORS AND WINDOWS The appliance must be installed in accordance
V' DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED with, and comply to, the current: Gas Safety
V' DO TURN OFF THE CONTROL VALVE AT THE METER Regulations, IE E Regulations, Building
Regulations, Building Standards (Scotland)
(Consolidation), Building Regulations (Northern
V' TELEPHONE THE NATIONAL GAS EMERGENCY SERVICE ON 0800111999
Ireland), local water by-laws, Health & Safety
Document 635 (The Electricity at Work

(/Jenc!Jmorl() Regulations 1989) and any other local

requirements.
A Benchmark Log Book is provided by the manufacturer for the installer to complete
including their CORGI registration number to confirm that the boiler has been installed, British Standards:
commissioned and serviced according to the manufacturer's instructions. The relevant British Standards should be followed,
IMPORTANT: The completed Benchmark Checklist will be required in the event of any including:
warranty work and may be required by the local Building Control Inspector. BS7074:1 :Code of practice for domestic and hot
water supply
HEALTH & SAFETY BS6891 : Installation of low pressure gas
The appliance contains no asbestos and no substances have been used in the pipework up to 28mm (R1)

construction process that contravene the COSHH Regulations (Control of Substances BS5546 : Installation of gas hot water supplies for
domestic purposes
Hazardous to Health Regulations 1988).
EN:12828: Central heating for domestic premises
BS5440:1 : Flues and ventilation for gas appli-
COMBUSTIBLE AND CORROSIVE MATERIALS
ances of rated heating not exceeding 70kW (net) :
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or
Flues
within the vicinity of the appliance.
BS5440:2 : Flues and ventilation for gas appli-
Chemically aggressive substances, such as halogenated hydrocarbons containing ances of rated heating not exceeding 70kW (net) :
chlorine or fluorine compounds can corrode the appliance and invalidate any warranty. Air Supply
BS7593 : Treatment of water in domestic hot
FITTING & MODIFICATIONS water central heating systems
Fitting the appliance and any controls to the appliance may only be carried out by a BS 6798 : Installation of gas fired boilers of rated
competent engineer in accordance with the Gas Safety (Installation and Use) input up to 70kW (net)
Regulations 1998. Where no specific instruction is given, reference
Flue systems must not be modified in any way other than as described in the fitting should be made to the relevant British Standard
codes of Practice.
instructions. Any misuse or unauthorised modifications to the appliance, flue or
associated components and systems could invalidate the warranty. The manufacturer
L.P.G. Installation:
accepts no liability arising from any such actions, excluding statutory rights.
An appliance using L.P.G. must not be installed in
a room or internal space below ground level unless
SERVICING one side of the building is open to the ground.
Advise the user to have the system serviced annually by a competent, qualified
engineer (such as British Gas or CORGI registered personnel) using approved spares, Timber framed buildings:
to help maintain the economy, safety and reliability of the appliance. Where the boiler is to be fitted to a timber framed
IMPORTANT- The service engineer must complete the Service Record in the building the guidelines laid down in BS5440: Part
Benchmark section after each service. 1 and IGE "Gas Installations in Timber Frame
Buildings" should be adhered to.

Potable water:
All seals, joints and compounds (including flux
and solder) and components used as part of
the secondary domestic water system must be
approved by WRAS.

CHwater:
Artificially softened water must not be used to
fill the central heating system.

SAFETY PRECAUTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11) Bosch Group
& INSTALLATION REGULATIONS
 GENERAL INFORMATION

STANDARD PACKAGE:

A- Wall hung gas fired condensing combi boil-

er for central heating and domestic hot water
B - Wall mounting plate
C - Hanging bracket
D - Pre-plumbing manifold
E - Hardware pack
F- Charging Link Assembly
G - Literature pack
H - Bottom panel
I- Trap I Syphon Outlet Connection
(22 mm Plastic Pipe)

c
B

max.
760mm
0 D

69~
I

SPECIFICATIONS:
Pre-wired and pre-plumbed
H
Galvanised steel inner frame
Digital control system
Automatic ignition
Direct burner ignition
Built-in frost thermostat (boiler protection)
Built-in fault finding diagnostics
Modulating automatic gas valve
Combustion air fan with speed regulator
CH temperature sensor & control
Pump anti-seizure protection
Flue gas temperature limiter
Condensate trap & syphon
DHW flow sensor & temperature control
Plate type DHW heat exchanger
Modulating circulating pump

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
GENERAL INFORMATION
Bosch Group 6 720 613 700a (2006/11)
 TECHNICAL DATA

NATURAL GAS L.P.G.

DESCRIPTION UNITS 25CDi 30CDi 37CDi 42CDi 25CDi 30CDi 37CDi 42CDi

Central Heating
Max. rated heat input kW 25.8 30.9 30.9 30.9 25.8 30.9 30.9 30.9

Max. rated heat output net 40/30°C kW 26.8 32.1 32.1 32.1 26.8 32.1 32.1 32.1
Max. rated heat output net 50/30°C kW 26.6 31.8 31.8 31.8 26.6 31.8 31.8 31.8
Max. rated heat output net 80/60°C kW 25.0 30.0 30.0 30.0 25.0 30.0 30.0 30.0
Min. rated heat output net 40/30°C kW 8.6 8.6 10.6 10.6 12.4 12.4 15.7 15.7
Min. rated heat output net 50/30°C kW 8.6 8.6 10.5 10.5 12.3 12.3 15.5 15.5
Min. rated heat output net 80/60°C kW 7.7 7.7 9.4 9.4 11,0 11.0 13.9 13.9
Min. rated heat input net kW 8.0 8.0 9.8 9.8 11.5 11.5 14.5 14.5
Max. flow temperature •c nom. 90 nom. 90 nom. 90 nom. 90 nom. 90 nom. 90 nom. 90 nom. 90
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Available pump head at 21 •c system temperature rise m 2 2 2 2 2 2 2 2
Gas flow rate- Max. 10 minutes from lighting
Natural Gas G20 2.6 3.2 3.9 4.4
Propane Gas (LPG) 2.0 2.4 2.9 3.3
Flue
Flue Gas Temp. 80/60°C, rated min. load •c 70/58 76/58 83/58 87/58 70/58 76/58 83/58 87/58
Flue Gas Temp. 40/30°C, rated min. load •c 51/33 55/33 60/35 66/35 51/33 55/33 60/35 66/35
C02 level at max. rated heat output % 9.6 9.6 9.7 9.7 11.5 11.5 11.5 11.5
C02 level at min. rated heat output % 9.0 9.0 9.1 9.1 10.5 10.5 10.5 10.5
NOx- class 5 5 5 5 5 5 5 5
Condensate
Max. condensation rate 2.3 2.7 2.7 2.7 2.3 2.7 2.7 2.7
pH value, approx. 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC .. .V 230 230 230 230 230 230 230 230
Frequency Hz 50 50 50 50 50 50 50 50
Max. power consumption w 135 150 160 175 135 150 160 175
General Data
SEDBUK band A A A A A A A A
Appliance protection rating IP X4D X4D X4D X4D X4D X4D X4D X4D
Appliance protection rating with mechanical or RF mech. timer fitted IP 20 20 20 20 20 20 20 20

Permissible ambient temperatures •c 0-50 0-50 0-50 0-50 0-50 0-50 0-50 0-50
Nominal capacity of appliance I 3.75 3.75 3.75 3.75 3.75 3.75 3.75 3.75
Noise output level (at DHW inlet pressure 3 bar) dB(A) 40 44 45 47 40 44 45 47
Total boiler weight (lift weight) kg 48.5 48.5 48.5 48.5 48.5 48.5 48.5 48.5
Packaged boiler weight kg 57 57 57 57 57 57 57 57
SEDBUK % 90.3 90.1 90.1 90.1 90.3 90.1 90.1 90.1

TECHNICAL DATA
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 LAYOUT & COMPONENTS

The diagram opposite shows the controls in the

servicing position and excludes the outer case.

FLAME VIEWING WINDOW

2 IGNITION ELECTRODE AND FLAME
SENSE ELECTRODE
3 HEAT EXCHANGER
28 ·--------- 4 OVERHEAT THERMOSTAT

--- --- 5 ACCESS POINT FOR CLEANING HEAT

--- --- --- 2 6

EXCHANGER
PLATE TO PLATE DHW
HEAT EXCHANGER
-- 3 7 PUMP
27 ------------
8 SYSTEM PRESSURE GAUGE
9 DRAIN POINT
4 10 MAINS COLD WATER IN
11 CH RETURN
12 CHARGING LINK ASSEMBLY
13 GAS INLET CONNECTION 22 mm
COMPRESSION
14 COVER FOR EXTERNAL WIRING
. 5 CONNECTIONS
15 CONTROL PANEL IN SERVICE
POSITION
16 ACCESS COVER FOR TRANSFORMER
&PCB
17 DHWOUT
18 CH FLOW
6
19 TRAP I SYPHON OUTLET CONNEC·
TION (22 mm PLASTIC PIPE)
7
20 INLET PRESSURE TEST POINT
21 TRAP I SYPHON
22 GAS VALVE
8 23 DHW TEMPERATURE SENSOR
24 AIR I GAS ADJUSTMENT SCREW
25 TESTING POINT FOR FAN PRESSURE
26 FAN
27 PRIMARY SENSOR
28 EXPANSION VESSEL
29 REMOVABLE TOP CASE PANEL FOR
................ 12 SERVICING

16 ·-

--- ........ 14

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CDI

6 720 613 700a (2006/11)

LAYOUT & COMPONENTS
Bosch Group
 LAYOUT & COMPONENTS

6 PLATE TO PLATE DHW HEAT

EXCHANGER
9 DRAIN POINT
32 SYSTEM PUMP
36 FLOW TURBINE
37 UNUSED PORT
38 AUTO AIR VENT
39 FLOW CONNECTION FROM BOILER
HEAT EXCHANGER
40 DHW SENSOR
41 CH FLOW CONNECTION TO SERVICE
VALVE
42 DHW OUT CONNECTION
43 COLD WATER IN CONNECTION
44 CH RETURN CONNECTION TO SER-
VICE VALVE
45 DIVERTER VALVE
46 PRESSURE RELIEF VALVE
47 COMPACT HYDRAULIC MOUNTING
SCREW (2) TO BOILER

I
I
I
I
I
I
I
I
I
I
I
I
I
---•---47
I
I
I
I
I
I

I ''46
I
I
I
I
',,1
1'-,
I ',,
I 45
I
I
I I •'
I
42 •'
•• •'
41
•••

''
', ; 48 CH TEMPERATURE CONTROL
' I 49 MAINS ON/OFF INDICATOR/DIAGNOS-
'I
TIC LIGHT (BLUE)
I
I 50 DHW TEMPERATURE CONTROL
t 51 CENTRAL HEATING BOOST BUTTON
52 SERVICE BUTTON
53 BURNER ON INDICATOR LIGHT
(GREEN)
54 MASTER SWITCH ON/OFF
55 HOLIDAY BUTTON
56 ECO BUTTON
57 FAULT RESET BUTTON
58 SYSTEM PRESSURE GAUGE
59 POSITION FOR OPTIONAL TEXT
DISPLAY WITH INTELLIGENT FUNC-
TIONALITY OR TIMER
60 DISPLAY
6720611927-10.10

LAYOUT & COMPONENTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 CLEANING PRIMARY SYSTEMS

IMPORTANT: Debris from the system can

IMPORTANT: All the following Pre-Installation sections must be read and
damage the boiler and reduce efficiency.
requirements met before starting boiler or flue installation. Failure to comply with the guidelines for
the use of water treatment with the appli-
ance will invalidate the appliance warranty.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER
KEEP THE EXISTING BOILER/
1 4 CIRCULATING PUMP WHERE POSSIBLE
OR USE A POWER FLUSHING MACHINE
TO AID THE CLEANSING PROCEDURE
BEFORE INSTALLING A NEW BOILER.

CLEANING THE PRIMARY SYSTEM:

Fill the system with cold water and check
for leaks.
2 Open all drain cocks and drain the system.
3 Close drain cocks and add a suitable
flushing agent at the correct strength for
the system condition in accordance with
the manufacturer's instructions.
~ Circulate the flushing agent before the
2 5 boiler is fired up.
4 Run the boiler/system at normal operating
temperature as directed by the manufacturer
of the flushing agent.
5 Drain and thoroughly flush the system to
remove the flushing agent and debris.

KEY

@ Valve

~
Flushing
Agent

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

CLEANING PRIMARY SYSTEMS
Bosch Group
 MAINS SUPPLIES

ELECTRIC SUPPLY:
Supply: 230V- 50Hz

f (See Technical Data for IP ratings.)

Cable: PVC insulated 0. 75mm2
(24 x 0.2mm) temperature rated to 90°C.
External 3A fuse to BS1362.
The appliance must be earthed.
• All pipes to the boiler must be cross-bonded.
Wiring must comply with lEE wiring regula-
tions and any local regulations which may
apply to fixed wiring to a stationary appliance.

GAS SUPPLY:
Boilers using NG must be connected to a
governed meter.
LPG boilers must be connected to a
regulator.
Installation and connection of the gas sup-
ply to the boiler must be in accordance with
BS6891.
Under no circumstances should the size of
the gas supply pipe be less than that of the
appliance inlet connection.
The meter or regulator and pipework to the
meter must be checked, preferably by the
gas supplier, to ensure it is in good working
order and can meet the gas flow and pres-
sure requirements in addition to the demand
from any other appliance being served. This
does not include the pipework from the
meter to the boiler.
For olive connections we recommend using
gas pipes with minimum 0.9 mm wall thickness.

WATER SUPPLY:
Water Mains Pressure:
Minimum mains water pressure 1.5 up to
2.5 bar (see technical data on page 6) for
maximum performance.
Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.

IMPORTANT: Non-return, back flow pre-

MAINS WATER EXPANSION VESSEL: vention devices (including those associat-
A- Mini expansion vessel, part No.7 716 102 105 ed with water meters) fitted to the mains
B - Mains water inlet pipe water supply can cause a pressure build
C- Non-return valve up which could damage the boiler and
D- Boiler D --------• other household appliances.

- Where the mains water supply has a non-

= return, back flow prevention valve fitted, a
mini expansion vessel (A) should be con-
nected to the mains water inlet pipe (B)
B
\
c between the non-return valve (C) and the
\
\
\
\ \
boiler (D) as shown opposite.
\ \
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 circuit.
In areas where the temporary water hardness
exceeds 200 ppm, consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances, the advice of
the local water authority should be sought.

MAINS SUPPLIES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 WATER SYSTEMS & PIPEWORK

PLASTIC PIPEWORK:
• Any plastic pipework must have a polymeric
barrier with 600 mm (minimum) length of
copper or steel pipe connected to the boiler.
Plastic pipework used for underfloor heating
must be correctly controlled with a thermo-
static blending valve limiting the temperature
of the circuits to approx. 50°C.
The pipework from the boiler to the blending
valve must be in copper or steel (protected
from corrosion).

CONNECTIONS/VALVES:
• All system connections, taps and mixing
valves must be capable of sustaining a pres-
sure up to 3 bar.
Radiator valves should conform to
BS2767:10.
• All other valves should conform to BS 1010.
On new installations, or extensions to exist-
ing systems where a radiator previously did
not exist, each radiator should be fitted with
a TRV, except the one fitted in the same
room/area as the room thermostat.
On boiler only replacement jobs, it is recom-
mended, (but not mandatory,) to fit a TRV on
each radiator. It is, however, a requirement,
for energy conservation purposes, to recom-
mend to the customer that a TRV is fitted to
each radiator.
• An automatic bypass may be required,
(downstream of the pump), in order to main-
tain the minimum flow-rate through the appli-
ance.
• A drain cock is required at the lowest point
on the system.
• An air vent is required at the highest point
on the system.

SHOWERS/BIDETS
If a shower head can be immersed in water
TYPICAL SEALED SYSTEM or comes closer than 25 mm from the top
A- Appliance expansion vessel edge of a bath or shower tray spill over level
- central heating then an anti-siphon device must be fitted to
B- Extra expansion vessel the shower hose.
- central heating return Bidets with direct hot & cold mains water
C- Drain cock can be used (with the approval of the local

~ ~ ~~ ~ ~ [
p- Pressure relief discharge water authority) and must be the over rim
R- Radiators flushing type with shrouded outlets to pre-
vent the fitting of hand held sprays.

SEALED PRIMARY SYSTEM:

The CH sealed system must be filled using
the built-in filling link (see page 23).
,,--, Where the system volume is more than
, '
'
I, A I
100 litres or exceeds 2.65 bar at maximum
\.... __ ... ,l heating temperature an extra expansion ves-
sel (B) must be fitted as close as possible
to the appliance in the central heating
return.
Pressurize the extra expansion vessel (B) to
the same figure as the expansion vessel
built into the appliance.
c Do not use galvanised pipes or radiators.
6 720 611 927-02.10

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

WATER SYSTEMS & PIPEWORK
Bosch Group
 CONDENSATE PIPEWORK

CONDENSATE PIPEWORK:
The condensate pipe must be a minimum of
22 mm 0 plastic pipe.
The condensate pipework must fall at least
50 mm per metre towards the outlet and
should take the shortest practicable route.
The pipework must follow one of the options
shown opposite into an internal serviceable
trap (min. 75 mm) such as a sink/washing
machine) and discharge direct into a vent stack
(E) min. 450 mm above pipe invert or into a gul-
3 4 'I ley (D) below ground but above the water level.
'I Wherever possible the condensate dis-
'I charge pipe work should be routed and ter-

~ 'I minated internally. Should this not be possi-

ble, and the only available route is external,
A+ ~

~1
'I/~
the following conditions should be
observed:

lnvectlb 'I
'I
'I : ~'
D
Pipe work length should be kept to a
minimum and the route as vertical as
possible.
Where pipe work could be subjected to
5 extreme cold or wind chill, a weather
Internal sink/washing machine
proof insulation should be used.
drain
G Alternatively the condensate pipework
2 Internal waste drainage system
could be increased to a minimum 32 mm
r1 : / 25mm 3 Soil/vent stack
without the requirement to insulate.

----------r~1 ~·~---f-- -- H
m1n. 4 External drainage system
5 External condensate absorption
IMPORTANT: Ensure there are no block-
point
400mm ages in the pipe run.
"·------K m1n. A - Condensate from boiler
m -------J B- Sink
C- 22 mm 0 plastic condensate pipe
D- Gulley
E- Internal soil and vent stack
F- Serviceable waste trap (75 mm min)
G- 300 mm x 100 mm 0 sealed plastic
tube
H - Ground level
J - Drainage holes 50 mm from base of
tube (12 mm 0 at 25 mm centres)
PRESSURE RELIEF PIPEWORK
facing away from building
K - Limestone chippings IMPORTANT: The pressure relief valve is a
safety device for the boiler and if activated
may discharge boiling water or steam
through the relief valve drain pipe.
Care should be taken when siting the out-
let pipe so that it does not cause an
obstruction or discharge above a window,
entrance or other public access where it
could cause a hazard.
- ................'•
The pressure relief drain pipe (M,O) from
"~\,
\ the boiler should be at least 15 mm diameter
\
\
copper pipe and run downwards away from
any electrics or other hazard, preferably to
an external drain or soakaway.
Pipe (M) should be finished with a partial
bend, near the outlet to face the external
L- Outside wall wall (as shown) to help prevent freezing.
M,O- Drain pipe Use waterproof pipe insulation in exposed
N- External drain positions and for external pipework.

CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
SERVICING CLEARANCES ~- - BOILER LOCATION &

CLEARANCES
+30mn
above elbow
This boiler is only suitable for installing internally
within a property at a suitable location onto a
fixed, rigid non-combustible surface at least the
same size as the boiler and capable of support-
ing the boiler weight.

COMPARTMENTS:
Using 1 00 mm flue kit Follow the requirements of BS6798 and
-1112 mm BS5440 Part 2 and note:
Using 1 25 mm flue kit 5mm Minimum clearances must be maintained
-1152 mm • An access door is required to install, service
'20mm and maintain the boiler and any ancillary
' to removable door equipment.
600mm • If fitting the boiler into an airing cupboard
' front clearance
use a non-combustible perforated material
' for service
(maximum hole sizes of 13mm) to separate
the boiler from the airing space.

' 200 mm '

BOILER CLEARANCES:
The diagram opposite shows the m1n1mu
space required to install and service the boiler.

VENTILATION
This is a room sealed appliance and does not
require any air for combustion from inside the
property. If the appliance is fitted into a cup-
board or a compartment is built around the
appliance after installation, then the compart-
ment must be separated from the boiler space
by a perforated non-combustible partition as
described in BS 6798.
Notwithstanding the requirements of BS 6798
and BS 5440 there is no need for ventilation
openings to be provided in the compartment
because of the low heat loss from the appliance
casing, if the clearances shown are maintained.
Do not operate the appliance if the flue terminal
fitted on the outside wall or roof is obstructed
or damaged.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

BOILER LOCATION & CLEARANCES
Bosch Group
 BOILER LOCATION &

CLEARANCES

aoomm
BATHROOMS:
The boiler can be installed in zones 2 or 3. If a
750mm
mechanical or RF mechanical timer or text dis-
play with room thermostat (IP 20 only) is fitted
® @ CD CD 2250mm
the boiler can only be installed in zone 3.

@ ® A Non mechanical timer can be installed in

zone 2.
See lEE wiring regulations.
(See Technical Data for IP ratings.}

IMPORTANT: any switch or appliance

control using 230 V mains electricity must
not be able to be touched by a person
using the bath or shower.

Electrical switches, fused spur and socket

outlets must not be situated in the bath-
aoomm room.

For further information about bathroom installa-

750mm
lions please consult Operational Procedures
Part 20, Electricity.

@ ® 2250mm

600mm radius
6720611927-13.10

BOILER LOCATION & CLEARANCES

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 c;J!:_ DHW Out (alternative from above appliance) 15 mm PLUMBING MANIFOLD

lU
•
Gas Supply (alternative from above appliance) 22 mm
CONNECTIONS:
:~
Heating System: 22 mm compression fittings
CH Flow c..~
c:;J!:_ Mains Water In (alternative from above appliance) 15 mm DHW: 15 mm compression fittings
(alternative ~- Gas: 22 mm compression fittings
1
from above I • CH Return (alternative from above appliance) 22 mm Use the fittings supplied in the Hardware
I
appliance) I pack.
22 mm I
I
I PREPLUMBING
H With the plumbing manifold installed,
pipework can be installed to the valves on the
manifold.
The system can be filled (without the boiler
being connected) using the charging link
assembly (see page 23).
The valves can be closed enabling the DHW
and CH systems to be tested. The boiler can
be installed at later date.

RUNNING PIPES BEHIND THE BOILER

If the boiler pipes are to be run behind the
appliance ensure that the pipes pass close to
the wall as shown in the diagram opposite,
and within the pipe guide.

CH flow
22 mm

DHW Out 15 mm

Mains Gas Supply 22 mm

• CH return 22 mm
Mains Water In 15 mm

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CDI

6 720 613 700a (2006/11)

PLUMBING MANIFOLD
Bosch Group
 FLUE TERMINAL POSITIONS

Minimum dimensions of flue terminal positions for balanced room sealed flues with The flue must be fitted and terminated in
fanned draught: accordance with the recommendations of
BS5440 : Part 1.
DRWG. TERMINAL POSITION DISTANCE The flue must not cause an obstruction.
REF: Discharge and any noise from the flue outlet
must not cause a nuisance.
A' Directly below an opening, air brick, opening windows, etc. 300mm
Flue gases have a tendency to plume and in
B' Above an opening, air brick, opening window, etc. 300mm certain weather conditions a white plume of
condensation will be discharged from the
C' Horizontally to an opening, air brick, opening window, etc. 300mm
flue outlet. Where this could be a nuisance,
D Below gutters, soil pipes or drain pipes 75mm for example, near security lighting, an alter-
nate position should be found.
E Below eaves 200mm
The air inlet/outlet duct and the terminal of
F2 Below balconies or car port roof (lowest point) 200mm the boiler must not be closer than 25mm to
any combustible material.
G From a vertical drain pipe or soil pipe 150mm
Detailed recommendations on protection of
H From an internal or external corner 300mm combustible materials are given in
BS 5440:1
I Above ground, roof or balcony 300mm
• A protective terminal guard must be fitted if
J From a surface facing the terminal 600mm the terminal is 2m or less above a surface to
which people have access.
K From a terminal facing the terminal 1200mm
The guard must be spaced equally (mini-
L2 From an opening in the car port (e.g. door, window) into the dwelling 1200mm mum 50 mm) around the flue and fixed to
the wall with plated screws. See Contact
M Vertically from a terminal on the same wall 1500mm
Information (inside front cover).
N Horizontally from a terminal on the same wall 300mm

0 From a non combustible vertical structure on the roof

*
p

0
Above intersection with roof

Adjacent to windows or openings on pitched and flat roofs

*
600mm

R Below windows or openings on pitched roofs 2000mm

In addition, the terminal should not be nearer than 150mm (fanned draught} to an opening
in the building fabric formed for the purpose of accommodating a built-in element such as a
window frame.
2 Not recommended.

* See instructions supplied with vertical flue kits.

FLUE TERMINAL POSITIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 FLUE OPTIONS 25CDi
STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL
--------~ START+ 2 BENDS
The diagrams (opposite) show the compo-
F bi 0' ----,1' lu
:z?' A nents used and the maximum flue length for
B L___ _ ____.. each configuration of 100 mm and

0100 co •
125 mm 0 flues.
Shaded flue components indicate the stan-
MAX 686 mm Ax 1
0100-8000 mm dard 100 mm 0 horizontal flue.
MIN 250 mm Ax 1*
A X 1+ cX2+ B X 10 • Only straight flue sections can be reduced
0125 + Fx 1 in length and cut.
MAX 1070 mm Ax 1 • The flue terminal end can be fitted from the
0125- 21000 mm
MIN 250 mm Ax 1* inside or outside of the building.
A X 1+ cX2+ B X 22
* Requires cutting Fixing kits are supplied with the flue exten-
+ Fx 1
sion kits.
Horizontal125 mm 0 and Vertical100 mm
and 125 mm 0 flue kits are available with
MAXIMUM FLUE HORIZONTAL MAXIMUM FLUE VERTICAL separate instructions. Contact your supplier
START+ 3 BENDS or Worcester Bosch.

F
B A c D
c 0 QH ilb--l 0 v
0100- 10000 mm
Ax1+Bx10
0100-6000 mm
Ax1+Cx3
+Bxg+Fx1
B
ED F
fd_
0125- 23000 mm
0125- 1gooo mm
Ax 1 + B x 23 A- Standard horizontal flue (100 mm 0 shown)
Ax1+Cx3
+ B X 21 + F X 1 B - Straight flue extension
C- Flue bend, goo
D - Flue bends, 45°
E - Vertical terminal (vertical adaptor supplied
with terminal)
MAXIMUM FLUE VERTICAL START+ 1 BEND MAXIMUM FLUE VERTICAL F- Vertical adaptor (used with horizontal
WITH 2 X 45° BENDS terminal)

E
B
0 c
D V Calculating the flue length:
Measure the total flue length required, noting
0100- 10000 mm
0100- g500 mm that the maximum straight flue length including
Ax1+Cx1+Bx11
(including terminal) the terminal is:
+ Fx 1
Bx10+Dx2+Ex1 Horizontal 60/100 mm 0: 10000 mm
0125- 23000 mm Horizontal80/125 mm 0: 23000 mm
0125- 21000 mm
AX 1 + cX1+ B X 23
(including terminal) Vertical60/100 mm 0: 11500 mm
+ Fx 1 Vertical 80/125 mm 0: 23000 mm
B X 21 + D X 2 + E X 1

Then reduce the total straight flue length for

each extra flue bend (excluding the turret) by:
2000 mm for goo
MAXIMUM FLUE HORIZONTAL+ 1 BEND VERTICAL FLUE WITH 1000 mm for 45°
2 X goo BENDS
Flue extension total lengths:
Horizontal & Vertical 60/100 mm 0: g5o mm
Horizontal & Vertical 80/125 mm 0: 1000 mm
E
0 c B Flue terminal total lengths:
Horizontal 60/100 mm 0: 800 mm
0100- 8000 mm c 0 Horizontal80/125 mm 0: 1200 mm
Ax1 + Bxg+Cx1
0100- 7500 mm Vertical60/100 mm 0: 1140 mm
0125- 21000 mm (including terminal) Vertical 80/125 mm 0: 1365 mm
A X 1 + B X 21 + cX1 Bxg+ Cx2 +Ex1
0125- 1gooo mm
(including terminal)
Bx20+ Cx2 +Ex1 6 720 611 927-08.1 0

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD•
FLUE OPTIONS 25CDi
Bosch Group 6 720 613 700a (2006/11)
 FLUE OPTIONS 30CDi
STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL
START+ 2 BENDS
The diagrams (opposite) show the compo-
QH IPA F .bi d I iPA nents used and the maximum flue length for
B ~---~ each configuration of 100 mm and

0100 co •
125 mm 0 flues.
Shaded flue components indicate the stan-
MAX 686 mm Ax 1
0100- 5goo mm dard 100 mm 0 horizontal flue.
MIN 250 mm Ax 1*
Ax1+Cx2+ Bx8 Only straight flue sections can be reduced
0125 + Fx 1 in length and cut.
MAX 1070 mm Ax 1 • The flue terminal end can be fitted from the
0125- 16500 mm
MIN 250 mm Ax 1* inside or outside of the building.
AX 1+ c X2+ B X 18
* Requires cutting Fixing kits are supplied with the flue exten-
+ Fx 1
sion kits.
Horizontal 125 mm 0 and Vertical 100 mm
and 125 mm 0 flue kits are available with
MAXIMUM FLUE HORIZONTAL MAXIMUM FLUE VERTICAL separate instructions. Contact your supplier
START+ 3 BENDS or Worcester Bosch.

F
B A c D
c 0 _QH IP 0 v
0100- 7goo mm
Ax1+Bx8
0100- 3goo mm
Ax1+Cx3
+Bx7+Fx1
B
EB F
Q
0125- 18500 mm
0125- 14500 mm
A X 1 + B X 18 A - Standard horizontal flue (1 00 mm 0 shown)
Ax1+Cx3
+Bx17+Fx1 B - Straight flue extension
C - Flue bend, goo
D - Flue bends, 45°
E - Vertical terminal (vertical adaptor supplied
with terminal)
MAXIMUM FLUE VERTICAL START+ 1 BEND MAXIMUM FLUE VERTICAL F- Vertical adaptor (used with horizontal
WITH 2 X 45° BENDS terminal)
_____ ,.,
I

0 c
E
B
B
D V Calculating the flue length:
Measure the total flue length required, noting
0100- 7goo mm
0100- 7400 mm that the maximum straight flue length including
Ax1+Cx1+Bxg
(including terminal) the terminal is:
+ Fx 1
Bx8+Dx2+Ex1 Horizontal 60/100 mm 0: 7goo mm
0125- 18500 mm Horizontal 80/125 mm 0: 18500 mm
0125- 16500 mm
Ax1+Cx1+Bx1g Vertical 60/100 mm 0: g400 mm
(including terminal)
+ Fx 1 Vertical 80/125 mm 0: 18500 mm
Bx17+ Dx2 +Ex1

Then reduce the total straight flue length for

each extra flue bend (excluding the turret) by:
2000 mm for goo
MAXIMUM FLUE HORIZONTAL+ 1 BEND VERTICAL FLUE WITH 1000 mm for 45°
2 X goo BENDS
Flue extension total lengths:
bJ Oc__ _JL__uc
iP A Horizontal & Vertical 60/100 mm 0: g5o mm

0 c
B
E
B
B Horizontal & Vertical 80/125 mm 0: 1000 mm

Flue terminal total lengths:

Horizontal 60/100 mm 0: 800 mm
0100- 5goo mm c 0 Horizontal 80/125 mm 0: 1200 mm
Ax1 + Bx7+Cx1
0100-5400 mm Vertical 60/100 mm 0: 1140 mm
0125- 16500 mm (including terminal) Vertical 80/125 mm 0: 1365 mm
Ax1 + Bx17+Cx1 Bx7+ Cx2 +Ex1
0125- 14500 mm
(including terminal)
Bx16+ Cx2 +Ex1 6 720 611 927-08.1 0

FLUE OPTIONS 30CDi

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 FLUE OPTIONS 37CDi
STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL
START+ 2 BENDS
The diagrams (opposite) show the compo-
_g) o I ii9 A F .!d. d I IP A nents used and the maximum flue length for
each configuration of 100 mm and
B ~---~
0100 co •
125 mm 0 flues.
Shaded flue components indicate the stan-
MAX 686 mm Ax 1
0100- 1000 mm dard 100 mm 0 horizontal flue.
MIN 250 mm Ax 1*
Ax1+Cx2+ Bx3 • Only straight flue sections can be reduced
0125 + Fx 1 in length and cut.
MAX 1070 mm Ax 1 • The flue terminal end can be fitted from the
0125- 13000 mm
MIN 250 mm Ax 1* inside or outside of the building.
A X 1+ cX2+ B X 14
* Requires cutting Fixing kits are supplied with the flue exten-
+ Fx 1
sion kits.
Horizontal125 mm 0 and Vertical100 mm
and 125 mm 0 flue kits are available with
MAXIMUM FLUE VERTICAL separate instructions. Contact your supplier
MAXIMUM FLUE HORIZONTAL
START+ 3 BENDS or British Gas.
A
F bJ. O:[===~=JiiL
iu
l i'
9
B A c D
c 0 QH l:b--" 0 v
0100- 3000 mm
Ax1+Bx3
0100- N/A
B
ED F
Jd.
0125- 15000 mm
0125- 11000 mm
Ax1+Bx14 A - Standard horizontal flue (1 00 mm 0 shown)
Ax1+Cx3
+ B X 13 + F X 1 B - Straight flue extension
C - Flue bend, goo
D - Flue bends, 45°
E - Vertical terminal (vertical adaptor supplied
with terminal)
MAXIMUM FLUE VERTICAL START+ 1 BEND MAXIMUM FLUE VERTICAL F- Vertical adaptor (used with horizontal
WITH 2 X 45° BENDS terminal)
'

'"
E
B
0 c
D V Calculating the flue length:
Measure the total flue length required, noting
0100-3000 mm
0100-4000 mm that the maximum straight flue length including
Ax1+Cx1+Bx4
(including terminal) the terminal is:
+ Fx 1
Bx4+Dx2+Ex1 Horizontal 60/100 mm 0: 3000 mm
0125- 15000 mm Horizontal 80/125 mm 0: 15000 mm
0125- 14000 mm
A X 1+ cX1+ B X 15
(including terminal) Vertical 60/100 mm 0: 6000 mm
+ Fx 1 Vertical 80/125 mm 0: 16000 mm
Bx14+ Dx2 +Ex1

Then reduce the total straight flue length for

each extra flue bend (excluding the turret) by:
2000 mm for goo
MAXIMUM FLUE HORIZONTAL+ 1 BEND VERTICAL FLUE WITH 1000 mm for 45°
2 X goo BENDS
Flue extension total lengths:
_g) 0'-------"'---M-iiY A Horizontal & Vertical 60/100 mm 0: g5o mm
B Horizontal & Vertical 80/125 mm 0: 1000 mm
E
0 c B Flue terminal total lengths:
Horizontal 60/100 mm 0: 800 mm
0100- 1000 mm c 0 Horizontal 80/125 mm 0: 1200 mm
Ax1+Bx1+Cx1
0100- 2000 mm Vertical60/100 mm 0: 1140 mm
0125- 13000 mm (including terminal) Vertical 80/125 mm 0: 1365 mm
A X 1 + B X 13 + cX1 Bx3+ Cx2 +Ex1
0125- 12000 mm
(including terminal)
Bx13+ Cx2 +Ex1 6 720 611 927-08.1 0

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
FLUE OPTIONS 37CDi
Bosch Group 6 720 613 700a (2006/11)
 FLUE OPTIONS 42CDi
STANDARD FLUE HORIZONTAL MAXIMUM FLUE VERTICAL
START+ 2 BENDS
The diagrams (opposite) show the compo-
QH IPA F .bi d I iPA nents used and the maximum flue length for
B ~---~ each configuration of 100 mm and

0100 co •
125 mm 0 flues.
Shaded flue components indicate the stan-
MAX 686 mm Ax 1
0100- N/A dard 100 mm 0 horizontal flue.
MIN 250 mm Ax 1*
Only straight flue sections can be reduced
0125 in length and cut.
MAX 1070 mm Ax 1 • The flue terminal end can be fitted from the
0125- 10500 mm
MIN 250 mm Ax 1* inside or outside of the building.
A X 1 + c X 2 + B X 12
* Requires cutting Fixing kits are supplied with the flue exten-
+ Fx 1
sion kits.
Horizontal 125 mm 0 and Vertical 100 mm
and 125 mm 0 flue kits are available with
MAXIMUM FLUE HORIZONTAL MAXIMUM FLUE VERTICAL separate instructions. Contact your supplier
START+ 3 BENDS or Worcester Bosch.

F
B A c D
c 0 _QH IP 0 v
0100- 2600 mm
Ax1+Bx2
0100- N/A
B
EB F
Q
0125-12500 mm 0125- 8500 mm
Ax1+Bx12 Ax1+Cx3 A - Standard horizontal flue (1 00 mm 0 shown)
+Bx11 +Fx1 B - Straight flue extension
C - Flue bend, goo
D - Flue bends, 45°
E - Vertical terminal (vertical adaptor supplied
with terminal)
MAXIMUM FLUE VERTICAL START+ 1 BEND MAXIMUM FLUE VERTICAL F- Vertical adaptor (used with horizontal
WITH 2 X 45° BENDS terminal)
_____ ,.,
I

0 c
E
B
B
D V Calculating the flue length:
Measure the total flue length required, noting
0100- 2600 mm
0100- 2goo mm that the maximum straight flue length including
Ax1+Cx1+Bx3
(including terminal) the terminal is:
+ Fx 1
Bx3+Dx2+Ex1 Horizontal 60/100 mm 0: 2600 mm
0125- 12500 mm Horizontal 80/125 mm 0: 12500 mm
0125- 14000 mm
A X1 + c X1 + B X 13
(including terminal) Vertical 60/100 mm 0: 4goo mm
+ Fx 1 Vertical 80/125 mm 0: 16000 mm
B X 14 + D X 2 +EX 1

Then reduce the total straight flue length for

each extra flue bend (excluding the turret) by:
2000 mm for goo
MAXIMUM FLUE HORIZONTAL+ 1 BEND VERTICAL FLUE WITH 1000 mm for 45°
2 X goo BENDS
Flue extension total lengths:
bJ Oc__ _JL__uc
iP A Horizontal & Vertical 60/100 mm 0: g5o mm

0 c
B
E
B
B Horizontal & Vertical 80/125 mm 0: 1000 mm

Flue terminal total lengths:

Horizontal 60/100 mm 0: 800 mm
0100-600 mm c 0 Horizontal 80/125 mm 0: 1200 mm
Ax1 + Bx1 +Cx1
0100- N/A Vertical 60/100 mm 0: 1140 mm
0125- 10500 mm Vertical 80/125 mm 0: 1365 mm
Ax1 + Bx11 +Cx1

0125- 12000 mm
(including terminal)
Bx13+ Cx2 +Ex1 6 720 611 927-08.1 0

FLUE OPTIONS 42CDi

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
IMPORTANT: All the previous Pre-Installation sections must be read UNPACKING WALL FRAME
and requirements met before starting boiler or flue installation.
AND ANCILLARY ITEMS

LIFTING AND CARRYING PRECAUTIONS:

Lift only a manageable weight, or ask for

help.
• When lifting the boiler, bend the knees,
and keep the back straight and feet apart.
Do not lift and twist at the same time.
Lift and carry the boiler close to the body.
• Wear protective clothing and gloves to
protect from any sharp edges.

A- Carton
B - Wall mounting plate
C - Hanging bracket
D - Pre-plumbing manifold
E - Hardware pack
F- Charging Link Assembly
G - Literature pack
H - Bottom panel

11
D B
I- Trap I Syphon Outlet Connection
(22 mm Plastic Pipe)
J - Upper support (polystyrene)

CJ

I 0
IMPORTANT HANDLING INSTRUCTIONS
• It is advised that two people are used to
carry the carton from the van to the point of
delivery.
• Once the carton has been delivered, the
top of the carton is opened. If a sharp imple-
ment is used make sure the carton is not
pierced and that the implement is used in
such a way so that it may not cause person-
al injury. All sharp objects must be covered
or the blade retracted after use and put
away in a safe place.
~ 1. The upper support is now removed with
the components (bottom panel, pre-plumb-
ing manifold, fixings, documentation set,
charging link, hanging bracket).
~ 2. The boiler wall mounting plate can now
be pulled out.

t
H
Additional requirements for roof space installa-
tion:
• The boiler should be first unpacked before
~A ascending ladder to loft space.
• Two sets of steps should be used.
• Two people should share the lifting of the
boiler up to the loft hatch, where the boiler
is entered into the loft space tilted and slid
on its back into the loft.
Once the appliance is removed from its pack-
aging check the contents against the packing
G
list.
Before installing appliance ensure system
has been cleaned as explained on page 9.
6 720 611 927-17.1 0

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

UNPACKING WALL FRAME AND
Bosch Group ANCILLARY ITEMS
 10mm0 WALL MOUNTING PLATE

FLUE OPENING

CAUTION: Ensure there are no pipes, elec-

tric cables, damp proof courses or other
hazards before drilling.

SAFETY:
All relevant safety precautions must be under-
taken. Protective clothing, footwear, gloves and
safety goggles must be worn as appropriate.

- hdeAf
0
'

!
FIXING THE POSITION OF THE WALL
MOUNTING PLATE:
The diagram opposite shows the relative
I' positions of the flue and the fixing of the wall
mounting plate, the mounting plate and pre-
I' plumbing manifold.
I' ~ Place the wall mounting plate against the
wall in the desired position.
I' ~ Mark 3 fixing points through the holes (A, B,

~
C) in the wall mounting plate.
~ Drill the 3 holes for wall mounting plate, wall
hanging bracket and pre-plumbing manifold.

OJ ~ Secure wall mounting plate with hanging

bracket with 3 screws (supplied with the
min. 5 mm boiler). Do not fully fasten the lower 2
-...: screws.
' -
:;~-=---
0 ~ Use the horizontal slots in the wall mounting
plate to level the hanging bracket, mark the
4th hole and drill.
~ Fix and secure the hanging bracket with
both screws.

FLUE OUTLET
~ Follow the diagram opposite to mark the
6 720 611927-04.10
centre of the flue for rear outlet (1, & 2) or
for side outlet (2 & 3).
** Note: increase this height by 52 mm for
every 1000 mm of horizontal length that the
flue outlet is away from the boiler.
~ For the 60/100 mm 0 flue make a 125 mm
diameter hole through the wall using a core
drill or similar.
For flues using an optional weather collar,
fitted from inside the building make a
150 mm 0 hole.
~ Clear away any debris.

FIXING THE PRE-PLUMBING MANIFOLD:

~ Mount the pre-plumbing manifold on the 2
lower screws and secure the screws.

WALL MOUNTING PLATE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11) Bosch Group
FLUE OPENING
 CHARGING LINK

(FILLING LOOP)

In order to fill or flush the system prior to the

boiler being hung, you must use your re-usable
System Filling Kit- Part Number 7716 192 282.
~ Fully close the isolating valves on both the
DHW inlet and CH return connections.
~ Check that the gas and water connections
are tight.
~ 1.1 Unscrew the blanking plugs from both
the DHW inlet and CH return connections.
~ Place the filter inside the inlet side of the
Charging Link ensuring that the filter mesh
is inside the inlet.
~ Fit the Charging Link assembly onto the
DHW inlet and CH return connections.
~ Do not insert the Charging Key at this stage.
~ 1.2 Ensure that the Charging Link is pushed
in fully to the stop tabs on both sides of the
Charging Link.
~ Fit two M4 screws complete with washers
to each of the two connections. NB: It is not
possible to access the third screw hole so
this can be left.
~ Do not attempt to turn the brass hexagon
0 connectors.
~ 1.3 Ensure that the white plastic Control
Screw on the Charging Link is turned fully
into its closed position, see diagram (1.3).
~ Open the isolating valves on both the DHW
inlet and CH return connections.
~ Insert the Charging Key initially aligning the
arrow on the key with the "unlock" symbol
on the Charging Link body. Ensure that the
key is inserted fully and turn to the "lock"
position. Check that the key is secure, see
diagram (1.3).
~ To fill the system from the DHW inlet turn
the white plastic Control Screw on the
Charging Link to the fully out position.
~ Once the system has been filled turn the
white Control Screw to its closed position
and then remove the Charging Key by turn-
ing back to its "unlock" position and with-
drawing. Store the Charging Key in the clip
provided on the inside of the bottom panel.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

CHARGING LINK (FILLING LOOP)
Bosch Group
 UNPACKING THE APPLIANCE

UNPACKING THE APPLIANCE

A - Outer carton

B - Packaging base
C - Protective wrapping
D - Appliance outer case
E- Screws
F- Clip
G - Protective packaging

~ t With the wall frame and ancillary items

removed (see p.21), lay the carton (A) on its
back.
~ 2. Open the carton bottom flaps and fold
under boiler. Do not remove the packaging
base.
~ 3. Stand carton (A) with boiler upright on
the packaging base (B).
~ 4. Remove outer carton (A) and place safely
away from the working area.
~ 5. Remove the protective wrapping (C)
~ 6. Lie the boiler on its back.
~ 7. Remove the packaging base (B) and
place safely away from the working area.

REMOVING OUTER CASE

~ 8. Loosen but do not remove the 2 screws
(E) securing boiler casing at the bottom of
the appliance.
~ 9. Pull upwards to release the clip (F) on top
of the boiler and pull the case upwards.
~ 10. Remove the outer case.
~ 11. Remove the protective packaging (G)
from the electrode assembly.

as handle

\ ~
[;)
9/ -------------

I
I
/ --
I
I
I
I
I
I
I
I
I
I
I
I
I

UNPACKING THE APPLIANCE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 .... -- ........... --, -, FITTING THE APPLIANCE
3 ,""" ',,
' ',
I
/ '' BOILER CONNECTIONS
I '' I
I I
I
I I
CAUTION: ISOLATE THE MAINS GAS
I
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
I
I GAS AND WATER CONNECTIONS:
I
/
~ System pipes may be run vertically upwards
behind the boiler or below it. See Plumbing
..... _1_- .........
Manifold Section on page 15.
I
....,. ____ I , A- CH flow (22 mm),
B - CH return (22 mm),
C- Gas inlet (22 mm),
D- DHW outlet (15 mm)
I E - Mains water inlet (15 mm),
I

' ',,
~ 1. Fit sealing washers to service valves
4A·----~--,·
before hanging boiler.
I
~ Remove dust caps from connections on
boiler.

IMPORTANT: Before hanging the boiler o

the wall mounting plate ensure that the pres
sure relief valve connection is in the D
position. This is located on the right hand
of the wall frame at the rear.
~ 2. Pull the extended tab/lever forward and
down until there is no further travel.
~ 3. Hang the boiler on to the hanging brack-
et. The lugs pass through the rectangular
holes in the boiler back panel.
I Take care not to disturb the washers on the
I
I connections.
I NOTE: It is recommended that this lifting
22mm 15mm 22mm 15mm 22mm I
,-- .......... --, I
I
operation is carried out by 2 people,
........... , I observing all precautions for the safe lifting
' I of heavy objects.
' I
' I Do not lift by the top case panel. There are
\ I two handling holes incorporated into the
I I
', I inner casing left and right in the lower sec-
~-----------~
tion of the appliance.
~ 4. Lower the control panel into the service
position by removing the screw (X) from the
retaining bracket.
~ 5. Make connections to the heating system.
~ Connect the gas supply to the boiler gas
cock 22 mm compression.
~ Connect mains water in and DHW out.
I
I
I
I
,
....... - ............... .. IMPORTANT: The pressure relief connector
I
I
..........
must be repositioned after the boiler has been
I 6I / --- '' correctly mounted to the wall mounting plate.
I
I I
' I
~ 6. Push the lever on the pressure relief con-
I I
I I U / I
nector UP until the stop on the inside of the
= Stop in ~

.
I -----------J ·---; ~0 _locked 1 handle is over the shoulder of the metal
I
I
A D c E B
I position 1 bracket to secure in place.
1 22mm 15mm 22mm 1 5mm 22mm I I
\ I I I
' I I
\ I \,, /
'
'-.., ~
I ',, -' '
.... .,.,

........................ - ..... "" ,,

,," '•,
........ ---- ......

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a(2006/ll)

FITTING THE APPLIANCE
Bosch Group BOILER CONNECTIONS
 FLUE INSTALLATION

85mm
HORIZONTAL FLUE

·-·-'-· (60/100 mm diameter)

For vertical flues and 80/125 mm horizontal flues,
please refer to separate Flue Kit instructions.
NOTE: to ease the assembly of flue components,
apply silicone lubricant to sealing surfaces.
The instructions for the 60/100 mm diameter flue
are shown below.

MEASURING THE FLUE (Standard Flue):

~ Measure from the outside wall to the centre
line of the flue turret (length L).
~ Subtract 52 mm from the length L to give
Edge of-·'-·-·-·-·-·-·-·-·-·-·-·-· the correct dimension to the flue elbow con-
case I nection.
1~220mm--.-
~ The terminal section should be cut to this
dimension, however it must not be shorter
than 250 mm.
~ After cutting the end must be square and
free from burrs to prevent damage to the
flue seals.

II
6720611927-06.1 0
![9
t
Flue

FLUE INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 FLUE INSTALLATION

MEASURING THE FLUE (Extension Flue Kits):

Ql m ~q ~p ONLY CUT EXTENDED FLUE LENGTHS

~ As with the Standard Flue measure from the
outside wall to the centre line of the flue tur-

t
Clamp
~
ret (length L).
Subtract the usable length of the standard
flue (634 mm) from length L.
~ Subtract the usable length of the turret
(52 mm) from length L.
~ Subtract 960 mm for each full length exten-
sian from the figure.
~ Cut one of the extensions to the remainder.
~ Cut both tubes square taking care not to distort
the tubes.
~ Remove any burrs.
2380mm
I EXAMPLE:
I Length L 2380 mm
I

aJ!t l:J l:J ~~

Subtract Standard Flue -634 mm
Subtract Turret -52mm

I I Subtract Full Extension -960 mm

t t t
Cut Length 734mm
I I I
52 mm 960 mm 734mm 634mm
Turret Extension Cut Length Standard Flue

1 Required Length 1

I I
!--------------------------~ .m
t NOTE: Where extensions are reduced, cut
.............................
i -----------· length which DOES NOT contain the seal.

Seal

I'..
1 94 mm
.. I1

'

I
ADDITION OF FLUE BENDS:
When flue bends are being used an allowance
of 94 mm per bend must be allowed from the
6 720 611 927-05.1 0
centre line of the bend. In the example shown
using a flue extension (960 mm) with 2 bends
will achieve a total length of 1148 mm.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD•
FLUE INSTALLATION
Bosch Group 6 720 613 700a (2006/11)
 FLUE INSTALLATION
A - Standard Flue

B - Internal Wall Seal ASSEMBLING THE FLUE

C - External Wall Seal Slide inner collar (B) onto terminal (A)
2 Additional extensions or bends:
D- Clamp
Push fit all extensions/bends/terminal
E - Extension Duct together and secure connections with
clamps (D). The slope of the terminal outlet
must face downwards.

FITTING THE FLUE

c 3 Fit the terminal (A) through the flue opening
in the wall, exposing the plastic outlet
A B section to the outside and fit the outer
flue collar ( C) over the notches to secure.

D
4 Assemble turret to boiler using the three
E screws (see below).
Note: Screws are in boiler or in flue kit.

FITTING THE TURRET:

Flue turret should push directly down and
This screw should not be twisted into correct position.
be fitted last for Fit turret onto appliance and retain with
easier installation three screws.
NOTE: The clamping plate flat should be at
the rear of the appliance.

ADDITIONAL NOTES AND REMINDERS:

Ensure that all cut lengths are square and
free from burrs.
The flue, when assembled, is fully sealed
and components are pushed home.
The flue is set at an angle of 3° or 52 mm
per additional 1 m length of extension used.

r - - - - - - - - - - - - - Flat at back

This screw should

be fitted last for
easier installation

FLUE INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 CONDENSATE CONNECTION

Never terminate or discharge into any open

source, including; sink, bath, shower, bidet,
toilet etc.

Note: any external condensate pipework of

excessive runs should be protected with
weather resistant insulation to help prevent
freezing.

Ensure that the condensate drain is 22 mm

diameter plastic pipe. It must fall at least
50 mm per metre towards the outlet.
An adapter (A) in 22 mm pipe is contained
in the fitting pack.

~1
-
' ,

~· ______ ;,
, ,
I
,
,,
I
I

,,,
I

''
''
\ I
I

,
I

,,
\A
,,
\
',
',

-- -- --- --------- -- ,.-""

'',,,

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
CONDENSATE CONNECTION
Bosch Group 6 720 613 700a (2006/11)
 ELECTRICAL

CAUTION: ISOLATE THE MAINS

ELECTRICITY SUPPLY BEFORE STARTING
ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS

Danger of short circuit: When connecting

the cables ensure that no cable pieces fall
into the Heatronic.
EARTH=«)
LIVE=•
Note: Mains supply to the boiler must be
NEUTRAL =4J
through a fused double pole isolator situated
SWITCHED LIVE=0
adjacent to the appliance. The isolator must
have a contact separation of 3 mm minimum in
8 -----. .
7 -----···-. '• all poles.

/~~:~~ 't;l~]'\
I ••••• - •••• -.- •••• - ••••• • I
.-/
/THERMOSTAT
FROST 0
i\ *\
·,,

L ............................................ ~
Access to electrical connections:
~ Remove boiler casing to access control panel.
---------------- ------ ------------ ----------- 1. Lower the control panel into the service
position by removing the screw (X) from the
I
I
retaining bracket.
I 2. Unscrew the three screws (B) on the back
I I
I
I I
I '' I
of the control panel and pull off the connec-
tions cover.
•' '
3. Unclip cable clamp (C).
4. Cut off the tapered cable entry to fit cable
diameter required.
5. Turn cable retaining screw (D) anti-clockwise.
Run cable over the main crossbar and
through the cable clamp (C), ensuring there
is ample cable to reach the connectors.
Turn cable clamping screw (D) clockwise to
secure cable and replace clamp (C) into
control panel.

6. Mains power 230 V connection (ST10):

~ Separate wires from cable end and strip to
I
6mm
~
'' ' Connect LIVE wire to terminal (L)
',
........... -.... ~ Connect NEUTRAL wire to the terminal (N)
~ Connect EARTH wire to the earth connec-
tor ( -::1:- l
NOTE: Earth cable to be longer so that it
pulls out last if mains cable is snagged.

7. Optional external frost thermostat connec-

tion (ST6):
~ Connect frost thermostat supply wire toter-
minal (Fs)
~ Connect frost thermostat return wire to ter-
minal (FR)

8. 230V room thermostat and/or external timer

(ST10):
~ Remove link
~ Connect room thermostat LIVE supply to
terminal (Ls)
~ Connect room thermostat LIVE return toter-
minal (LR)
~ Connect room thermostat NEUTRAL toter-
minal (Ns)

9. Refit control panel cover:

~ Refit panel and secure with screws (B).
~ Bring the control panel to its upper position
and fix it with screw (A).

ELECTRICAL
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 POSITION OF WI RED

COMPONENTS

/ FLAME SENSE SPARK /),

I
ELECTRODE

o••••• ~ Il ELECTRODEs77

18\ 18\ ~ I
~~I I
FLOW NTC""L..J
~ -~__lr-------,
:~0·•=···--
HEAT
EXCHANGER
OVERHEAT
FAN STAT
1lc

![]
8

----......._

OVER~ ~T~L ·,
1
GAS
VALVE
"'
STAT '---------------
R~ L--------------------
SAFETY Black
SOLENOIDr-r.~==============~F===============================================~
Black
Orange

re~e s~:~~~~TER
FLOW
TURBINE
SAFETY
SOLENOIDf-1-
DHW 1/ PlJ_MP \ PUMP ""'
B
SENSOR
0 CONTROL
Yellow
~[i;:.:'

MAINS
l~O=~~;;, ~=L.------1--tt----+-+-t-IH...,
SUPPLY [Link]r
~
Earth
PUMP
230 VROOM STAT/ §o+:>-----+------1 SUPPLY
PROGRAMMER ~~--+---4---------;

13J-:~:-:-:-:-:;-;I :I Colc:n;;;Jnce r.u~

~ TEM~:~TURE
cH TEM- _ ,.......!, _ h II l
rn"', "l CONTROL

_ ,.......!, _ ~ o-o- D
PERMURE~
CONTROL ~
~~~~~~t;--~~~4-~--------~~
~
~
ST6 4 o-
0
D
!99~ ST4 ~ 2 o-o ST19
- lilli
1
1

II
1
STS ~ 1-::-=
---~---='1
1 o-o
F o- D
51
~NsN-~~L ,----J ~ Al2:c!::!
--

Fuse, slow lQLJ

2,5A,AC230V -
TRANSFORMER - L-

'---. ST17 ~
230 V EXTERNAL
FROST STAT
-?=
;
(OPTIONAL)
;

Jt]
230V
rl-9;;;;-,
I I I
ST9
~

lf-4 I
1 1230V/AC
I
I
Fuse, slow T 0.5 A

~
[f~J LI---W Fuse, slow T1 .6 A

~ ST18
ST1 nnnn DIAGNOSTIC CODE-~
UUUU INTERFACE PLUG luuuul 6 720 612 485-01 .1 0

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CDI
POSITION OF WIRED
Bosch Group 6 720 613 700a (2006/11)
COMPONENTS
 PRE-COMMISSIONING

CHECKS

CAUTION: ISOLATE THE MAINS

SUPPLIES BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS

~ 1. Check that the service and water pipes

are connected to the correct position on the
manifold.

A · CH flow (22mm),
B · CH return (22mm),
C ·Gas inlet (22mm),
D · DHW outlet (15mm)
E · Mains water inlet (15mm),

~ 2. Check the gas type specified on the iden·

tification plate (F) matches that of the gas
~ supply. Turn on the main gas supply, check
~
k the gas pipework, connections and rectify
~
\ any leaks.
\
\ ~ 3. Check that the pressure relief connector,
\
\ located on the right hand side at the bottom
\
\ of the wall frame, in its up position.
I
I ~ 4. Check that the condensate pipe has been
I connected to the adapter.
I
I
I

'~ ~- .1.------------., IMPORTANT: If the boiler is not to be com-

3 I ,'' ' missioned immediately then: after sucess-
I '' fully completing all of the checks and any
I '' rectification work, close the gas and water
I
I
'
I
I
valves, shut off the gas supply and electri-
I
I
cally isolate the boiler.

I A I
I
\ 22mm 15mm 22mm 15mm 22mm I I
I I
\ I
' I '' I
\ I ''' I
~~.... ;I ' .........
............
...... _____ ......... "' ,,""' ·- ............. _--- ....

,."" ( r...
,""' .... ~
2 1' I ::>
I
I
I

I
I
I

''
'' ' '' '
' ' ......... ' .........
·-. ............. ___ ... ·- ............. --- ...

PRE-COMMISSIONING CHECKS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 FILLING THE SYSTEM

Ensure all system and boiler drain points are

closed.
2 Remove the bottom panel (if fitted).
I 3 Ensure that the white plastic control screw
r---1I (C) on the charging link is turned fully into
I its closed position.
I
I 4 Open the isolating valves on both the DHW
I
\ inlet and CH return connections.
5 Insert the charging key (D) (situated in its
\\,,0------- storage position (E) on the bottom cover of
'• '• the boiler) initially aligning the arrow on the
·~ .............. _____ ,...,., key with the "unlock" symbol on the charg-
ing link body. Ensure that the key is inserted
fully and turn to the "lock" position. Check
that the key is secure.
6 To fill the system from the DHW inlet turn
the white plastic control screw (C) on the
charging link to the fully out position.
7 Once the system has been filled to a pres-
sure of 1 bar turn the white control screw
(C) to its closed position.
8 Vent all radiators, retighten when completed
and check the system and correct any leaks.
• The boiler integral expansion vessel is
precharged to 0.75 bar (equal to a static
head of 7.5 meters [22 ft]). A Schraeder
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 return, adjust to the same
pressure as the appliance internal expan-
sion tank, refer to separate instructions with
the extra expansion vessel.
9 Briefly open the pressure relief valve to test
its operation.
10 Refill the system up to 1 bar. Turn the white
control screw (C) to its closed position and
then remove the charging key by turning
back to its "unlock" position and withdraw-
ing.
11 Place the charging key (D) in its storage
position (E) on the bottom cover of the boil-
er.

GAS SUPPLY
~ Open gas cock on the boiler and purge the
gas supply to the boiler ensuring that the
room is well ventilated.
~ Test gas supply for soundness as described
in BS 6891.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

FILLING THE SYSTEM
Bosch Group
 STARTING THE APPLIANCE
N

IMPORTANT: Never run the appliance

when the appliance/system is empty
or partially filled.

SWITCHING THE APPLIANCE ON/OFF:

~ Turn on mains power supply.
~ Turn on any external controls.
Set the thermostatic radiator controls to
maximum temperature.
Set the clock/programmer to continuously
ON and the room thermostat to maximum
temperature.
2 A · On/off button
B ·On/off and fault indicator (BLUE)
C · Central heating temperature control
D ·Burner indicator (GREEN)

E · Reset button
F · Service button
G · DHW temperature control
H · ECO button
I ·System pressure gauge
J · Cover or optional programmer with
intelligent functionality
L-------------------
K ·Display
L · Central heating boost button
M · Holiday button
N · Automatic air vent

~ Press button (A) and the power on indica·

tor (B) illuminates BLUE. After a few seconds
the display will show the flow temperature.

3 ~Turn the CH temperature control (C) to

maximum. The burner on indicator (D) illumi·
nates GREEN when the burner has lit.
NOTES:
• The first time the appliance is switched
I on, a once-only venting function is activat-

BlEil @\
I
ed. The heating pump then switches on and
,'A --~~o K I off at intervals. This sequence lasts about 8
I
I D--t~ 0 rn- E minutes. The display shows shows 0 0 in
alternation with the CH flow temperature.
F----+;~0 c:J•aD H
The automatic air vent (N) must be open,
L ----+;.,;. D Dd' M please verify.
• The boiler runs for 15 minutes at minimum
heating output to fill the condensate trap,
I the display (K) alternates between "-II-"
\ I
I and the central heating flow temperature.
This occurs every time the mains supply
has been interrupted.

4 ~ If the boiler fails to light the BLUE power

indicator (B) and reset button (E) will flash
alternately.
To reset press and hold the reset button (E)
for 2 seconds. The boiler will be reset.

CAUTION: DO NOT PRESS POWER

INDICATOR (B) TO RESET BOILER.

STARTING THE APPLIANCE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 WATER TREATMENT

IMPORTANT: Debris from the system can

damage the boiler and reduce efficiency.
Failure to comply with the guidelines for
the use of water treatment with the appli-
ance will invalidate the appliance warranty.

ENSURE THAT THE SYSTEM HAS BEEN

CLEANED AS ON PAGE 9 OF THESE
INSTRUCTIONS.

FLUSHING (Central Heating):

1. ~Switch off the boiler (A).
~ Open all drain cocks (B) and drain the
system (C) while the appliance is hot.
2. ~ Close drain cocks (D) and add a suitable
flushing agent (E) at the correct strength for
the system condition in accordance with the
manufacturer's instructions.
3. ~ Run the boiler/system at normal operating
temperature (F) for the time stated by the
manufacturer of the flushing agent (G).
4. ~ Drain (H) and thoroughly flush the system
to remove the flushing agent and debris (1).

INHIBITOR (Central Heating):

5. ~ Check drain cocks are closed (J) and all
radiator valves are open (K) before adding a
suitable* inhibitor (or combined inhibitor/
anti·freeze if the system is exposed to freez·
ing conditions) to the heating system water
(L) in accordance with the manufacturers
instructions.
6. ~ Fill via the built·in filling loop to between 1
and 2 bar using the filling key (M).
7. ~Vent all radiators; retighten vents when
complete (N).
8. ~ Re·pressurise if necessary to 1 bar (0).
~Set all controls to maximum (R).
~ Record the date when the inhibitor was
4 added to the system on the guarantee card.

NOTE: The concentration level of inhibitor in

the system should be checked every 12
months or sooner if system content is lost.

The addition of sealing agents to the system

water is not recommended as this can cause
problems with deposits left in the heat
exchanger.

KEY
@ Valve

~
Flushing
Agent

~
Inhibitor
6 720 611 927-27.1 0

* compatible with aluminium. The pH

value of the system water must be less
than 8 or the appliance guarantee will
be invalidated.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

WATER TREATMENT
Bosch Group
 COMMISSIONING
NOTE: When running in the central
heating boost mode, the boiler will
operate both the central heating and THE COMBUSTION FOR THE APPLIANCE
the domestic hot water circuits. This IS FACTORY SET.
is to allow sufficient time for this part NO ADJUSTMENT IS REQUIRED IF THE
of the commissioning procedure. It GAS INLET PRESSURE IS CORRECT.
will be necessary to run water
through the domestic hot water cir-
CHECKING GAS INLET PRESSURE:
cuit to ensure that the boiler will not
The inlet pressure to the appliance must be
cycle on low heating demands.
checked using the following procedure:
SETTING THE BOILER TO MAXIMUM:
~ Press central heating boost button (L) for
ten seconds and set Central Heating tem·
perature to maximum.
• The central heating boost button will illumi·
nate continually.

MEASURING THE INLET PRESSURE:

2 ~ Slacken the screw in the inlet pressure
test point and connect a manometer.
~ Measure the pressure with the boiler
running at maximum.
~ Check the gas supply working pressure at
the gas valve inlet point:
N.G. minimum 18 mbar
L.P.G. 37 mbar
~ The gas rate should be measured at the
gas meter after 10 minutes operation at
maximum. See technical data section at the
front of this manual.
~Ensure inlet pressure is satisfactory with
all other gas appliances working.
I
I ~Replace controls cover. NOTE: This boiler

I
,A
I
0 K
is designed with a differential of 2o•c
I D 0 across the heating system.

F CJ IMPORTANT: Do not continue

L CJ commissioning until the correct
gas inlet pressure is achieved.

~\."
I ~ If pressure is satisfactory press the central
\ c I
I
heating boost button (L) again and the boil·
.o o'/MU I
\ er will return to normal operation.
\ • If left in the central heating boost mode the
control will return to normal operation after
15 minutes.
~ Re·seal the screw in the gas inlet pressure
test point.

DOMESTIC HOT WATER:

Controlling the hot water temperature
A · On/off button ~ The hot water temperature can be set to
B ·On/off and fault indicator (BLUE) between approximately 40°C and 60°C
C · Central heating temperature control using the temperature control (G).

D ·Burner indicator (GREEN)

DOMESTIC HOT WATER PRE·HEAT:
E · Reset button Pre·heat reduces the time taken to produce hot
F · Service button water at the tap and is controlled by the ECO
G · DHW temperature control button (H).
~ Press the ECO button to select either:
H · ECO button
I· System pressure gauge When the ECO button is not illuminated the
J · Cover or optional programmer with boiler will be in pre·heat mode (which will
reduce the time taken to produce hot water at
intelligent functionality
the tap).
K · Display
L · Central heating boost button
OR

M · Holiday button When the ECO button is illuminated the boiler

will be in Economy mode with pre·heat no
longer active.

COMMISSIONING
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 FINISHING COMMISSIONING

The boiler has been factory set, so there

should be no need to adjust combustion
settings.
,A
:---------------1
I I REPLACE OUTER CASING:
/ I
I Replace outer casing making sure that the
securing points are properly located.
~ Press the clip (A) downwards to secure
casing on top.
~ Retighten bottom two screws (B).

INSTALLING BOTTOM PANEL:

2 The bottom panel slides onto two ledges
(C) either side of the boiler frame.
~ Hold the panel up against the underside
of the boiler and slide towards the rear until
it is fully engaged.

HAN DOVER:
~ Complete the Benchmark check list.
~ Open the facia cover by gently pressing the
centre top of the cover (D).
~ Set up the controls and show the user how
to operate all the controls shown in the User
Guide.
~ Place the user guide into the tray (E) on the
inside of the facia cover.
~ If the appliance is unused and exposed to
freezing conditions; shut off all the mains
supplies and drain the system and boiler.

/~""
.,.,.- ...------................. ,,
....

'\
\\
------~\
I
I
I
I
I
I
I
I
I
D
/
/

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
FINISHING COMMISSIONING
Bosch Group 6 720 613 700a (2006/11)
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS INSPECTION AND SERVICE
SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: Any service work must be
IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS carried out by competent registered engi-
CHECK FOR GAS SOUNDNESS WHERE RELEVANT AND CARRY OUT neers such as British Gas or Corgi regis-
FUNCTIONAL CHECKS AS DESCRIBED IN COMMISSIONING. tered engineer.
ANY 0-RING OR GASKET THAT APPEARS DAMAGED MUST BE
REPLACED. • To ensure the continued efficient operation
of the appliance it must be checked at regu·
lar intervals.
• The frequency of servicing will depend upon
the particular installation conditions and
usage. However, an annual service is rec·
om mended.
• The extent of the service required by the
appliance is determined by the operating
condition of the appliance when tested by
fully qualified engineers.

INSPECTION
1. Check that the terminal and the terminal
guard, if fitted, are clear and undamaged.
2. If the appliance is in a compartment or cup·
board check that the specified service
space around the appliance is clear.
3. Check all the joints and connections in the
system and remake any that show signs of
leakage. Refill and re·pressurise if applica·
ble as described in Commissioning.
~ Operate the appliance and take note of
any irregularities. Call up the last fault stored
by the Bosch Heatronic, Service Function
.0. Refer to Fault Finding for rectification
procedures.
4. Please consult Operational Procedures
Part 11, Servicing Policy.

INSPECTION AND SERVICE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 ,- ,.,. ........................... 1.1 INSPECTION AND SERVICE
1 '•'•
I
I '\
I \
COMPONENT ACCESS
I \1I
I
I
1. Removing outer case

I
I
1. Remove bottom panel by pulling it forward
\
and off.
\
'• '• 1.1 Undo but do not remove the 2 screws
'• ................. -.... (A) securing boiler casing at the bottom of
the appliance.
1.2 Pull upwards to release the clip (B) on top
of the boiler.
1.3 Pull case forward and remove.

2. Adjusting boiler control to

service position
2.1 Remove screw (X) securing control.
2.2 Gently pull forward until it comes to
rest in service position.
I
I
I
''

.........
. . ·--------------------I

Primary Heat Exchanger

There is a special accessory kit available
specifically designed for cleaning the heat
exchanger. If required order 7 719 001 996.
3. ~ Check fan pressure at the test point next
to the fan using an electronic manometer
~The boiler must be run at maximum output.
Pressure will read negative and be greater
than:
25CDi - 2.8 mbar
30CDi- 3.9 mbar
37CDi- 3.9 mbar
42CDi - 4.8 mbar

~ Pressures measured below these figures

will indicate that the heat exchanger will
require cleaning.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
INSPECTION AND SERVICE
Bosch Group 6 720 613 700a (2006/11)
 INSPECTION AND SERVICE

Setting Boiler to Maximum.

NOTE: When running in the heating boost

mode, the boiler will operate both the Central
Heating and OHW circuits. This is to allow suf-
ficient time for setting procedure.
It will be necessary to run water through the
OHW circuit to ensure that the boiler will not
cycle on low heating demands.

A - On/off button
B-On/off and fault indicator (BLUE)

C - Central heating temperature control

D- Burner indicator (GREEN)
E - Reset button
F - Service button

G - DHW temperature control

H - ECO button

I - System pressure gauge

J - Cover or optional programmer

K- Display
L - Central heating boost button

M - Holiday button

~ Press and HOLD central heating boost

button (L) for 10 seconds and set Central
Heating temperature to maximum.
0 rn- E • The central heating boost button will illumi-
nate continually.
D D·- H
• The boiler will stay in this mode for 15
D M minutes unless the central heating boost
button is pressed again.

~tl·" ~(3:
\

m:~ ~a
2 ~ Pull the cover off and connect a manome-
\ c--~ G I
I ter to the fan pressure test point.
.o oiiiD.

'' I
I
I ~After
cover.
measurement replace test point

Pressure will read negative and be greater than:

25CDi - 2.8 mbar
30CDi- 3.9 mbar
37CDi- 3.9 mbar
42CDi - 4.8 mbar

• Pressures measured below these figures

will indicate that the heat exchanger will
require cleaning.
• There is a special accessory kit available
specifically designed for cleaning the heat
exchanger. If required order 7 719 001 996.

INSPECTION AND SERVICE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 INSPECTION AND SERVICE

COMBUSTION TESTING MUST BE CARRIED

OUT BY A COMPETENT PERSON. IT MUST
NOT BE ATTEMPTED UNLESS THE PERSON
I
I
CARRYING OUT THE COMBUSTION CHECK
\ IS EQUIPPED WITH A COMBUSTION
\
ANALYSER CONFORMING TO BS 7927 AND
' IS COMPETENT IN IT'S USE.

To Clean the Heat Exchanger

~ Remove outer case and base panel and
isolate the appliance from power.
1. ~ Remove cleaning access cover (B), seal
(C) and metal plate (D) securing it, if pre-
sent.
2.1 ~ Loosen any deposits in the heat exchanger
from top to bottom using the cleaning blade.
2.2~ Clean the heat exchanger from top to bot-
tom using the brush.
~ Refit the clean out coverplates in reverse
order using a new seal (C) and tighten
screws.

2 1 .............. -----------....•..
;,.,..'"" -.,
I
\\
I
I \I
I I
I
I I
I I
I
I I
I I
I
I
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I
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....................... _-- ..

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD•
INSPECTION AND SERVICE
Bosch Group 6 720 613 700a (2006/11)
 INSPECTION AND SERVICE

To Clean the Burner

1. ~ Remove cover panel (A) by removing the
screws (B).
~ Check that the boiler is completely isolat-
ed from the gas supply.
o I 2. ~ Remove the clips (C) and unscrew the
I
I two bolts (D).
I
I ~ Unscrew and remove the two hexagon
I
I screws (E) securing the fan.
I
I
~Slacken fully the rear securing bolt (F).
,,,/ ~ Remove the burner cover plate (G).
3. ~ Remove the burner (H) and clean compo-
nents. Do not use a wire brush.

To Check the Diaphragm

in Burner Cover
4. ~ Carefully withdraw diaphragm (J) from fan
intake tube and check for soiling and splits.
~ Carefully refit diaphragm (J) the correct
way round into the fan intake tube.
Note: The flaps of the diaphragm (J) must
open upwards.
~ Re-assemble burner in reverse order using
a new seal (K).
~Adjust gas/air ratio. Refer to section
"Setting the gas/air ratio".

To Clean the Condensate Trap

5.1 ~ Pull condensate pipe out of the adapter.
5.2~ Remove trap from boiler.
~ Clean trap and check that the connection
to the heat exchanger is clear.
~ Fill the condensate trap with approxi-
mately 1/4 litre of water and refit in reverse
order.

.......... _____ .. ... ... ____ ....

INSPECTION AND SERVICE

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS REPLACEMENT OF PARTS
SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS.

.....,
,,.,. .. --····-...... 1.1 IMPORTANT: AFTER REPLACEMENT OF
ANY COMPONENTS ALWAYS CHECK FOR
\ GAS SOUNDNESS WHERE RELEVANT
AND CARRY OUT FUNCTIONAL CHECKS
AS DESCRIBED IN COMMISSIONING.
ANY 0-RING OR GASKET THAT APPEARS
DAMAGED MUST BE REPLACED.

1. Removing outer case

1. ~ Remove bottom panel by pulling it forward
and off.
1.1 ~ Loosen but do not remove the 2 screws
(A) securing boiler casing at the bottom of
the appliance.
1.2 ~ Pull upwards to release the clip (B) on top
of the boiler.
1.3 ~ Pull case forward and remove.

2. Moving boiler control to service

position
2.1 ~ Remove screw (X)securing control.
2.2~ Gently pull forward.

3. Primary sensor
~ Press retaining clip on plastic moulding
and pull upwards until clear of pocket in
heat exchanger.
~ Separate sensor from connector, coat
new sensor with heat conductive paste and
replace.

4. Overheat thermostat
~ Remove two electrical connectors from
thermostat.
~ Unscrew the sensor.

5. Flue limit thermostat

......... 4. ~ Remove electrical connections .
'• ~ Unscrew thermostat from flue.
\
I
'' I
I
I I 6. Expansion Vessel
I
I I ~ Drain the appliance.
I I
I I 6.1 ~Remove locking screw (D).
I I 6.2~ Undo the union connection (E) at the bot·
I I
•• J - I tom of the expansion vessel.
I
~ ~ Remove expansion vessel from boiler.
/
~ Set the pressure of the new vessel to that
-- required by the system.

\ I
\

\ ----- ,, ,,.
I
------t....
I

61
D ...... "' • .... 6.2
1/c;·~~~
-- I
....
~
~"'
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I
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\,~~
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''\ \\
'•'•, '• '•,

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

INSPECTION AND SERVICE
Bosch Group
 REPLACEMENT OF PARTS

7. Gas valve
~ Isolate gas supply at boiler gas cock.
~ Push air inlet tube (A) upwards.
7.1 ~ Undo top gas connection (B) to gas valve.
7.1 ~ Undo bottom gas connection (C) to gas
valve.
7.2 ~ Undo two securing screws (D) on the
underside of casing.
~ Pull valve up and forward out of boiler.
~ Disconnect electrical connections.
~ Replace valve with new seals and check
for gas soundness.
Note: The valve will require setting, follow pro-
cedure "Setting the gas/air ratio" in the gas
conversion section.

8. Siphon
8.1 ~ Pull condensate pipe out of the adapter.
8.2~ Remove trap from boiler.
~ Clean trap and check that the connection
to the heat exchanger is clear.
~ Fill the condensate trap with approxi-
mately 1/4 litre of water and refit in reverse
order.

REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 REPLACEMENT OF PARTS

9. Access to boiler control

components
~ Remove 3 screws (A) and remove
cover from control.

10. PCB fuse

~ Remove fuse (B) from the PCB and
replace.
~ There is a spare fuse clipped into the
cover.

11. Transformer I PCB

~ Disconnect all electrical connections
from the control.
~ Remove 5 screws (C) retaining the
rear panel of the control and remove
panel.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
REPLACEMENT OF PARTS
Bosch Group 6 720 613 700a (2006/11)
 REPLACEMENT OF PARTS

IMPORTANT: AFTER REASSEMBLY

THE COMBUSTION MUST BE
CHECKED USING THE PROCE-
DURE IN THE SECTION "SETTING
THE GAS AIR RATIO". MEASURE-
MENT AND SETTING (IF NECES-
SARY) OF THE GAS RATIO MUST
NOT BE ATTEMPTED UNLESS THE
PERSON IS EQUIPPED WITH A
COMBUSTION ANALYSER CON-
FORMING TO BS 7927 AND IS COM-
PETENT IN ITS USE.

12. Fan assembly

~ Remove electrical connector from fan.
~ Remove condensate trap
(see page 42).
12.1 ~ Undo the union connection (A).
~ Remove wire clip (B) from air/gas
adjustment assembly (C) then pull gas
pipe down.
12.2 ~ Unscrew two screws (D).
12.3 ~ Remove fan from boiler.
12.4 ~ Remove three screws retaining the
air/gas adjustment assembly (E).
~ Reassemble with new fan assuring that
seals are correctly fitted.

13. Electrode assembly

~ Disconnect spark electrodes and flame
sensor connection.
~ Remove two screws (F).
~ Remove spark/flame electrode assem·
bly (G) from heat exchanger.

12.~4
,, ... •············••· .••
I ~ "-.
I \
I \

/I ~ \I
I
I

\I I
~
I
\
\
\
••'• ..

' If~: ~''

......
\
\
I
II
I
I
II
/
/
,I

REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 REPLACEMENT OF PARTS

14. Air/gas manifold

14.1 ~ Remove cover panel (A) by removing
the screws (B).
~ Check that the boiler is completely iso·
lated from the gas supply.
14.2 ~ Remove the clips (C) and unscrew the
two bolts (D).
~ Unscrew and remove the two hexagon
screws (E) securing the fan.
~ Slacken fully the rear securing bolt (F).
14.3 ~ Remove air/gas manifold (I)
14.4 ~ Open air/gas manifold (1).
~ Carefully withdraw diaphragm (J) from
fan intake tube and check for soiling and
splits.

15. Burner
~ Remove the burner (H).
~ Replace new burner in correct posi·
lion.
~ Ensure that a new seal (K) is used.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
REPLACEMENT OF PARTS
Bosch Group 6 720 613 700a (2006/11)
 REPLACEMENT OF PARTS

16. Heat exchanger

~ Isolate flow and return valves and drain
the boiler.
~ Remove condensate trap
(see page 42).
~ Remove fan assembly (see page 46).
16.1 ~ Remove plastic nut (A) from the base
of the inner casing.
16.2 ~ Remove return pipe at the bottom of
heat exchanger.
16.3 ~ Remove screw at the top of the heat
exchanger (C).
~Unscrew the flow pipe (D).
16.4 ~ Undo flue connection (E) from
sump (F).
~ Pull flue pipe up.
~ Remove the heat exchanger.

......
.
16 1;
I
;
.. ~~~~········~,
... '•
I \
\

\ AI'
'•'• ,"
~--------------~
16.4
I

REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 REPLACEMENT OF PARTS

17. Diverter valve motor

There is no need to drain the appliance.
~ Disconnect the electrical connector
from the diverter valve motor.
17.1 ~ Pull the motor assembly (A) towards
you. The assembly will slide free from the
valve.
~ To refit, follow the above in reverse.
Note: In case of problems when refitting
the motor: Connect the electrical con-
nector to the motor and switch the appli-
ance on. Then the motor goes to the
middle position and you can refit it with-
out difficulty.

.... 18. Diverter valve

.... .... ~ Ensure the appliance has been fully
drained.
~ Disconnect the electrical connector
from the diverter valve motor.
~ Undo the two screws holding the valve
to the plastic housing.
18.1 ~ Withdraw the valve (B) and clean the
valve chamber if necessary.
~ To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.

19. Auto air vent

~ Ensure the appliance has been fully
drained.
19.1 ~ Use a screwdriver or similar to rotate
the air vent anticlockwise.
19.2 ~Lift the air vent (C) out of the housing
and remove.
~ To refit, follow the above in reverse.

20. DHW temperature sensor

~ Ensure the domestic hot water circuit
is fully drained.
~ Disconnect the electrical connection
from the sensor.
~ Withdraw the spring clip.
~ Withdraw the sensor (D) from the
housing.
~ To refit, follow the above in reverse.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

REPLACEMENT OF PARTS
Bosch Group
 -·· ...... --····· REPLACEMENT OF PARTS
,
I
I
I
I 21. Pump head
I ~ Ensure the appliance has been fully
drained.
21.1 ~ Disconnect the electrical connections
from the pump following steps 1 to 4.
21.2 ~ Remove the four Allen bolts (A) secur-
ing the pump at each corner.
21.3 ~ Gently pull the pump towards you and
remove.
~ To refit, follow the above in reverse.

22. Pressure gauge

~ Ensure the appliance has been fully
I
I drained.
I
I ~ Withdraw the spring clip from the pres-
I
I
sure sensing head housing.
I ~ Undo the nut on the rear of the pres-
I
I sure gauge.
I
I ~ Remove the pressure sensing head
I

, , I
I and pressure gauge capillary from the
housing.
~
•' To refit, follow the above in reverse.

,.
.........-· •'

............................ .
DO NOT omit the washer from the capil-
lary when fitting a replacement gauge.
,, ........
23.1 ,. ... 23. Flow sensor, flow restrictor
/ housing and filter
I
I
I ~ Ensure the domestic hot water circuit
I
I is fully drained.
I ~ Disconnect the electrical connection to
I
I the turbine.
~ Remove the spring clip from the hous-
ing and move the brass pipe to one side.
23.1 ~ Withdraw the flow sensor and filter
from the housing.
~ Using the cartridge tag, withdraw the
flow restrictor housing. If the regulator
housing has become stuck, a pair of long
nosed pliers may be used to grip the
housing.
~ To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.

24. Flow regulator

~ Remove the flow restrictor housing
(See Removing the flow sensor, flow
regulator and filter).
24.1 ~ Using a small Allen key or similar, push
the flow restrictor cartridge out of its
housing.
~ To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.

25. Drain tap

~ Ensure the appliance has been fully
drained.
25.1 ~ Rotate the drain tap fully anticlockwise.
25.2 ~ Withdraw the drain tap from its housing.
I
I ~ To refit, follow the above in reverse.
I
I Ensure any seals that have been dis-
I
turbed are renewed.
/
,, ,,
..................... --- .... ,.,.,., -·
REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 ,.. _,* ... ----------........... -- 26 1
. REPLACEMENT OF PARTS
,,,'' ... ,"""......,
, ''
I ,, ' \
I
I \
\
26. Hydraulic Block
I \
I
I \
\
~ Ensure the appliance has been fully
I \
I \ drained.
,
, '
l
I l ~ Disconnect the electrical connections
I l
l I
l l to the NTC, Turbine and pump.
l l
l ,
~ Undo the nuts securing the copper
''
\
,,
I water pipes to the manifold (there is no
\ I
\ I
\
\ I
I need to remove the gas pipe).
,~ ! ~ Release the spring clips securing
"""f/111'"' \\ ,' these water pipes to the plastic housing
., '',......
..... _________i ,,
,,,,'' and remove the pipes.
______ ... ~ Release the spring clip securing the
expansion vessel pipe to the plastic
I
housing and remove the pipe.
26.2 ~ Undo the nut securing the pressure
,,,,'' gauge to its bracket and remove the

, ,' I
gauge.
I
I
~ Release the locking devices that
I
I
secure the two copper water pipes lead-
,,
I

, ing to the combustion chamber by

,, squeezing the two tabs together and
I
I
I rotating anticlockwise (viewed from
l
l
above).
'' 26.1 ~ Undo the two screws securing the
''
' \
\
hydraulic block to the chassis (located
\
\
\
top left/top right of the housing).
' ',,____ _ 26.2 ~ Lift the left hand side of the block
slightly, then manoeuvre the block out,
,, _:>-------------..........
-- starting with the right hand side.
,,,,' ...... ...... ~ Take care not to snag the harness or

,,,,--· pressure gauge bracket.

NOTE: the block will still contain a small
,
I
I
amount of water, which will spill if the
I
I
I block is tilted.
I
~
I
I To refit, follow the above in reverse.
I
I
I
Ensure any seals that have been dis-
I
I
I turbed are renewed.
I
I
l
l
l 27. CH pressure relief valve
'' ~ Remove the Hydraulic block from the
' '' boiler (See Removing the Hydraulic
'
' \
\
Block).
\
\
\ I
, I
27.1 ~ Remove the spring clip from the

,,
I
' ', ,' Pressure relief valve housing.
',, ___ _ ___
27.2 ~ Withdraw the pressure release valve

·-·-............. ___ .......... ..

, (A) from its housing.

-------- ~ To refit, follow the above in reverse.

Ensure any seals that have been dis-
turbed are renewed.

I
I
I
I
I
I
I
I
I

''
' \
\
\
',
'•,

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

REPLACEMENT OF PARTS
Bosch Group
 REPLACEMENT OF PARTS

28. Plastic protection device

~ Ensure the system is fully drained.
~ Disconnect all pipes connected to the

I
pump housing.
I
I ~ Remove the electrical connection to
I
'' the pump.
\~ 28.2 ~ Withdraw the metal clip to the right of
,,
'•, the pump head to release the pump
housing.
~ Slide the device to the left and then
withdraw it from the appliance.
28.1 ~ Remove the spring clip from the pres-
sure relief valve housing.
28.2 ~ Withdraw the pressure relief valve (A).
~ To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.

29. DHW Heat exchanger

~ Remove the Hydraulic block from the
boiler (See Removing the Hydraulic
Block).
29.1 ~ Undo the two screws (B) securing the
plastic housings to the heat exchanger.
29.2 ~ Remove the heat exchanger.
~ To refit, follow the above in reverse.
Ensure any seals that have been dis-
turbed are renewed.

REPLACEMENT OF PARTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON SETTING THE GAS/AIR RATIO
SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT
THE CONVERSION IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927
AND IS COMPETENT IN ITS USE
5. Setting the C0 2
Note: When running in the central heating
boost mode, the boiler will operate both the
. . : ...... ------:,:............ 5.1 central heating & DHW circuits. This is to allow
,,......... ...,,, sufficient time for the setting procedure. It will
,, '' be necessary to run water through the DHW
I
, '\
circuit to ensure that the boiler will not cycle on
I \
I \
I
I
\
I low heating demands.
I I
5.1 ~ Connect manometer to inlet pressure
:c :
I I

\ I point on the gas valve.

\ I
\ I
\ I ~ To adjust the C02 it will be necessary to
\
\ , I

'', ,',
first operate the boiler at maximum output.
......... , ...' ~ Press and hold down the central heating
......... , ...
boost button (A) for 10 seconds until illumi-
~~~~-,----~~let Test Nipple
I nated.
I 5.2~ Turn central heating control to maximum;

--------------., I
the boiler will then go to maximum output.
Note: The control will resume normal opera-
tion after 15 minutes or if the central heating
boost button is pressed for over a second.
5.3~ Using a flat blade screwdriver set the
C02 via adjuster (B) using table below.
Note: C02 should be measured 10 minutes
after firing the appliance.
Gas type Ico 2. setting
max1mum
I C?~ setting
m1mmum
Greenstar 25CDi and 30CDi
Natural gas I 9.6% ±0.2 1 9.0% ±0.2

,,"""' ... --- ... ........ '

LPG
I 11.5% ±0.2 1 10.5% ±0.2
Greenstar 37CDi and 42CDi

I
I
1,' ,1- '\
\
I
Natural gas I 9.7% ±0.2 1 9.1% ±0.2
I
-b
I LPG
I 11.5% ±0.2 1 10.5% ±0.2
L---(
II
\
\
f I
I
J----1
II
~ Check CO is less than 200 ppm.
~Measure the inlet pressure; it should be a
' I
minimum of 18 mbar for natural gas and
'.... A__..~ -,/
........... .2./-~ 37 mbar for LPG.
5.4~ Set the central heating control to mini-
mum. This will make the boiler go to mini-
mum power.
5.5~ Measure the C02; it should now be at
figure for minimum output. If not adjust (C)
on the gas valve until correct.
~ Return to maximum and re-check the

C02. If correct press and hold down the

central heating boost button for 2 seconds;
the button will cease to be illuminated and
the blue power indicator will be permanently
illuminated.
~ Remove manometer and re-seal inlet pres-
sure point on gas valve.
~ Fit new plastic sealing cover on to outlet
adjuster (B).
~ Fit white cover over valve adjuster (C) and
secure with black security tag.
~ Remove red arrow from data plate and fit
new one in correct position for gas type.
~ Re-assemble and refit boiler case.
~ Re-connect mains electrical supply and
check boiler operation as stated in the com-
missioning section.
~ Fit new label from kit over existing label on
the appliance bottom panel.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CD•

6 720 613 700a (2006/11)

SETTING THE GAS/AIR RATIO
Bosch Group
1 2 3
- SHORT PARTS LIST

Fan
WHS Part No. 8 717 204 453 0
GC No. H26 536
2 Burner
WHS Part No. 8 718 006 658 0
GC No. E27 200
3 Burner skin seal
4 5 6 WHS Part No. 8 711 004 168 0
GC No. E27 201
4 Gas valve
WHS Part No. 8 716 107 053 0
GC No. H26 539
5 Control board
WHS Part No. 8 748 300 536 0
GC No. H22 456
6 Temperature limit sensor
WHS Part No. 8 722 963 858 0
7 8 9 GC No. HOB 291
7 Electrodes
WHS Part No. 8 718 107 089 0
GC No. H22 458
8 Flow reg. Type E 91itre orange
WHS Part No. 8 716 141 143 0
GC No. 324 823
9 Flow reg. Type E 111itre brown
WHS Part No. 8 716 107 044 0
10 11 12 GC No. H22 460
10 Flow reg. Type E 131itre olive
WHS Part No. 8 716 107 045 0
GC No. H31 958
11 Flow reg. Type E 151itre light green
WHS Part No. 8 716 105 869 0
GC No. H31 959
12 Pressure relief valve DHW
WHS Part No. 8 717 401 029 0
14 15 GC No. H02 526
Pump assembly
WHS Part No. 8 716 106 354 0
GC No. H22 463
14 Pressure gauge
WHS Part No. 8 717 208 107 0
GC No. H02 528
15 Flow sensor
WHS Part No. 8 716 107 223 0
GC No. H02 529
16 17
16 DHW temperature sensor
WHS Part No. 8 714 500 081 0
GC No. H02 538
18 Heat exchanger
WHS Part No. 8 716 108 212 0
GC No. H22 465
18 Diverter valve assembly
WHS Part No. 8 716 106 845 0
GC No. H02 533
19 20 21 GREENSTAR CDi 19 Diverter valve motor
····" "· ""·~ ·~.; ""' "·''""'"' ''~" · '
WHS Part No. 8 716 106 847 0
GC No. H02 534
20 Control sensor - primary
WHS Part No. 8 714 500 087 0
GC No. E74 536
21 Service booklet
Part No. 6 720 612 361 0
GC No. TO BE CONFIRMED

SHORT PARTS LIST

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
 L.P.G. CONVERSION

ISOLATE MAINS ELECTRICAL

SUPPLY AND REMOVE OUTER CASE
AS SHOWN IN THE INSTALLATION,
COMMISSIONING & SERVICING
INSTRUCTIONS

THE CONVERSION MUST BE CARRIED OUT

BY A COMPETENT PERSON. IT MUST NOT
BE ATTEMPTED UNLESS THE PERSON
CARRYING OUT THE CONVERSION IS
EQUIPPED WITH A COMBUSTION ANALYSER
CONFORMING TO BS 7927 AND IS
COMPETENT IN ITS USE.

Important: The appliance shall not be installed

into a room or internal space below ground
level when it is intended for use with LPG
(propane - G31). This does not preclude the
installation into a room or space which is a
basement on one side of the building but open
to ground on the opposite side.
Installation Regulations
In addition to those specified in the main
booklet the following standard applies when
converting to an LPG appliance: BS 5842
Domestic Propane Gas Burning
Installations.
All conversions will require the air gas ratio to
be set correctly for the gas used. The
procedure for setting the air gas ratio is at
the rear of these instructions.

1. Moving boiler control to service

position
~ Remove boiler case, as described on
page 39.
1.1 ~ Remove screw (X) from retaining bracket.
1.2 ~ Lower control panel into service position.

2. Code plug
2.1 ~ Remove 3 screws (D) retaining plastic
cover at rear of control box and remove.
2.2~ Replace code plug (E) with new one sup-
plied with conversion kit ..

Gas type Code plug

No.

I
25Cdi
I

2.2 30CDi
,,,,''
,
,,
I
,, 37CDi
I
I
I
I
I
I
I
I
42CDi
I I
I I I I
I I \ I
I I \ I
\ I \ I
\ I \ I
\
\ I
I \ I
~ Replace plastic cover.
\ I ' I
' I
' I ' I ~ Place control in normal position and
'' ,, '' ,,
' I ' I

' ',, ,,''/ ' ',, E ,,''/

secure with screw.

............ ,,'' ............ ,,''

................. _____ ............ "" .................. _____ ............ "" THE GAS I AIR RATIO MUST BE
RESET AFTER CONVERSION. THE
PROCEDURE CAN BE FOUND IN
THE REPLACEMENT PARTS SECTION
OF THIS MANUAL.

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDci42CDI

6 720 613 700a (2006/11)

L.P.G. CONVERSION
Bosch Group
 FAULT FINDING

NOTE: This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be
competent.

The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply but, by flashing dur-
ing a fault, provides a guide to the cause as listed.

This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e. not a first installation error).

PRELIMINARY CHECKS: Preliminary electrical system checks are the first electrical checks to be carried out during a fault-finding procedure.
On completion of the Service/Fault-Finding task which has required the breaking and remaking of electrical connections, check
(a) EARTH CONTINUITY, (b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.

An optional text display is avaliable which gives a text description of the service functions of the boiler

Display code Description Remedy

A7 Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for
circuit breaks/short circuits.

AS Break in communication to TD200 or/and RT10. Check electrical connections.

b1 Code plug not detected. Insert code plug correctly, test and replace if necessary.

C6 Fan speed too low. Check fan lead and connector, and fan; replace as
necessary.

E2 CH flow NTC sensor defective. Check CH flow NTC sensor and connecting lead.

E9 Safety temp. limiter in CH flow has tripped. Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed appli-
ance.

EA Flame not detected. Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and C02 level.

FO Internal error. Check electrical connector contacts, programmer inter-

face module ignition leads are not loose; replace pcb if
necessary.

F7 Flame detected even though appliance switched off. Check electrode assembly, dry pcb. Flue clear?

FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Clean conden-
sation trap and check electrode assembly. Flue clear?

Fd Reset button pressed by mistake. Press reset button again.

More detailed fault finding procedures are described in the Service booklet for the Engineer number 6 720 612 361.

FAULT FINDING
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDI/30CDI/37CDI/42 co; ~ORCESTER
6 720 613 700a (2006/11)
Bosch Group
[~
~~
.sm Over temperature
!!I
m 3 minute wait
Gas valve OFF.
Fan overrun
shut-down if water
::a 30 seconds
temperature is 5•c
above set value.
m z
~
"' (fl
2S
m F
w~
:s"'w 0z 0
i3 (fl
Room
8 ~
~ ~ thermostat and/or
z
Gl mains
z
programmer ON
~
Fan (&gas)
(or link fitted at modulation
'1 GREEN 10 second END OF
0
z
POWER BLUE ST10)
CENTRAL IIrr-
~
Fan to
~SEQUENCE~
IGNITION
FLAME
f--.
to achieve f-...,
~ ~ AND ~ start 1.... stabilisation BOILER
(fl
~ SWITCH LIGHT HEATING LIGHT set
jl Facia mounted DEMAND speed. (see detail) period. DEMAND
~
ON ON ON temperature
jl programmer (if (35-aa•c)
hi fitted) ON
~rn
0
(fl
n
:r:
Gl
CD
AND
CH control knob
ON
Diverter valve
in CH position
Pump ON.
1
IGNITION SEQUENCE
m
m
z
(fl

~ Gas valve
"nm OFF
0 Spark I YES Pump run 3
~
n ignition BURNER
0 LIT? minutes
4 seconds
~
n
Fan run 30
0
seconds
~
n
9
NO

NO
I ()
m
()
I z
-I
~
m
z 5th
Stop spark.
-I
::0 LOCKOUT Wait r
)> attempt? I
r
10 seconds
m
~
I
m
~ z
z G)
G)
"Tl
"Tl
c c
z z
~
0
~
z 0
z
 Burner shut down if
"""0
::0 primary temperature
m g5•c ~
I
m Diverter valve opens
~ toCH
)>
z
0 Over temperature
0 Wait shut-down if water
I - 5 seconds
Gas valve OFF.
temperature is 1o·c ~
:2: above set value.
"Tl
c
z
~
0

..
z DOMESTIC
Tap open HOT
WATER
(recognised
by flow
.... DEMAND
(priority over
-
Fan (&gas)
z turbine) all other
modulation
"1
"'
~
0
demands)
to achieve
set
..... DEMAND
END
z
temperature
"'
~
~
(4o-5o •c)
<
iS
z
Gl
z
Gas valve
~ Diverter valve GREEN
'1
0
z
(fl
POWER
SWITCH
ON
..... BLUE
LIGHT
ON
ECO button
inDHW
position ~
Fan to
start
speed.
..... IGNITION
SEQUENCE
(see detail)
___.. FLAME
LIGHT
OFF
Pump run 3
minutes
~ not Pump ON. ON
!iS illuminated • Fan run 30
~
CD (ie preheat seconds
n
§ requested)
c;j AND
rn
0
(fl
20 minutes
n
:r: since last pre-
!ll;n heat demand IGNITION SEQUENCE Fan (&gas)
;n
modulation DEMAND
z
(fl
AND ~ END
~ PREHEAT to achieve "U
L., temperature ~ DEMAND
- (40-60 •c) ;::o
m "'m at least 1o· m
"' n
below set YES

~
I
"'
0
~
w
0~
~
n point. ___..., BURNER _____.. m
~
"' 0 LIT?
0 "w 4 seconds
w "'
~m ~ ·set by )>
'
~
~

"'ng pressing ECO z

button. If pro- NO NO Gas valve 0
grammer is OFF 0

~~
Stop pump I
fitted this is
set by a com-
....-----------.,YES 5th
Stop spark.
Stop fan ~
LOCKOUT Wait "Tl
bination of attempt?
,.,;:a 10 seconds c
~n
programmer
(DHW)
z
..,m
!!I demand and ~
m ECO button. 0
:::a z
 PROTECTION FUNCTION

Boiler temperature f--. Run autofroststat

below s·c function

Pump run 5 seconds

Pump antiseize
every 24hrs

DHW demand active

Holiday mode
Frost protection active
set to ON

All other demands not

active

~ORCESTER INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH GREENSTAR 25CDV30CDV37CDc!42CD'
PROTECTION FUNCTION
Bosch Group 6 720 613 700a (2006/11)
INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING
& SERVICING

EXCELLENCE COMES AS STANDARD

Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. 01905 754624 Fax. 01905 754619
Worcester, Bosch Group is a trading name of
BBT Thermotechnology UK Ltd.
[Link]

6 720 613 700a (2006/11) OSW