- Worcester Bosch
Contents
1. SYSTEM BOILER CONNECTIONS PRE WIRED LINK All these points are wired to D this point gt Fe OD LOM EG Fee ar Q Sees zw Q All these points are wired to N J this point es 5 NUL ISIN rem em ent 8 All these points are wired to E this point EEE EEE Room T Stat Programmer NI Cylinder NTC Sensor efe fel Tos ol lol lollo LONDENSOS HGH Helps Dio 2 o loi o loi Jo la lollo jo e je 2 E co DANE 5 amp 5 Fig 26 Wiring diagram WC 6720816348 19 1Wo Fig 27 System layout Radiators in rooms with room thermostats must be uncontrolled and therefore must not have a TRV fitted F Flow LSV Lock shield valve R Return T1 Cylinder NTC sensor DPFS Double pole fused spur T2 Room thermostat WC Wiring centre PROG Programmer TRV Thermostatic radiator valve Table 14 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 17 WORCESTER Fitting the integral diverter valve kit Bosch Group 5 7 6 Unvented cylinder with High limit thermal cutout PRE WIRED LINK SYSTEM BOILER CONNECTIONS e m Fe QD ia Hz LE frirsjorle em B CACT zav M2. PRE WIRED LINK SYSTEM BOILER CONNECTIONS Fe OWE RES br Some gt e9 SEES m Lln Lefn zehier Junction box eeeeeesee eee Wiring Centre 230V N MAINS SUPPLY Intelligent lin 1 ntrolle ti 5e i b is i L Cylinder Safety Limit N 1 Thermostat Thermostat F 1 F Ca fatu Valua nn nn nn nn nnd 1 8 utdoor s Safety Valve Dual Thermostat i th FW100 onl Cylinder Components d e T2 KEEP o ews A oms OR W CRF 6720816348 23 1Wo Fig 31 System layout example is showing with Worcester controls Radiators in rooms with room thermostats must be uncontrolled and therefore must not have a TRV fitted F Flow LSV Lock shield valve R Return T1 Cylinder NTC sensor DPFS Double pole fused T2 Worcester time and temperature spur controller JB Junction box T3 Outdoor sensor TRV Thermostatic T4 Dual thermostat radiator valve Table 16 Hot water temperature settings gt Cylinder thermostat on the dual thermostat should be set to maximum approximately 68 C Appliance DHW thermostat set to 60 C Time and temperature control options Although the example here shows the use of Worcester controls with the modified mains supply to the appliance the options listed for the additional equipment are also via
3. 6720816348 12 1Wo Low voltage terminal strip Low voltage room thermostat input EMS bus connections External cut off switch NOT USED Outdoor weather compensation sensor Cylinder temperature sensor Low Loss Header sensor NOT USED Table9 Keytofigure 18 OD on P wIw re Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 11 Fitting the integral diverter valve kit WORCESTER Bosch Group 5 6 Mounting optional plug in controls 5 6 1 Plug in programmer timers The programmers timers listed can be used with the optional integral diverter valve kit Partnumber Integral controls option description 7716192038 DT20 Facia mounted twin channel digital timer 7716192054 DT2ORF digital RF thermostat with twin channel programmer Plug in receiver amp twin channel programmer with radio frequency room thermostat transmitter 7716192052 DT10RF digistat Plug in receiver amp hot water programmer with radio frequency programmable room thermostat 7716192053 DT1ORF optimiser Plug in receiver amp hot water programmer with radio frequency optimum start programmable room thermostat 7716192065 FR10 intelligent room thermostat used in conjunction with DT20 EMS wired wall mounted 7716192066 FR110 programmable room thermostat EMS wired wall mounted 7116192067 FW100 weather compensation co
4. 1 General layout 0 cc cece cece eee eens 6 3 1 1 Systemlayout overview ccc cece eee eee 6 3 2 Plumbing manifold 0 0 cece eee 7 3 21 Connmections 0 eee e cee eee eee eens 7 3 2 2 Diverter valve kit considerations 8 3 2 3 Appliance Installation and Commissioning 8 3 2 4 Fitting the cylinder flow and return service valves 8 A Installation 2 0 3 40 e t Ur berede 8 4 1 Wall mounting template 00 eee 8 4 1 1 Fixing the wall mountingframe 8 4 1 2 Hanging theappliance 0 cece eee eee 8 5 Fitting the integral diverter valve kit 9 5 1 Assembly of the internal cylinder pipes to the appliance i deco px er REN UP NEED 9 5 1 1 Diverter valve kit plumbing 222 22 9 5 2 Fitting the diverter valve motor 9 5 3 Access to the HCM Heating Control Module 9 5 4 Fitting the HCM Heating Control Module 10 5 5 Cylinder temperature sensor installation 10 5 5 1 Fittingthe cylindertemperaturesensor 10 5 6 Mounting optional plug in controls 12 5 6 1 Plug in programmer timers 12 5 6 2 EMScontrols 00 c cece cece ee eee ees 12 5 6 3 Remove the blanking plate 00 12 5 6 4 Fitting the plug in controller 0 13 5 6 5 Secure the plug in c
5. 20816348 02 1Wo Fig 3 General pipe layout Unvented cylinders In all cases the cylinder manufacturer must be contacted for confirmation their product is suitable for the installation layout shown in figure 3 Although the accepted common practice of a 2 port motorised valve installed in the primary flow pipe to the cylinder and wired to the dual thermostat supplied with the cylinder It is possible to use the integral diverter valve kit and not need the 2 port motorised valve to cut the flow of heat to the cylinder to comply with Building Regulation Part G3 Theintegral diverter valve kit cylinder sensor must be used The general layout figure 3 can be used for unvented cylinder by utilising the high limit thermal cut out of the cylinder dual thermostat to interrupt the permanent live to the appliance preventing any heat being produced from the appliance Wiring example gt section 5 7 6 page 18 General layout with unvented cylinder amp cylinder safety valve If required by the cylinder manufacture to fit use the cylinder safety valve then this can also be carried out figure 4 with the integral diverter valve kit The cylinder safety valve and dual thermostat control thermostat and high limit thermal cut out are wired to interrupt the permanent live to the appliance preventing any heat being produced from the appliance Wiring example gt section 5 7 7 page 19 777 Oyl
6. AINS SE ees E eiue NIL P SUPPLY Lll eeleeeee lee J d Cylinder Safety Limit Thermostat Thermostat Dual Thermostat 6720816348 20 1Wo Fig 28 Wiring diagram example is showing with Worcester controls EMS 6720816348 21 1Wo Fig 29 System layout example is showing with Worcester controls Radiators in rooms with room thermostats must be uncontrolled and therefore must not have a TRV fitted F Flow LSV Lock shield valve R Return T1 Cylinder NTC sensor DPFS Doublepolefused T2 Worcester time and temperature spur controller JB Junction box T3 Outdoor sensor TRV Thermostatic TA High limit thermal cut out separated radiator valve from the dual thermostat Table 15 Time and temperature control options Although the example here shows the use of Worcester controls with the modified mains supply to the appliance the options listed for the additional equipment are also viable Mixed controls gt 5 7 4 External 230V controls gt 5 7 5 18 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Fitting the integral diverter valve kit 5 7 7 Unvented cylinder with dual thermostat and safety valve
7. Fig 13 HCM identification detail 1 Software version number boiler Donot use an LPG HCM ona natural gas boiler or vice versa NOTICE Heating Control Module N gt Ensure that the correct HCM is fitted for the type of gt Refer to figure 14 gt Disconnect the plug from the original HCM 1 and discard the HCM gt Connect the plug to the appropriate new HCM 2 from the kit and fit into the control unit x N E 3 amp E S N N Fig 14 Fitting new Heating Control Module 5 5 Cylinder temperature sensor installation 5 5 1 Fitting the cylinder temperature sensor This requires placing the cylinder temperature sensor into a suitable pocket or location on the cylinder ensuring satisfactory contact with the surface ofthe cylinder This replaces the traditional cylinder thermostat and must be connected to the Greenstar i System appliance If the domestic hot water cylinder is a unvented type the cylinder thermostat sensor is used in conjunction with equipment on the unvented cylinder gt system connection and layouts gt Refer to the cylinder installation instructions for the position of the sensor There may already be a sensor pocket available If there are multiple sensor pockets on the cylinder make sure the correct sensor pocket is used Foam insulated cylinders without sensor pocket CAUTION Damage to cylinder N Damage by piercing the wall of the cylinder gt Cut
8. G a F 5A H 230 V X2 S e miersTclera cle rere leramcler rc X16 Worcester 24V controls point 998 CH TEMPERATURE O Pina CONTROL EMS BUS point TO LCD DISPLAY HCM at rear of PCB DHW TEMPERATURE CONTROL DIAGNOSTIC INPUT X12 GIY 6720816348 13 1Wo Fig 2 Electrical diagram Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 Pre installation WORCESTER Bosch Group 3 Pre installation 3 1 General layout This appliance is designed to operate on a sealed system only The appliance will require a second return pipe from the water cylinder to the wall mounting frame and terminate in 15mm copper pipe The following system layouts show a simplified example of the pipe configuration to the appliance 3 1 1 System layout overview NOTICE Drain point gt Adraincock should be fitted at the lowest point s of the heating circuit and beneath the appliance Pump overrun function gt Atthe end of a demand the integral diverter valve will move to the CH position if not already in that position and the pump will run for 3 minutes to dissipate the heat General layout Cylinder return Cylinder flow pill Heating flow Heating return 67
9. ICE General information The mains electrical supply to the appliance must be through either a fused double pole isolator or a fused three pin plug and unswitched socket gt Theisolator shall be situated next to the appliance for new systems and where practicable replacement appliances gt The isolator must have a contact separation of 3mm minimum in both poles Any system connected to the appliance must not have a separate electrical supply gt External fuse rating 3A When stripping wires always ensure copper strands do not fall into the control box 5 7 1 General information The optional integral diverter valve kit replaces the more common Y plan and S plan type systems Thestandard configuration for both the 230V mains supply and time and temperature controls are shown Worcester controls section 5 7 3 Mixedcontrols section 5 7 4 External 230V controls section 5 7 5 Thisallows for multi zone configurations by using a 2 port motorized valve for each central heating zone in addition to the integral diverter valve which are wired back to the wiring centre 5 7 2 Unvented cylinders It has been a general consensus mainly driven by training and accreditation bodies that the only way of complying with the Building Regulation requirements for the installation of an unvented cylinder is to install a 2port motorised valve on the primary flow from the appliance to the cylinder This is not the case and o
10. Installation instructions Wall hung RSF gas fired condensing System boiler Greenstar i System Compact Optional Integral Diverter Valve For sealed central heating systems and indirect mains fed domestic hot water Read these instructions in conjunction with the appliance Installation Commissioning and Servicing Instruction manual Diverter valve kit numbers 27kW 7733600 220 30kW 7733600 221 These appliances are for use with Natural Gas or L P G Cat II 2H 3P type C13 C33 amp C53 Model GC Number Natural Gas 27i System Compact EP 41 406 58 30i System Compact 41 406 60 L P G 27i System Compact E 41 406 59 30i System Compact E 41 406 61 6720816348 00 1Wo benchmar THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS WORCESTER Bosch Group 6 720816 348 2015 03 WORCESTER Contents Bosch Group Contents 1 Key to symbols and safety instructions 3 1 1 Key to symbols un eier 3 1 2 Safety precautions 00 cc cece eee eee 3 2 Generalinformation eeeeeeeeeeees 4 2 1 Standard package 0 cece ence nee e anes 4 2 1 1 DHW temperature control 0c cee ae 4 2 1 2 Electrical diagram 0 ccc ccc eee eee ee 5 3 Preinstallation ee eroi ee Gennes ot ohne eens 6 3
11. Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Fitting the integral diverter valve kit 5 Fitting the integral diverter valve kit The optional Integral Diverter Valve kit can be installed without removing any major components and with the boiler mounted on the wall 5 1 Assembly of the internal cylinder pipes to the appliance Remove the siphon and discharge pipe to gain access to il the Hydraulic manifold 5 1 1 Diverter valve kit plumbing gt Onthe hydraulic manifold release but do not remove the two clips 1 securing the blanking plugs 2 Remove and discard the blanking plugs 2 6720816348 06 1Wo Fig 8 Blanking plug removal gt Connect the pre formed flow 4 and return 3 pipes as showninthe figure below gt Replace the clips 1 to secure the pipes 6720816348 07 1Wo Fig 9 Hot water flow amp return pipe fitting gt Connect the flow 4 and return 3 pipes to the isolation valves fitted earlier 5 2 Fitting the diverter valve motor gt Pull the diverter valve blanking plate 1 towards you to release from the diverter valve body 6720816348 08 1Wo Fig 10 Removing the diverter valve blanking plate gt To fit the diverter valve motor 3 push the motor 3 into the housing until the motor clicks securely into place ensuring that the diverter valve actuator arm locates into the middle of the H receptacle o
12. ature for the cylinder from the control panel Use the natural gas or LPG version of the HCM depending on the boiler type Refer to section for installation of the HCM Discard the other HCMs Hot water cylinder sensor lead housing and retaining strap 3 2 3 Appliance Installation and Commissioning When fitting the optional integral diverter valve kit please refer to the Greenstar i System Compact Installation Commissioning and Service Instructions for Appliance and Technical information Unpacking Condensate and flue options Appliance location and clearances Pre installation Installation Commissioning 3 2 4 Fittingthe cylinder flow and return service valves Before hanging the boiler on the wall frame fit the two extra isolation valves to the hydraulic manifold as shown in the figure below 1 Fitthe cylinder flow service valve using the screws provided 2 Fitthe cylinder return service valve using the screws provided E i 3 N N amp O A R Fig 7 Fitting cylinder service valves 4 Installation 4 1 Wall mounting template WARNING Damage to property N Damage caused by drilling into pipes electrical cables damp proof course or other hazards gt Before drilling ensure that there are no obstructions Safety All relevant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appro
13. ble Mixed controls gt 5 7 4 External 230V controls gt 5 7 5 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 19 Bosch Group WORCESTER Fitting the integral diverter valve ki Central heating function 5 8 OML 69 8099790229 KARA JIM SIU pa qeua si apow Hues A6saua duund jlx spuooes og UNJJSAO Ue sojnuiu UnJ43A0 duind 440 Onjen SED 9678 08 s nyessdwa 195 MEIS HOS SADIYDE 0 puooes ZOT uonejnpow ue GNVNI3G 4311 08 JO QN3 anjen jes anoge Joy S 3N eJeduio9 J9 e JI UMOP jnus eJnje1eduJo9 I9AO spuooes o ad nd se8 pue yseds dois spuo2es y l seg pue YINYUNE vous y eds AONANOAS NOILINDI eJ p ees JONINDAS NOLLINDI SPUO93S OE uniJaAo ue4 440 ALA sey 1003201 NO dunq umop uonisod HO ul DACA J9J9AIq NO pany 1 JeuureJ8oJd pajunow eiose Jj NO HV ANY AlddnS ONILVAH NO Jawweigoid YIMOd VHlN3O pany xui 10 SNIVIN surew Jo pue ye SowWayy wooy en eA Jas MoJaq SI a nyessdwe nun yeM Fig 32 Central heating function Greenstar i System Compact E Optional Integral Diverter Valve 6 720 816 348 2015 03 20 Fitting the integral diverter valve ki Cylinder heat function Bosch Group WORCESTER 5 9 OMT EC 69v v90779 spuooes o YEM dwaye se3 pue ur xX1eds dois 10104201 spuooes p ll seg pue YINYNE UONIUS
14. cates a situation that will result in severe injury or death Important information This symbol indicates important information where there is no risk to people or property Additional symbols Symbol Meaning 1 a numbered step in an action sequence 2 astep in an action sequence gt a reference to a related part in the document or to other related documents 1 areference number to identify or referto a part or item alist entry alist entry second level Table1 Symbols Examples of additional symbols used Anumbered step in an action sequence Asequence of numbered steps or actions carried out in a specific order to complete a task 1 First action 2 Second action 3 Third action etc Astep in an action sequence A sequence of defined actions or steps carried out in order to complete atask Action Next action gt etc Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 Areference to a related part in the document or to other related documents To refer the reader to a specific figure table section within the manual gt e g figure 1 Areference number to identify or refer to a part or item In arelated figure items or parts identified by a sequential number List entries first and second levels Asingle component item Acomponent list made up of multiple parts items Sub component or sublist of main component list etc Symbols use
15. d in this manual Domestic Hot Water m Central Heating TTE TL a Hot Water Storage Cylinder I Electrical Supply Gas Supply Table 2 Commonly used symbols Central Heating Flow Central Heating Return Diameter Natural Gas Liquid Petroleum Gas Central Heating Domestic Hot Water Domestic Cold Water Domestic Water Treatment Association Pressure Relief Valve Negative Temperature Coefficient sensor Ingress Protection Residual Current Device Thermostatic Radiator Valve Emergency Control Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom Table 3 Abbreviations use in this manual 1 2 Safety precautions Please read these instructions in conjunction with the appliance Installation Commissioning and Servicing Instructions carefully before starting installation gt Observe all the safety precautions described in the Installation Commissioning and Servicing Instructions for the Greenstar i System Compact F range appliances General information WORCESTER Bosch Group 2 General information gt These instructions are additional information for the fitting and operation of the optional integral diverter valve and must be used in conjunction with the Installation Commissioning and Service manual gt Ensure that the integral diverter valve kit Instructions al
16. evel of control over the DHW set point temperature allowing the DHW set point temperature to be adjusted at these controls and not only via the DHW temperature control knob on the appliances s facia With these controls the appliance facia s temperature control knob becomes the maximum temperature limiter If this is set too low the DHW set point temperature on the control cannot be achieved Worcester facia plug in mechanical timers cannot be used with this appliance 4 Greenstar i System Compact E Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group General information 2 1 2 Electrical diagram Fan wiring Live Brown FAN AIR PRESSURE SWITCH RETURN PUMP SUPPLY FLUE gt Neutral Blue STAT u SPARK n ELECTRODES FLAME SENSE EON ELECTRODE NTC MAX SAFETY NTC xL w lt se V FLAME SENSE az GROUND ONL SAFETY SOLENOID Red Blue S SAFETY Orange SOLENOID mr PUMP DIVERTER VALVE PUMP CONTROL EMS i ef CONTROLS Cylinder 238 na temperature EEG I I sensor NTC pt I i PRE WIRED LINK f E T LI eeelr Fuse slow FOE alrslir aar GE BA
17. gh limit thermal cut out of the dual thermostat The high limit thermal cut out of the dual thermostat must be wired to interrupt the permanent live to the appliance gt The2 port valve supplied with the unvented cylinder will not be used If it is already physically installed in the pipework it should be removed and electrically disconnected from the wiring centre Dual thermostat and safety valve If the cylinder manufacturer requires the use of the dual il thermostat and safety valve then this method can be used with the integral diverter valve kit wiring and schematic gt 5 7 7 By utilising the dual thermostat and safety valve to interrupt the electrical supply permanent live to the appliance the appliance shuts down and can no longer provide heat to the cylinder Wiring and schematic gt 5 7 7 gt Cylinder temperature sensor supplied with the integral diverter valve kit must be fitted to control the hot water temperature The cylinder temperature sensor is fitted into the same sensor phial pocket as the control thermostat gt The dual thermostat and safety valve are wired in series to interrupt the permanent live to the appliance The wiring of the components is either using awiring centre part of the cylinder package following the connection terminals as described in the cylinder manufacturers instructions for the cylinder package ajunction box separate to the cylinder package gt Cylinder ther
18. inder return Oylinder flow l Fig 4 General pipe layout unvented cylinder amp cylinder safety valve Heating flow Heating return 6720816348 03 1Wo 1 Appliance expansion vessel CH 2 Extra expansion vessel CH return 3 Pressure relief discharge 4 Bypass 5 6 Cylinder safety valve Radiator valve flow 7 Lock shield valve return Table5 Key to figures 3 amp 4 6 Greenstar i System Compact E Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Pre installation 3 2 Plumbing manifold 3 2 1 Connections If the boiler pipes are to be run behind the appliance ensure that the pipes pass either side of the expansion vessel as shown in figure 6 Further guidance on pipe routing can be found printed il onthe appliance template supplied with the appliance For further ease of fitting an optional Vertical Pre piping Assembly kit is available comprising four pre formed copper water pipes Part number 7 716 192 733 A pipe cross bonding strip is also available Part number 7 716 192 686 Heating System 22mm compression fittings Gas 22mm compression fitting Cylinder Flow amp Return 15mm compression fitting Usethe fittings supplied in the Hardware literature pack and the Optional Diverter Valve Kit NOTICE Fitting the service valves gt Refer to figure 6 gt The service valves 3 and 5 from the Optional D
19. ion points 5 6 3 Remove the blanking plate The control panel must be released and swung forward slightly to gain access to the top cover panel refer to the Installation Commissioning and Service Instructions for details gt Release the captive screws 1 securing the top cover panel 2 Remove the cover panel 2 to enable the blanking plate to be removed gt Release the three captive screws 6 enough to allow the Installer access cover 5 to be lowered by 10mm gt Lower the Installer access cover 5 to allow the blanking panel 4 to be removed gt Use the tab 3 to lift and also press up on the bottom edge of the blanking plate to release the clips from the slots in the control panel gt Pull the blanking plate 4 forward to remove 10mm a 6720816348 25 1Wo Fig 19 Removing the blanking plate 12 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Fitting the integral diverter valve kit 5 6 4 Fittingthe plug in controller There are two type of connections within the control panel for plug in controls Non Worcester EMS plug in controls use a plug and socket connection Socket connection 3 figure 20 Worcester EMS plug in controls use pin to plate contact connection Contact connection 4 figure 20 Non EMS plug in controller only gt Connect the ribbon cable p
20. iverter Valve Kit must be fitted and secured to the wall mounting frame with the screws supplied before the wall mounting frame is fitted to the wall 6720646608 05 1Wo Fig 5 Pipe dimensions Fig 6 Plumbing manifold with wall frame 6720808226 04 1Wo Fromleft Diameter of Function case edge pipe 1 Condensate drain 33mm 22mm 2 CH flow 65mm 22mm 3 Cylinder flow 130mm 15mm 4 Gas 195mm 22mm 5 Cylinder return 260mm 15mm 6 Pressure Relief Valve 291mm 15mm CH return 325mm 22mm Table 6 Key to figures 5 amp 6 7 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 Installation WORCESTER Bosch Group 3 2 2 Diverter valve kit considerations The optional Integral Diverter Valve kit can be installed without removing any major components and with the boiler mounted on the wall The optional integral diverter valve kit involves fitting the following gt Cylinder flow and return service valves for the connection to the cylinder flow and return pipework to the plumbing manifold Internal flow and return pipes attached to the hydraulic manifold for cylinder flow and return gt Diverter valve motor and electrical connector Heating Control Module HCM that allows control of the hot water temper
21. lug to the socket 3 in the control panel ensuringthatthe ribbon cable will fit into the recess above the socket in the control panel gt Align the clips on the back of the plug in unit with the slots in the control panel gt Once the plug in unit 1 is aligned and push into the slots 2 gt Push the plug in unit 1 down to secure into position EMS plug in controller fitting gt Align the clips on the back of the plug in unit with the slots in the control panel gt Once the plug in unit 1 is aligned and push into the slots 2 gt Push the plug in unit 1 down to secure into position 6720816348 26 1Wo Fig 20 Connecting the plug in controller example shown EMS receiver unit 5 6 5 Secure the plug in controller With the plug in unit 3 is in position Slide the Installer access cover 4 up into position Secure with the three captive screws 5 Replace the top cover panel 2 Secure in position with the captive screws 1 v Re secure the control panel 6720816348 27 1Wo Fig 21 Secure the plug in controller in position Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 13 Fitting the integral diverter valve kit WORCESTER Bosch Group 5 7 Integral diverter valve kit electrical connection and system layout NOT
22. mostat on the dual thermostat should be set to maximum approximately 68 C gt Appliance DHW thermostat set to 60 C 14 Greenstar i System Compact E Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Fitting the integral diverter valve kit 5 7 3 Worcester controls PRE WIRED LINK SYSTEM BOILER CONNECTIONS MOE Frees om exem gt ee eges ymor lols elv ef Nye SSeS eee T I 23 BB AF Intelligent Outdoor sensor Cylinder controller option with FW100 only NTC Sensor 6720816348 14 1Wo Fig 22 Wiring diagram a I I EIRF 6720816348 15 1Wo Fig 23 System layout Radiators in rooms with room thermostats must be uncontrolled and therefore must not have a TRV fitted F Flow LSV Lock shield valve R Return T1 Cylinder NTC sensor DPFS Double pole fused spur T2 Worcester time and temperature controller TRV Thermostatic radiator valve T3 Outdoor sensor Table 12 Worcester control options FR10 intelligent room thermostat EMS amp DT 20 twin channel digital programmer FR110 programmable room thermostat FW100 weather compensation controller DT20RF digital RF thermostat with twin channel prog
23. n the motor 3 gt Connect the plug 2 for the diverter valve motor from the main harness on the right hand side of the boiler into the socket on the diverter valve motor 6720816348 09 1Wo Fig 11 Fitting diverter motor and cover gt Refit the siphon and discharge pipe Ensure that the siphon has been filled with approximately 250ml of clean water 5 3 Access to the HCM Heating Control Module DANGER Danger to life through electrical shock Before carrying out work on electrical components isolate them from the power supply 230 V AC fuse circuit breaker and secure against unintentional reconnection gt Move the Control unit into the service position Remove the retaining screws 1 and release the cover by pinching the tabs 2 either side 6720816348 05 1Wo Fig 12 HCM location access Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 9 Fitting the integral diverter valve kit WORCESTER Bosch Group 5 4 Fitting the HCM Heating Control Module Diverter valve kit Gas HCM software version number 27 i System Compact Kit NG 1598 L P G 1599 30 i System Compact Kit NG 1596 L P G 1597 Table 7 Key to HCM software version number location refer to figure 13 gt Confirm that the identification number on the HCM corresponds to the gas type in table 7 6720816348 04 1Wo
24. ntroller Faciamounted EMS or EMS wired within wall mounting socket supplied with outdoor sensor 7733600001 Comfort I RF Plug in EMS receiver with twin channel programmer and a radio frequency room thermostat transmitter 7733600002 Comfort II RF Plug in EMS receiver and hot water radio frequency programmable room thermostat 7 733600003 Comfort Facia mounted EMS Digital timer optional accessory allows wall mounting 7 733 600039 Comfort wall plate kit 7 738111064 Sense Il advanced weather compensating controller EMS wired wall mounted 7716192072 Worcester Wave thermostat Remote room thermostat EMS wired wall mounted Table 10 5 6 2 EMS controls gt Use electrical cable with a minimum rating of HO5 VV NYM I gt Toavoid inductive interference lay all low voltage cables separately to cables carrying 230V or 400V with a minimum separation of 100mm gt Permissible cable Thetwo wires are not polarity sensitive Cable length Cross section 80m 0 40mm lt 100m 0 50mm lt 150m 0 75mm lt 200m 1 00mm lt 300m 1 50mm Table 11 Full details for controls installation can be found in the respective installation instructions Refer to the Programmer Timer manual for set upand operation ofthe unit When connecting Worcester plug in or EMS intelligent controls the links Live 230V out and the LR for CH amp DHW must be left in the connect
25. ong with the User Guide and Installation Commissioning and Service manual with the Benchmark checklist and service record is left with the appliance or homeowner 2 1 Standard package 6720816348 01 1Wo Fig 1 Standard package 1 Sensor housing 2 Wire strap 3 Diverter valve motor 4 Cylinder sensor 5 HCM NG or L P G for appropriate output kit 6 Cylinder flow service valve 15mm compression nut 15mm olive fibre washer and service valve screws 7 Cylinder flow pipe 8 Cylinder return service valve 15mm compression nut 15mm olive fibre washer and service valve screws 9 Cylinder return pipe 2 1 1 DHW temperature control DHW temperature control The optional integral diverter valve kit with cylinder sensor is required to enable the hot the hot water temperature control to be used gt the accessories that can be fitted when the integral diverter valve is fitted with which accessory the DHW control is exclusively responsible for the stored DHW temperature DHW control exclusively responsible Integraldiverter Externaldiverter Accessory valve valve DT10 PF Digistat YES N A DT10 RF Optimiser YES N A DT20 YES N A DT20 RF YES N A FR110 NO N A FW100 NO N A Comfort I RF YES N A Comfort II RF YES N A Comfort YES N A Sense II NO N A Worcester Wave YES N A Table 4 The FR110 FW100 and Sense II provide an additional il l
26. ontroller 13 5 7 Integral diverter valve kit electrical connection and systemlayout eins 14 5 7 1 Generalinformation c cee ences 14 5 7 2 Unvented cylinders 0 0 00 cece eee e ee 14 5 7 3 Worcestercontrols 0 ese e cece eee ees 15 5 7 4 Mixedcontrols 00 0 cece cece eee ees 16 5 7 5 External 230V controls 00e eee eee 17 5 7 6 Unvented cylinder with High limit thermal cutout 18 5 7 7 Unvented cylinder with dual thermostat and safety valve 2 usa 19 5 8 Central heating function 2 20 5 9 Cylinder heatfunction 22222222 21 2 Greenstar i System Compact E Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Key to symbols and safety instructions 1 Key to symbols and safety instructions 1 1 Key to symbols Warnings Warnings in this document are identified by a warning triangle printed against a grey background Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken The following keywords are defined and can be used in this document NOTICE indicates a situation that could result in damage to property or equipment CAUTION indicates a situation that could result in minor to medium injury WARNING indicates a situation that could result in severe injury or death DANGER indi
27. out the foam insulation carefully for sensor and housing installation Anarea of insulation needs to be removed 1 from the cylinder for the sensor and housing Refer to figure 15 gt Place the sensor housing 2 on the cylinder body approximately one third of the cylinder height from the bottom of the cylinder Mark the outline of the sensor housing onto the body of the cylinder gt Using a sharp knife cut through the insulation and remove the piece of insulation 3 Make sure the exposed surface is clean to allow good surface contact with the sensor 6720806948 15 1Wo Fig 15 Preparing the sensor housing location 10 Greenstar i System Compact E Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Fitting the integral diverter valve kit Refer to figure 16 gt Assemble the sensor housing 4 and slide the sensor 5 up into the housing gt Route the sensor cable through the housing gt Apply heat conductive paste 6 not supplied to the exposed section of the sensor body gt Fitthe sensor and housing 4 into the cut out in the cylinder body Ensure that the sensor touches the cylinder wall Secure the sensor housing to the cylinder with the wire strap 7 provided 6720806948 16 1Wo Fig 16 Fitting the sensor and housing Extending the cylinder temperature sensor cable gt Recommended cross
28. priate 4 1 1 Fixing the wall mounting frame gt The boiler wall mounting template shows the relative positions of the flue and the top and bottom fixing of the wall mounting frame gt Fixthe wall mounting template to the wall in the desired position Drill 4 holes for the wall mounting frame through the template The wall mounting template has been sized to allow for minimum clearances of 5mm sides 200mm base and 30mm above a 100mm diameter flue elbow gt Follow the actions described in the Installation Commissioning and Servicing Instructions for the fixing of the wall mounting frame and flue openings installation Appliance and wall mounting frame preparation gt Follow the actions described in the Installation Commissioning and Servicing Instructions for the following Unpackingthe appliance Removingthe outer case Pre plumbing connections Gas water condensate and PRV 4 1 2 Hanging the appliance CAUTION Hanging the appliance N Remove the plastic strip fitted to pipes before hanging the appliance gt Follow the actions described in the Hanging the boiler section of the Installation Commissioning and Servicing Instructions for the following Removing the expansion vessel blanking plug Mounting points and PRV support bracket removal Hanging the appliance onto the wall mounting frame Connection of the expansion vessel 8 Greenstar i System Compact E Optional Integral Diverter
29. rammer DT10RF Digistat DT10RF optimizer Comfort I RF Comfort II RF e Sense ll Worcester Wave Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 15 Fitting the integral diverter valve kit WORCESTER Bosch Group 5 7 4 Mixed controls Cylinder NTC Sensor HERE Wee LINK SYSTEM BOILER CONNECTIONS E 0 IN ke 13 FR Fs LR LR our Q GA Omi S9 Seles men Lene elv elv ainf eeesjeee SEE a Gs Room T Stat 6720816348 16 1Wo Fig 24 Wiring diagram 6720816348 17 1Wo Fig 25 System layout Radiators in rooms with room thermostats must be uncontrolled and therefore must not have a TRV fitted Worcester control options DT20twin channel digital programmer Comfort F Flow LSV Lock shield valve R Return T1 Cylinder NTC sensor DPFS Double pole fused spur T2 Room thermostat TRV Thermostatic radiator valve Table 13 16 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Fitting the integral diverter valve kit 5 7 5 External 230V controls
30. section 0 7 5mm gt 0 5mm Thetwo wires are not polarity sensitive gt Use electrical cable with a minimum rating of HO5 VV NYM I When extending the cylinder temperature sensor cable use the following cross sections Cable length Cross section 20m 0 75mm 1 50mm 30m 1 00mm 1 50mm gt 30m 1 50mm Table 8 DANGER Danger to life through electrical shock gt Before carrying out work on electrical components isolate them from the power supply 230 V AC fuse circuit breaker and secure against unintentional reconnection Accessing Low voltage connections gt Referring to figure 17 remove the three screws 1 retaining the installer access cover gt The access cover can now be removed with the flap 6720816348 10 1Wo _ Fig 17 Removing the connection cover Cylinder temperature sensor connection on the Low voltage terminal strip gt To avoid inductive interference lay all low voltage cables separately to cables carrying 230V or 400V with a minimum separation of 100mm gt Wire the cable from the cylinder temperature sensor through the cable retainer clamp and to the plug supplied in the kit gt Connect the cylinder temperature sensor lead to the cylinder sensor 5 connection of the low voltage terminal strip Secure the cable retainer clamp into position eo Fges D 019118 Fig 18 Low voltage connectors
31. spuooes o hus UNLISAO UP SAA y eds spuooes o unJJeAo dwnd 440 AONANOAS NOILINDI ONEA Sec 9002 04 s nyessdws NO dung 440 an3 yas YUE jeep ees s awn WoL NO dn uonisod j puewop 1HON ANVN3A ana ype oi 39N3no3s dn id sabuadios MOSG Klddns ania MHG uone npouJ NOILINSI MHG U H3MOd aunyesoduua yue ue4 SALA 19 9AIq SNIVIN jepnno 10 Areuuud 104 juu peuyopaud e spuooes OE en eA jas Mojaq S Spaeoxe a nyeladus UNJ3A0 uej s nyelodus Jayem JI UMOP INYS 440 SARA sey HUN EM ainyesodwa J9AQ 21 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 Fig 33 Cylinder heat function WORCESTER Bosch Group Notes 22 Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 WORCESTER Bosch Group Notes Greenstar i System Compact Optional Integral Diverter Valve 6 720 816 348 2015 03 23 Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 0330 123 9559 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 816 348 2015 03 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0330 123 9779 LITERATURE 0330 123 9119 TRAINING 0330 123 0166 SALES 0330 123 9669 WORCESTER Bosch Group
32. ther alternative methods can also comply It is possible to cut the flow of heat to the cylinder from the appliance use the optional integral diverter valve kit and still comply with Building Regulation Part G3 It involves re routing the electrical mains supply to pass either through the high limit thermal cut out or the dual thermostat and safety valve before going to the appliance In the event of a cylinder over temperature situation the power is cut to the appliance preventing any heat production High limit thermal cut out to isolate appliance Before using this method the cylinder manufacturer il must be contacted for approval that their product can be connected in this manner wiring and schematic gt 5 7 6 By utilising the high limit thermal cut out part of the dual thermostat to interrupt the electrical supply permanent live to the appliance the appliance shuts down and can no longer provide heat to the cylinder Wiring and schematic gt 5 7 6 The following actions must be carried out gt Cylinder temperature sensor supplied with the integral diverter valve kit must be fitted to control the hot water temperature The cylinder temperature sensor is fitted into the same sensor phial pocket as the control thermostat gt The control thermostat of the cylinder s dual thermostat is not used the wiring of the dual thermostat may have to altered depending on cylinder and thermostat manufacturer to only use the hi
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