Professional Documents
Culture Documents
Gas Boiler Wiring Guide
Gas Boiler Wiring Guide
Contents
Introduction Greenstar Ri Regular Greenstar CDi Regular Greenstar CDi System Greenstar CDi Combi Greenstar FS CDi Regular Greenstar HF CDi Combi Greenstar Si Combi Greenstar i Junior Combi Greenstar i System Notes Page 4 Page 5 Page 17 Page 29 Page 42 Page 53 Page 65 Page 71 Page 82 Page 93 Page 105
Page 3
Introduction
NEW COMPLETE SYSTEM INSTALLATIONS If a new complete heating system installation is in a new build property or it is a first time installation in an existing property, then the heating system must conform to current building regulations Part L1a. All new heating systems in dwellings must have at least two heating zones. Each of these zones will be controlled by a thermostat and zone valve. An alternative would be individual electronically controlled TRVs. If the hot water is provided from a storage system then the DHW cylinder will require separate time and temperature control. All radiators must have TRVs fitted in all rooms except bathrooms and rooms with thermostats. The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total useable floor area. Then this type of dwelling can be controlled as one zone. EXISTING INSTALLATIONS For boiler replacements on an existing system, it is not necessary to zone the upstairs and downstairs differently, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat. While the system is drained down, TRVs may be fitted to all rooms except the bathrooms and the room with the thermostat.
Page 4
= Live
N = Neutral
= Earth
Greenstar Ri Regular
L N E
= Live = Earth
N = Neutral E
LP NP LR
Room T/Stat
N
N E
~
M
Cylinder T/Stat
C 1 2
reset
max
L
L N E
10
E
HW ON CH ON
External Pump
N L
N E
~
M
Page 5
= Live
N = Neutral
= Earth
L Greenstar Ri Regular N E
= Live = Earth
E
N = Neutral E
LP NP LR
Room T/Stat
N
Cylinder T/Stat
C 1 2
reset
max
L
L N E
10
E
HW OFF
N L
Time Controller
Page 6
HW ON
CH ON
External Pump
= Live
N = Neutral
= Earth
Greenstar Ri Regular
L N E
= Live = Earth
N = Neutral E
LP NP LR
N E
~
M
Cylinder T/Stat
C 1 2
reset
max
L
L N E
10
CH Zone 2 ON
External Pump
CH Zone 1 ON HW ON
N E
~
M
N L
~
M
Page 7
= Live
N = Neutral
= Earth
Greenstar Ri Regular
L N E
= Live = Earth
N = Neutral E
LP NP LR
~
M
reset
max
L
L N E
10
CH Zone 1 ON
CH Zone 2 ON
External Pump
N L
N E
~
M
Page 8
= Live
N = Neutral
= Earth
Greenstar Ri Regular
L N E
= Live = Earth
N = Neutral E
LP NP LR
N E
~
M
Cylinder T/Stat
C 1 2
reset
max
L
L N E
10
CH Zone 1 ON
External Pump
HW ON
N E
~
M
N L
Demand
Page 9
= Live
N = Neutral
= Earth
L Greenstar Ri Regular N E
= Live = Earth
N = Neutral E
LP NP LR
N E
~
M
reset
max
L
L N E
10
E L N E
External Pump
N L
Demand
Page 10
= Live
N = Neutral
= Earth
L Greenstar Ri Regular N E
N = Neutral E
LP NP LR
reset
max
L
L N E
10
External Pump
N L
Page 11
= Live
N = Neutral
= Earth
L Greenstar Ri Regular N E
N = Neutral E
N
L N LP NP LR
reset
max
L
L N E
10
External Pump
N L
Page 12
= Live
N = Neutral
= Earth
IMPORTANT NOTE The pump over-run of the pump plan module, causes the hot water pump to run regardless of the hot water cylinder demand, to dissipate boiler heat. Worcester will only recommend the Grundfoss pump plan system on a vented cylinder.
Greenstar Ri Regular
LP NP LR
Warning! 240V - Isolate electrical supply before removing wiring centre cover.
reset max
FUSE 2.5A
L N L S/L
BOILER
Frost T/Stat
(if required)
(N/U)
FROST T/STAT
2
C
(N/U)
P/L L N L N CH on HW on N L
HW Pump
Demand
NO
HW PUMP CH PUMP
N L N
ROOM T/STAT
em
N NO C
Room T/Stat
2 (N/U) 1
an
CHPump
CH on
(N/U)
De
CYLINDER T/STAT
C
(N/U)
an
NO
PROGRAMMER
Earth terminal for: Controls, Boiler, Pumps Electrical Mains Supply
HW on 3
4
(N/U)
CH/HW Programmer
Cylinder T/Stat
1 (N/U) 2
Page 13
= Live
N = Neutral
= Earth
Greenstar Ri Regular
LP NP LR
reset
max
SMARTFIT FROST PROTECTION ROOM UNIT Y PLAN POLARITY FREE ACCESSORY PORT
L N E
CH VALVE (S)
CYLINDER SENSOR
External Pump
Page 14
= Live
N = Neutral
= Earth
NOTE A pump must be wired to each boiler for pump over-run to dissipate heat from within the boiler. The connections are Live of pump to LP and Neutral of pump to NP and the Earth of the pump to the Earth point of each boiler. HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90 C.
Wiring from Zone/s Controls
IMPORTANT NOTE: The Relay should be mounted within a suitable electrically safe housing.
NO NC NC NO
C N O N C
Coil Coil Live Neutral Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
Greenstar Ri Regular
Greenstar Ri Regular
LP NP LR
LP NP LR
reset
max
reset
max
L N E
L N E
Shunt Pump
Shunt Pump
Page 15
= Live
N = Neutral
= Earth
NOTE A frost thermostat is normally used to protect locations which have no heat source e.g. a garage. It is recommended that a pipe thermostat is also used (wired in series with the frost thermostat) to avoid long periods of heat demand if the air temperature does not satisfy the frost thermostat.
Pipe T/Stat
L N E
= Live = Earth
N = Neutral E
LP NP LR
Room T/Stat
N
Cylinder T/Stat
C 1 2
reset
max
10
E
HW ON CH ON
L N E
External Pump
Time Controller
Page 16
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
Room T/Stat
N E
~
M
Cylinder T/Stat
C 1 2
N NS LS LR
10
L
L N E
E
HW ON CH ON
N E
~
M
E N
External Pump
Page 17
= Live
N = Neutral
= Earth
= Live = Earth
E
N = Neutral E
N NS LS LR
10
L
L N E
E
HW OFF
E N L
External Pump
Time Controller
Page 18
HW ON
CH ON
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
Cylinder T/Stat
C 1 2
~
M
N NS LS LR
10
CH Zone 2 ON
L
L N E
CH Zone 1 ON
N E
~
M
HW ON
External Pump
N L
~
M
Page 19
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
~
M
N NS LS LR
10
CH Zone 1 ON
CH Zone 2 ON
L
L N E
N E
~
M
E N
External Pump
Page 20
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
Cylinder T/Stat
C 1 2
~
M
N NS LS LR
10
CH Zone 1 ON
L
L N E
HW ON
N E
~
M
E N L N E
External Pump
Demand
Page 21
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
L
L N E
E L N E
N L
Demand
External Pump
Page 22
= Live
N = Neutral
= Earth
N = Neutral E
LZ NZ
N NS LS LR
10
L
L N E
N E L
External Pump
Page 23
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
Room T/Stat
N NS LS LR
10
L
L N E
N E L
External Pump
Page 24
= Live
N = Neutral
= Earth
IMPORTANT NOTE The pump over-run of the pump plan controls, causes the hot water pump to run regardless of the hot water cylinder demand, to dissipate boiler heat. Worcester would only recommend the Grundfoss pump plan system on a vented cylinder.
LZ NZ
N NS LS LR
Warning! 240V - Isolate electrical supply before removing wiring centre cover. 2.5A Fuse - RS Components stock no 415-604
FUSE 2.5A
L N L
BOILER
Frost T/Stat
(if required)
(N/U)
S/L
FROST T/STAT
2
C
(N/U)
P/L L N L N CH on HW on N L
HW Pump
Demand
NO
HW PUMP CH PUMP
N L N
ROOM T/STAT
em
N NO C
Room T/Stat
2 (N/U) 1
an
CHPump
CH on
(N/U)
De
CYLINDER T/STAT
C
(N/U)
an
NO
PROGRAMMER
Earth terminal for: Controls, Boiler, Pumps Electrical Mains Supply
HW on 3
4
(N/U)
CH/HW Programmer
Cylinder T/Stat
1 (N/U) 2
Page 25
= Live
N = Neutral
= Earth
LZ NZ
N NS LS LR
L N E
HW VALVE (S)
CH VALVE (S)
External Pump
Page 26
= Live
N = Neutral
= Earth
NOTE A pump must be wired to each boiler for pump over-run function to dissipate heat from within the boiler. The connections are pump live to Lz, pump neutral to Nz and pump earth to the Earth point of each boiler. HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90C.
C N O N C
Coil Coil Live Neutral Example relay shown is a double pole mains voltage relay. This isolates the boilers electrically in case of a fault condition.
LZ NZ
LZ NZ
N NS LS LR
N NS LS LR
L N E
L N E
Shunt Pump
Shunt Pump
Page 27
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
LZ NZ
N NS LS LR
Earth to Wiring Centre Neutral Feed to Wiring Centre Live Feed to Wiring Centre Switch Live from Wiring Centre
L N E
External Pump
Page 28 Worcester wiring guide Greenstar gas-fired boilers
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
E Room T/Stat
N E
~
M
Cylinder T/Stat
L N NS LS LR
C 1 2
10
E
HW ON CH ON
N E
~
M
N L
Page 29
= Live
N = Neutral
= Earth
= Live = Earth
N E
N = Neutral E
N NS LS LR
10
N L
Time Controller
Page 30
HW ON
CH ON
HW OFF
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
C 1 2
10
CH Zone 2 ON
CH Zone 1 ON HW ON
N E
~
M
N L
~
M
Page 31
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 1 ON
CH Zone 2 ON
N E
~
M
N L
Page 32
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 1 ON
HW ON
N E
~
M
N L
Demand
Page 33
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
E L N E
N L
Demand
Page 34
= Live
N = Neutral
= Earth
L N E
N = Neutral E
N NS LS LR
10
N L
Page 35
= Live
N = Neutral
= Earth
L N E
N = Neutral E
N NS LS LR
10
N L
Page 36
= Live
N = Neutral
= Earth
N NS LS LR
HW VALVE (S)
CH VALVE (S)
Page 37
Greenstar CDi System Internal Diverter Valve, Worcester RF Controls & Unvented Cylinder
The generic Live, Neutral and Earth feed/s to equipment must return to the respective connection on the wiring centre. These connections are denoted as follows:
L
L
= Live
N = Neutral
= Earth
There is a unclarity within the Industry that in order to protect an Unvented Hot Water Cylinder from potentially dangerous high temperatures from the boiler circuit, a 2-port motorised valve must be installed. This is not the case, although it is the most common interpretation and approach. FURTHER DETAILS Building Regulation Approved Document G3, paragraph 3.6 states 'the non-self-resetting thermal cut out should be wired to a motorised valve or some other suitable device to shut off the flow to the primary heater'. The latter part of this sentence can be interpreted to mean as long as we, as responsible Manufacturer's, are confident our method provides an equal amount of protection to the common approach, we may instruct installers of our equipment to follow a different approach. A summary is provided below.
l
The installer will use the cylinder sensor supplied with the Integral Diverter Valve kit to control the hot water temperature. The installer, therefore, will NOT need to use the hot water control thermostat of the cylinder's dual thermostat. The installer may have to alter the wiring of the dual thermostat (depending on cylinder and thermostat manufacturer) to only use the high 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 Greenstar CDi System Boiler. The 2-port valve supplied with the unvented cylinder will NOT be used. If it is already physically installed in the pipe work is should be removed and electrically disconnected from the wiring centre.
Connector Block
Green\Yellow
(made safe)
Blue
Brown
IMPORTANT NOTE: UNDER NO CIRCUMSTANCES SHOULD THE FEED TO THE LIMIT STAT BE TAKEN THROUGH THE CONTROL STAT. ST8
9 8
ST10
LR LS NS N
FR FS NP LP
ST6
Pump Harness
Fan Harness
S11 2.5 A 230 V AC
FR FS NP LP
B B 4 2 1 A F
B B 4 2 1 A F
CYLINDER TEMPERATURE SENSOR (SUPPLIED IN
DIVERTER KIT)
Page 38
N NS LS LR
Main Harness
9 8 7
Code Plug
Greenstar CDi System Internal Diverter Valve, Worcester FX Controls & Unvented Cylinder
The generic Live, Neutral and Earth feed/s to equipment must return to the respective connection on the wiring centre. These connections are denoted as follows:
L
L
= Live
N = Neutral
= Earth
There is a unclarity within the Industry that in order to protect an Unvented Hot Water Cylinder from potentially dangerous high temperatures from the boiler circuit, a 2-port motorised valve must be installed. This is not the case, although it is the most common interpretation and approach. FURTHER DETAILS Building Regulation Approved Document G3, paragraph 3.6 states 'the non-self-resetting thermal cut out should be wired to a motorised valve or some other suitable device to shut off the flow to the primary heater'. The latter part of this sentence can be interpreted to mean as long as we, as responsible Manufacturer's, are confident our method provides an equal amount of protection to the common approach, we may instruct installers of our equipment to follow a different approach. A summary is provided below.
l
The installer will use the cylinder sensor supplied with the Integral Diverter Valve kit to control the hot water temperature. The installer, therefore, will NOT need to use the hot water control thermostat of the cylinder's dual thermostat. The installer may have to alter the wiring of the dual thermostat (depending on cylinder and thermostat manufacturer) to only use the high 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 Greenstar CDi System Boiler. The 2-port valve supplied with the unvented cylinder will NOT be used. If it is already physically installed in the pipe work is should be removed and electrically disconnected from the wiring centre.
Connector Block
Green\Yellow
(made safe)
Blue
Brown
IMPORTANT NOTE: UNDER NO CIRCUMSTANCES SHOULD THE FEED TO THE LIMIT STAT BE TAKEN THROUGH THE CONTROL STAT. ST8
9 8
ST10
LR LS NS N
FR FS NP LP
ST6
Pump Harness
Fan Harness
S11 2.5 A 230 V AC
FR FS NP LP
B B 4 2 1 A F
B B 4 2 1 A F
B FW 100 B CONTROLLER
N NS LS LR
Main Harness
9 8 7
Code Plug
Page 39
= Live
N = Neutral
= Earth
HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90 C.
C N O N C
Coil Coil Live Neutral Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
N NS LS LR
N NS LS LR
Page 40
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
N NS LS LR
Earth to Wiring Centre Neutral Feed to Wiring Centre Live Feed to Wiring Centre Switch Live from Wiring Centre
Page 41
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
Cylinder T/Stat
C 1 2
N NS LS LR
10
E
HW ON CH ON
N E
~
M
N L
Page 42
= Live
N = Neutral
= Earth
= Live = Earth
E
N = Neutral E
Room T/Stat
N
Cylinder T/Stat
C
N NS LS LR
10
E
HW OFF
N L
Time Controller
HW ON
CH ON
Page 43
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
Cylinder T/Stat
C 1 2
N NS LS LR
10
CH Zone 2 ON
CH Zone 1 ON HW ON
N E
~
M
N L
~
M
Page 44
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
~
M
10
CH Zone 1 ON
CH Zone 2 ON
N E
~
M
N L
Page 45
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
~
M
Cylinder T/Stat
L N NS LS LR
C 1 2
10
CH Zone 1 ON
HW ON
N E
~
M
N L
Demand
Page 46
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
E L N E
L
L
Demand
Page 47
= Live
N = Neutral
= Earth
Series Connector Not supplied. Once wired in make connector safe in electrical cover. Greenstar CDi Combi Room T/Stat
N NS LS LR
Time Controller
Page 48
= Live
N = Neutral
= Earth
N NS LS LR
C NC NO
The Link between the Live (L) and Common (C) may already be fitted as part of the Programmable Thermostat, if not then a link must be fitted.
Page 49
= Live
N = Neutral
= Earth
N NS LS LR
HW VALVE (S)
CH VALVE (S)
Page 50
= Live
N = Neutral
= Earth
NOTE A pump must be wired to each boiler for pump over-run to dissipate heat from within the boiler. The connections are pump live to Lz, pump neutral to Nz and pump earth to the Earth point of each boiler. HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90C.
C N O N C
Coil Coil Live Neutral Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
N NS LS LR
N NS LS LR
Page 51
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
N NS LS LR
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
Room T/Stat
N
LZ NZ
N E
~
M
Cylinder T/Stat
C 1 2
10
L
L N E
E
HW ON CH ON
N E
~
M
External Pump
Page 53
= Live
N = Neutral
= Earth
L N E
N = Neutral E
N NS LS LR
LZ NZ
Room T/Stat
N
Cylinder T/Stat
C 1 2
10
L
L N E
E
HW OFF
External Pump
N L
Time Controller
Page 54
HW ON
CH ON
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
N E
~
M
Cylinder T/Stat
C 1 2
10
CH Zone 2 ON
L
L N E
CH Zone 1 ON HW ON
N E
~
M
External Pump
N L
~
M
Page 55
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
~
M
10
CH Zone 1 ON
CH Zone 2 ON
L
L N E
N E
~
M
External Pump
Page 56
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
N E
~
M
Cylinder T/Stat
C 1 2
10
CH Zone 1 ON
L
L N E
HW ON
N E
~
M
External Pump
Demand
Page 57
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
N E
~
M
10
L
L N E
E L N E
N L
Demand
External Pump
Page 58
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
Cylinder T/Stat
C 1 2
10
L
L N E
N L
External Pump
Page 59
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
Room T/Stat
N
10
L
L N E
N L
External Pump
Page 60
= Live
N = Neutral
= Earth
IMPORTANT NOTE The pump over-run of the pump plan controls, causes the hot water pump to run regardless of the hot water cylinder demand, to dissipate boiler heat. Worcester would only recommend the Grundfoss pump plan system on a vented cylinder.
N NS LS LR
LZ NZ
Warning! 240V - Isolate electrical supply before removing wiring centre cover. 2.5A Fuse - RS Components stock no 415-604
FUSE 2.5A
L N L
BOILER
Frost T/Stat
(if required)
(N/U)
S/L
C N
P/L L N L N CH on HW on N L
HW Pump
Demand
NO
HW PUMP CH PUMP
N L N
ROOM T/STAT
em
N NO C
Room T/Stat
2 (N/U) 1
an
CHPump
CH on
(N/U)
De
CYLINDER T/STAT
C
(N/U)
an
NO
PROGRAMMER
HW on 3
4
(N/U)
CH/HW Programmer
Cylinder T/Stat
(N/U) 2
Page 61
= Live
N = Neutral
= Earth
N NS LS LR
LZ NZ
L N E
HW VALVE (S)
CH VALVE (S)
CYLINDER SENSOR
External Pump
Page 62
= Live
N = Neutral
= Earth
NOTE A pump must be wired to each boiler for pump over-run to dissipate heat from within the boiler. The connections are pump live to Lz, pump neutral to Nz and pump earth to the Earth point of each boiler. HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90C.
IMPORTANT NOTE: The Relay should be mounted within a suitable electrically safe housing.
NO NC NC NO
C Coil Live
C Coil Neutral
N O
Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
N NS LS LR
N NS LS LR
LZ NZ
LZ NZ
L N E
L N E
Shunt Pump
Shunt Pump
Page 63
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
L N E
= Live = Earth
N = Neutral E
N NS LS LR
LZ NZ
Earth to Wiring Centre Neutral Feed to Wiring Centre Live Feed to Wiring Centre
FR FS NP LP
Frost Stat
L N E
External Pump
Page 64 Worcester wiring guide Greenstar gas-fired boilers
= Live
N = Neutral
= Earth
Greenstar HF CDi
L N NS LS LR
L N E
= Live = Earth
N = Neutral E
N
NC
~
Heating Zone 1 Valve
10
CH Zone 1 ON
CH Zone 2 ON
N E
HW ON
~
Heating Zone 2 Valve
N L
Page 65
= Live
N = Neutral
= Earth
Greenstar HF CDi
L N NS LS LR
L N E
= Live = Earth
N = Neutral E
N
NC
N E
~
Radiators Zone Valve
10
CH Rads ON
L
HW Heat Bank ON
N L
Demand
Page 66
= Live
N = Neutral
= Earth
Greenstar HF CDi
L N NS LS LR
Room T/Stat
N
NC
Series Connector Not supplied. Once wired in make connector safe in electrical cover.
Time Controller
CH ON
HW Heat Bank ON
Page 67
= Live
N = Neutral
= Earth
Greenstar HF CDi
L N NS LS LR
C NC NO
N
NC
HW Heat Bank ON
The Link between the Live (L) and Common (C) may already be fitted as part of the Programmable Thermostat, if not then a link must be wired in.
Page 68
Greenstar HF CDi combi Large heating circuit with low loss header
The generic Live, Neutral and Earth feed/s to equipment must return to the respective connection on the wiring centre. These connections are denoted as follows:
L
L
= Live
N = Neutral
= Earth
If the heating system requires a larger pump to circulate the water, then a header can be used to prevent the boiler and system pump from conflicting with each other. NOTE The system pump is wired with the heating demand so it will only activate when the heating is called for. Size the system pump according to system design specifications and water content. HEADER LIMIT THERMOSTAT This cuts the Demand to the boiler in the event of excessive temperature within the header due to lack of circulation. Ideally this should be set to 90C.
N = Neutral E
Greenstar HF CDi
L N NS LS LR
C N C
N
NC
10
HW Heat Bank ON
CH ON
L N E
Time Controller
System Pump
Page 69
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
Greenstar HF CDi
L N NS LS LR
Frost T/Stat
N
NC
FR FS NP LP
Page 70
= Live
N = Neutral
= Earth
L N E Greenstar Si Combi
N
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
E
HW ON CH ON
N E
~
M
N L
Page 71
= Live
N = Neutral
= Earth
L N E Greenstar Si Combi
N
= Live = Earth
N E
N = Neutral E
Room T/Stat
Cylinder T/Stat
C
N NS LS LR
10
N L
Time Controller
Page 72
HW ON
CH ON
HW OFF
= Live
N = Neutral
= Earth
L N E Greenstar Si Combi
N
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 2 ON
CH Zone 1 ON HW ON
N E
~
M
N L
~
M
Page 73
= Live
N = Neutral
= Earth
L N E Greenstar Si Combi
N
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 1 ON
CH Zone 2 ON
N E
~
M
N L
Page 74
= Live
N = Neutral
= Earth
L N E Greenstar Si Combi
N
= Live = Earth
N = Neutral E
~
M
Cylinder T/Stat
L N NS LS LR
C 1 2
10
CH Zone 1 ON
HW ON
N E
~
M
N L
Demand
Page 75
= Live
N = Neutral
= Earth
= Live = Earth
N E
N = Neutral E
~
M
N NS LS LR
10
CH ON
L
L
Demand
Page 76
= Live
N = Neutral
= Earth
Series Connector Not supplied. Once wired in, make connector safe in electrical cover. Room T/Stat
Greenstar Si Combi
N NS LS LR
Time Controller
CH ON
Page 77
= Live
N = Neutral
= Earth
Greenstar Si Combi
Programmable Thermostat
N NS LS LR
C NC NO
The Link between the Live (L) and Common (C) may already be fitted as part of the Programmable Thermostat, if not then a link must be wired in.
Page 78
= Live
N = Neutral
= Earth
Greenstar Si Combi
N NS LS LR
HW VALVE (S)
CH VALVE (S)
Page 79
= Live
N = Neutral
= Earth
HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90 C.
C N O N C
Coil Coil Live Neutral Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
Greenstar Si Combi
Greenstar Si Combi
N NS LS LR
N NS LS LR
Page 80
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
N NS LS LR
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
E
HW ON CH ON
N E
~
M
N L
Page 82
= Live
N = Neutral
= Earth
= Live = Earth
N E
N = Neutral E
Room T/Stat
Cylinder T/Stat
C
N NS LS LR
10
N L
Time Controller
HW ON
CH ON
HW OFF
Page 83
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 2 ON
CH Zone 1 ON HW ON
N E
~
M
N L
~
M
Page 84
= Live
N = Neutral
= Earth
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 1 ON
CH Zone 2 ON
N E
~
M
N L
Page 85
= Live
N = Neutral
= Earth
= Live = Earth
N = Neurtal E
~
M
Cylinder T/Stat
L N NS LS LR
C 1 2
10
CH Zone 1 ON
HW ON
N E
~
M
N L
Demand
Page 86
= Live
N = Neutral
= Earth
= Live = Earth
N E
N = Neutral E
~
M
N NS LS LR
10
CH ON
L
L
Demand
Page 87
= Live
N = Neutral
= Earth
Series Connector Not supplied. Once wired in, make connector safe in electrical cover. Greenstar i Jnr Combi Room T/Stat
N NS LS LR
Time Controller
Page 88
CH ON
= Live
N = Neutral
= Earth
Programmable Thermostat
N NS LS LR
C NC NO
The Link between the Live (L) and Common (C) may already be fitted as part of the Programmable Thermostat, if not then a link must be wired in.
Page 89
= Live
N = Neutral
= Earth
N NS LS LR
HW VALVE (S)
CH VALVE (S)
Page 90
= Live
N = Neutral
= Earth
HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90 C.
C N O N C
Coil Coil Live Neutral Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
N NS LS LR
N NS LS LR
Page 91
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
N NS LS LR
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
Greenstar i System
N
N E
~
M
N NS LS LR
10
E
HW ON CH ON
N E
~
M
N L
Page 93
= Live
N = Neutral
= Earth
L N E
= Live = Earth
N = Neutral E
Greenstar i System
N
Room T/Stat
Cylinder T/Stat
C
N NS LS LR
10
N L
Time Controller
Page 94
HW ON
CH ON
HW OFF
= Live
N = Neutral
= Earth
L N E Greenstar i System
N
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 2 ON
CH Zone 1 ON HW ON
N E
~
M
N L
~
M
Page 95
= Live
N = Neutral
= Earth
L N E Greenstar i System
N
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 1 ON
CH Zone 2 ON
N E
~
M
N L
Page 96
= Live
N = Neutral
= Earth
L N E Greenstar i System
N
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
10
CH Zone 1 ON
HW ON
N E
~
M
N L
Demand
Page 97
= Live
N = Neutral
= Earth
L N E Greenstar i System
= Live = Earth
N = Neutral E
N E
~
M
N NS LS LR
L = Live
L N E 4 5 6 7 8 9 10
N = Neurtal E = Earth
CH ON
N L
Demand
Page 98
= Live
N = Neutral
= Earth
L N E
N = Neutral E
Greenstar i System
N NS LS LR
10
N L
Page 99
= Live
N = Neutral
= Earth
L N E
N = Neutral E
Greenstar i System
N NS LS LR
10
N L
Page 100
= Live
N = Neutral
= Earth
Greenstar i System
N NS LS LR
HW VALVE (S)
CH VALVE (S)
CYLINDER SENSOR
Page 101
Greenstar i System
Internal Diverter Valve with Worcester Controls & Unvented Cylinder
The generic Live, Neutral and Earth feed/s to equipment must return to the respective connection on the wiring centre. These connections are denoted as follows:
L
L
= Live
N = Neutral
= Earth
There is a unclarity within the Industry that in order to protect an Unvented Hot Water Cylinder from potentially dangerous high temperatures from the boiler circuit, a 2-port motorised valve must be installed. This is not the case, although it is the most common interpretation and approach. FURTHER DETAILS Building Regulation Approved Document G3, paragraph 3.6 states 'the non-self-resetting thermal cut out should be wired to a motorised valve or some other suitable device to shut off the flow to the primary heater'. The latter part of this sentence can be interpreted to mean as long as we, as responsible Manufacturer's, are confident our method provides an equal amount of protection to the common approach, we may instruct installers of our equipment to follow a different approach. A summary is provided below.
l
The installer will use the cylinder sensor supplied with the Integral Diverter Valve kit to control the hot water temperature. The installer, therefore, will NOT need to use the hot water control thermostat of the cylinder's dual thermostat. The installer may have to alter the wiring of the dual thermostat (depending on cylinder and thermostat manufacturer) to only use the high 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 Greenstar CDi System Boiler. The 2-port valve supplied with the unvented cylinder will NOT be used. If it is already physically installed in the pipe work is should be removed and electrically disconnected from the wiring centre.
Connector Block
(made safe)
CYLINDER THERMOSTAT
Brown
ST8
9 8
LR LS NS N
ST10
FR FS NP LP
ST6
Pump Harness
Fan Harness
S11 2.5 A 230 V AC
FR FS NP LP
Page 102
N NS LS LR
Main Harness
S12 0.5 A S13 1.6 A
Code Plug
9 8 7
= Live
N = Neutral
= Earth
HEADER LIMIT THERMOSTAT This cuts the Demand to the boilers in the event of excessive temperature within the Header due to lack of circulation. Ideally this should be set to 90 C.
C N O N C
Coil Coil Live Neutral Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.
Greenstar i System
Greenstar i System
N NS LS LR
N NS LS LR
Page 103
= Live
N = Neutral
= Earth
The boiler has inbuilt frost protection. When the primary temperature drops below 8C the pump is switched on. When then temperature rises above 9C the pump switches off after a 3 minute pump overrun. If the primary temperature drops below 5C, a central heating demand is activated until the primary temperature rises above 12 C. The demand switches off followed by the pump after a 3 minute overrun. The boiler has the facility to connect an external frost protection device to protect in at risk areas (terminal block ST6, contacts FS and FR). This is used if the boiler is not located in the area needing protection i.e. boiler in kitchen but pipe work in the garage that needs frost protection. If external frost thermostat is calling, i.e. temperature within frost thermostat below the set point, but the primary temperature of the boiler is above 5C, the pump will run until the temperature within the frost thermostat rises above the set point. If external frost thermostat is calling and the primary temperature is below 5C, a central heating demand is activated until primary temperature is above 12 C. If the frost thermostat is still calling the pump will run until the temperature within the frost thermostat location rises above the set point.
N NS LS LR
Earth to Wiring Centre Neutral Feed to Wiring Centre Live Feed to Wiring Centre Switch Live from Wiring Centre
Page 104
Page 105
Page 106
Useful Numbers
L
L
The generic Live, Neutral and Earth feed/s to equipment must return to the respective connection on the wiring centre. These connections are denoted as follows:
= Live N
N = Neutral
= Earth
www.worcester-bosch.co.uk
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Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. This is leaflet is accurate at the date of printing, buy may be superseded and should be disregarded if specification and/or appearances are changed in the interest of continued improvement. The statutory rights of the consumer are not affected. 6 720 646 965 Issue A (09/11)
Worcester, Bosch Group, Cotswold Way, Warndon, Worcester, WR4 9SW. Tel: 0844 892 9900