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Worcester wiring guide

Greenstar gas-fired boilers

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

Worcester wiring guide Greenstar gas-fired boilers

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

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Ri Regular 2 x 2 Port Valves (S-Plan)


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

Greenstar Ri Regular

L N E

= Live = Earth

N = Neutral E

LP NP LR

Room T/Stat
N

N E

~
M

230V Mains Voltage Double Pole Fused Spur


L N E

Cylinder T/Stat
C 1 2

reset

max

Heating Zone Valve

L
L N E

10

E
HW ON CH ON

External Pump
N L

N E

~
M

Cylinder Zone Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 5

Greenstar Ri Regular Mid Position Valve (Y-Plan)


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

L Greenstar Ri Regular N E

= Live = Earth
E

N = Neutral E

Mid Position Valve


N
Green/Yellow Blue White Grey Orange

LP NP LR

Room T/Stat
N

Cylinder T/Stat
C 1 2

230V Mains Voltage Double Pole Fused Spur


L N E

reset

max

L
L N E

10

E
HW OFF

N L

Time Controller

Page 6

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

External Pump

Greenstar Ri Regular 3 x 2 Port Valves (S-Plan Plus)


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

Greenstar Ri Regular

L N E

= Live = Earth

N = Neutral E

LP NP LR

Room T/Stat Zone 1


N

N E

~
M

230V Mains Voltage Double Pole Fused Spur


L N E

Cylinder T/Stat
C 1 2

reset

max

Heating Zone 1 Valve

L
L N E

10

CH Zone 2 ON

External Pump

CH Zone 1 ON HW ON

N E

~
M

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Worcester wiring guide Greenstar gas-fired boilers

Page 7

Greenstar Ri Regular 2 x Radiator Heating Zones


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

Greenstar Ri Regular

L N E

= Live = Earth

N = Neutral E

LP NP LR

Room T/Stat Zone 1


N

230V Mains Voltage Double Pole Fused Spur


L N E

Room T/Stat Zone 2


N

~
M

reset

max

Heating Zone 1 Valve

L
L N E

10

CH Zone 1 ON

CH Zone 2 ON

External Pump
N L

N E

~
M

Heating Zone 2 Valve Time Controller

Page 8

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Ri Regular 2 x 2 Port Valves & Underfloor Heating


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

Greenstar Ri Regular

L N E

= Live = Earth

N = Neutral E

LP NP LR

Room T/Stat Zone 1


N

N E

~
M

230V Mains Voltage Double Pole Fused Spur


L N E

Cylinder T/Stat
C 1 2

reset

max

Heating Zone 1 Valve

L
L N E

10

CH Zone 1 ON

External Pump

HW ON

N E

~
M

N L

Cylinder Zone Valve


L N E

Time Controler Twin Channel

Demand

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 9

Greenstar Ri Regular Zoned Radiator & Underfloor Heating


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

L Greenstar Ri Regular N E

= Live = Earth

N = Neutral E

LP NP LR

Room T/Stat Radiators Zone


N

N E

~
M

230V Mains Voltage Double Pole Fused Spur


L N E

reset

max

Radiators Zone Valve

L
L N E

10

E L N E

External Pump
N L

Demand

Time Controller Single Channel

Underfloor Controls Wiring Centre

Page 10

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Ri Regular Single Hot Water Zone (Vented 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

L Greenstar Ri Regular N E

= Live = Earth Cylinder T/Stat


C

N = Neutral E

LP NP LR

230V Mains Voltage Double Pole Fused Spur


L N E

reset

max

L
L N E

10

External Pump

N L

Time Controller Single Channel

Worcester wiring guide Greenstar gas-fired boilers

Page 11

Greenstar Ri Regular Single Heating Zone


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

L Greenstar Ri Regular N E

= Live = Earth Room T/Stat

N = Neutral E

N
L N LP NP LR

230V Mains Voltage Double Pole Fused Spur


L N E

reset

max

L
L N E

10

External Pump

N L

Time Controller Single Channel

Page 12

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Ri Regular Grundfoss Pump Plan


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

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

230V Mains Voltage Double Pole Fused Spur


L N E
N

LP NP LR

Warning! 240V - Isolate electrical supply before removing wiring centre cover.
reset max

2.5A Fuse - RS Components stock no 415-604

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

N/U = Not Used

UPP 15-50 PUMP PLAN - WIRING CENTRE CONNECTIONS

Worcester wiring guide Greenstar gas-fired boilers

Page 13

Greenstar Ri Regular Smartfit Control Pack


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

Greenstar Ri Regular

LP NP LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E

reset

max

Smartfit Layout: Example shown S Plan configuration


N L L SL PL N N L HW VALVE (S) S PLAN

MAINS BOILER PUMP

SMARTFIT FROST PROTECTION ROOM UNIT Y PLAN POLARITY FREE ACCESSORY PORT

L N E

CH VALVE (S)

3 PORT VALVE (Y)

CYLINDER SENSOR

External Pump

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Page 14

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Ri Regular Cascaded boilers 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

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

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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

230V Mains Voltage Double Pole Fused Spur


L N E

reset

max

reset

max

L N E

L N E

Shunt Pump

Shunt Pump

Worcester wiring guide Greenstar gas-fired boilers

Page 15

Greenstar Ri Regular Frost Protection


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

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.

Frost T/Stat Greenstar Ri Regular

Pipe T/Stat

L N E

= Live = Earth

N = Neutral E

LP NP LR

Room T/Stat
N

230V Mains Voltage Double Pole Fused Spur


L N E

Cylinder T/Stat
C 1 2

reset

max

Heating Zone Valve

10

E
HW ON CH ON

L N E

External Pump

Time Controller

Page 16

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Regular 2 x 2 Port Valves (S-Plan)


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

L N E Greenstar CDi Regular


N
LZ NZ

= Live = Earth

N = Neutral E

Room T/Stat
N E

~
M

Cylinder T/Stat
C 1 2

N NS LS LR

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

E
HW ON CH ON

N E

~
M

E N

External Pump

Cylinder Zone Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 17

Greenstar CDi Regular Mid Position Valve (Y-plan)


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

L N E Greenstar CDi Regular


N
LZ NZ

= Live = Earth
E

N = Neutral E

Mid Position Valve


N
Green/Yellow Blue White Grey Orange

Room T/Stat Cylinder T/Stat


C

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

E
HW OFF

E N L

External Pump

Time Controller

Page 18

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

Greenstar CDi Regular 3 x 2 Port Valves (S-Plan Plus)


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

L N Greenstar CDi Regular


N
LZ NZ

= Live = Earth

N = Neutral E

E Room T/Stat Zone 1

Cylinder T/Stat
C 1 2

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L
L N E

10

CH Zone 2 ON

L
L N E

CH Zone 1 ON

N E

~
M

HW ON

External Pump

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Worcester wiring guide Greenstar gas-fired boilers

Page 19

Greenstar CDi Regular 2 x Radiator Heating Zones


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

L N Greenstar CDi Regular


N

= Live = Earth

N = Neutral E

E Room T/Stat Zone 1


LZ NZ

Room T/Stat Zone 2


N

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

L
L N E

N E

~
M

E N

External Pump

Heating Zone 2 Valve Time Controller

Page 20

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Regular 2 x 2 Port Valves & Underfloor Heating


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

L N Greenstar CDi Regular E Room T/Stat Zone 1


LZ NZ

= Live = Earth

N = Neutral E

Cylinder T/Stat
C 1 2

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

L
L N E

HW ON

N E

~
M

E N L N E

Cylinder Zone Valve

External Pump

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 21

Greenstar CDi Regular Zoned Radiator & Underfloor Heating


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

L N E Greenstar CDi Regular Room T/stat Radiators Zone


N
LZ NZ

= Live = Earth

N = Neutral E

N E

~
M

N NS LS LR

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

E L N E

N L

Demand

External Pump

Time Controller Single Channel

Underfloor Controls Wiring Centre

Page 22

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Regular Single Hot Water Zone (Vented 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

L N E Greenstar CDi Regular

= Live = Earth Cylinder T/Stat


C

N = Neutral E

LZ NZ

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

N E L

External Pump

Time Controller Single Channel

Worcester wiring guide Greenstar gas-fired boilers

Page 23

Greenstar CDi Regular Single Heating Zone


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

L N E

= Live = Earth

N = Neutral E

Greenstar CDi Regular


N
LZ NZ

Room T/Stat

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

N E L

External Pump

Time Controller Single Channel

Page 24

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Regular Grundfoss Pump Plan


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

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.

Greenstar CDi Regular

LZ NZ

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E
N

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

N/U = Not Used

UPP 15-50 PUMP PLAN - WIRING CENTRE CONNECTIONS

Worcester wiring guide Greenstar gas-fired boilers

Page 25

Greenstar CDi Regular Smartfit Control Pack


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

Greenstar CDi Regular

LZ NZ

N NS LS LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE

L N E

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

ACCESSORY PORT CYLINDER SENSOR

External Pump

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Page 26

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Regular Cascaded boilers 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

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.

Wiring from Zone/s Controls


IMPORTANT NOTE: The relay should be mounted within a suitable electrically safe housing.
NO NC NC NO

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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 CDi Regular

Greenstar CDi Regular

LZ NZ

LZ NZ

N NS LS LR

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

L N E

L N E

Shunt Pump

Shunt Pump

Worcester wiring guide Greenstar gas-fired boilers

Page 27

Greenstar CDi Regular Frost Protection


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

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.

Frost T/Stat Greenstar CDi Regular


FR FS NP LP

LZ NZ

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

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

Greenstar CDi System 2 x 2 Port Valves (S-Plan)


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

L N Greenstar CDi System


N

= Live = Earth

N = Neutral E

E Room T/Stat

N E

~
M

Cylinder T/Stat
L N NS LS LR

C 1 2

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E
HW ON CH ON

N E

~
M

N L

Cylinder Zone Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 29

Greenstar CDi System Mid Position Valve (Y-Plan)


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

L N E Greenstar CDi System


N

= Live = Earth
N E

N = Neutral E

Mid Position Valve


Green/Yellow Blue White Grey Orange

Room T/Stat Cylinder T/Stat


C

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller

Page 30

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

HW OFF

Greenstar CDi System 3 x 2 Port Valves (S-Plan Plus)


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

L N E Greenstar CDi System


N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Cylinder T/Stat

N E

~
M

N NS LS LR

C 1 2

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 2 ON

CH Zone 1 ON HW ON

N E

~
M

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Worcester wiring guide Greenstar gas-fired boilers

Page 31

Greenstar CDi System 2 x Heating Zones


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

L N E Greenstar CDi System


N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Room T/Stat Zone 2


N

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

N E

~
M

N L

Heating Zone 2 Valve Time Controller

Page 32

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi System 2 x 2 Port Valves & Underfloor Heating


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

L N Greenstar CDi System


N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

HW ON

N E

~
M

N L

Cylinder Zone Valve


L N E

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 33

Greenstar CDi System Zoned Radiator & Underfloor


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

L N E Greenstar CDi System Room T/Stat Radiators Zone


N

= Live = Earth

N = Neutral E

N E

~
M

N NS LS LR

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E L N E

N L

Demand

Time Controller Single Channel

Underfloor Controls Wiring Centre

Page 34

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi System Single Hot Water Zone (Vented 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

L N E

= Live = Earth Cylinder T/Stat


C 1 2

N = Neutral E

Greenstar CDi System

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller Single Channel

Worcester wiring guide Greenstar gas-fired boilers

Page 35

Greenstar CDi System Single Heating Zone


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

L N E

= Live = Earth Room T/Stat

N = Neutral E

Greenstar CDi System


N

N NS LS LR

230V Mains Voltage

Double Pole Fused Spur


L N E

10

N L

Time Controller Single Channel

Page 36

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi System Smartfit Control Pack


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

Greenstar CDi System

N NS LS LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

ACCESSORY PORT CYLINDER SENSOR

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Worcester wiring guide Greenstar gas-fired boilers

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.

Below you will find an electrical diagram for this arrangement.


230V MAINS SUPPLY N E L
Brown

DUAL THERMOSTAT SAFETY LIMIT THERMOSTAT CYLINDER THERMOSTAT

Connector Block

Green\Yellow

(made safe)

Blue

NOT REQUIRED USE CYLINDER SENSOR SUPPLIED

Brown

IMPORTANT NOTE: UNDER NO CIRCUMSTANCES SHOULD THE FEED TO THE LIMIT STAT BE TAKEN THROUGH THE CONTROL STAT. ST8
9 8

NOTE: Leave link

ST10

LR LS NS N

FR FS NP LP

NOTE: Leave link ST19

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

DIVERTER VALVE MOTOR PLUG


Pump Control

S12 0.5 A S13 1.6 A

Code Plug

Worcester wiring guide Greenstar gas-fired boilers

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.

Below you will find an electrical diagram for this arrangement.


230V MAINS SUPPLY N E L
Brown

DUAL THERMOSTAT SAFETY LIMIT THERMOSTAT CYLINDER THERMOSTAT

Connector Block

Green\Yellow

(made safe)

Blue

NOT REQUIRED USE CYLINDER SENSOR SUPPLIED

Brown

IMPORTANT NOTE: UNDER NO CIRCUMSTANCES SHOULD THE FEED TO THE LIMIT STAT BE TAKEN THROUGH THE CONTROL STAT. ST8
9 8

NOTE: Leave link

ST10

LR LS NS N

FR FS NP LP

NOTE: Leave link ST19

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

A OUTSIDE F SENSOR CYLINDER TEMPERATURE SENSOR (SUPPLIED IN


DIVERTER KIT)

Worcester wiring guide Greenstar gas-fired boilers

N NS LS LR

Main Harness

9 8 7

DIVERTER VALVE MOTOR PLUG


Pump Control

S12 0.5 A S13 1.6 A

Code Plug

Page 39

Greenstar CDi System Cascaded boilers 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

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

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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 CDi System

Greenstar CDi System

N NS LS LR

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Page 40

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi System Frost Protection


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

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.

Frost T/Stat Greenstar CDi System


FR FS NP LP

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Earth to Wiring Centre Neutral Feed to Wiring Centre Live Feed to Wiring Centre Switch Live from Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 41

Greenstar CDi Combi 2 x 2 Port Valves (S-Plan)


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

L N E Greenstar CDi Combi Room T/Stat


N

= Live = Earth

N = Neutral E

N E

~
M

Cylinder T/Stat
C 1 2

N NS LS LR

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E
HW ON CH ON

N E

~
M

N L

Cylinder Zone Valve Time Controller

Page 42

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Combi Mid Position Valve (Y-Plan)


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

L N E Greenstar CDi Combi

= Live = Earth
E

N = Neutral E

Mid Position Valve


N
Green/Yellow Blue White Grey Orange

Room T/Stat
N

Cylinder T/Stat
C

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

E
HW OFF

N L

Time Controller

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

Page 43

Greenstar CDi combi 3 x 2 Port Valves (S-Plan Plus)


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

L N E Greenstar CDi Combi

= Live = Earth

N = Neutral E

Room T/Stat Zone 1


N

N E

~
M

Cylinder T/Stat
C 1 2

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 2 ON

CH Zone 1 ON HW ON

N E

~
M

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Page 44

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi combi 2 x Heating Zones


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

L N E

= Live = Earth

N = Neutral E

Greenstar CDi Combi Room T/Stat Zone 1


N N
L N NS LS LR

Room T/Stat Zone 2

~
M

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

N E

~
M

N L

Heating Zone 2 Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 45

Greenstar CDi Combi 2 x 2 Port Valves & Underfloor Heating


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

L N E Greenstar CDi Combi


N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1


N E

~
M

Cylinder T/Stat
L N NS LS LR

C 1 2

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

HW ON

N E

~
M

N L

Cylinder Zone Valve


L N E

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Page 46

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Combi Zoned Radiator & Underfloor Heating


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

L N E Room T/Stat Radiators Zone


N

= Live = Earth

N = Neutral E

Greenstar CDi Combi

N E

~
M

N NS LS LR

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E L N E

L
L

Demand

Time Controller Single Channel

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 47

Greenstar CDi Combi separate Time Controller & Room Thermostat


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

Series Connector Not supplied. Once wired in make connector safe in electrical cover. Greenstar CDi Combi Room T/Stat

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Time Controller

Page 48

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Combi Programmable Thermostat


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

Greenstar CDi Combi Programmable Thermostat

N NS LS LR

C NC NO

230V Mains Voltage Double Pole Fused Spur


L N E

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.

Worcester wiring guide Greenstar gas-fired boilers

Page 49

Greenstar CDi Combi Smartfit Control Pack


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

Greenstar CDi Combi

N NS LS LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

ACCESSORY PORT CYLINDER SENSOR

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Page 50

Worcester wiring guide Greenstar gas-fired boilers

Greenstar CDi Combi Cascade boilers 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

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.

Wiring from Zone/s Controls


IMPORTANT NOTE: The Relay should be mounted within a suitable electrically safe housing.
NO NC NC NO

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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 CDi Combi

Greenstar CDi Combi

N NS LS LR

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Worcester wiring guide Greenstar gas-fired boilers

Page 51

Greenstar CDi Combi Frost Protection


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

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.

Frost T/Stat Greenstar CDi Combi


FR FS NP LP

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E
Page 52 Worcester wiring guide Greenstar gas-fired boilers

Greenstar FS CDi Regular 2 x 2 Port Valves (S Plan)


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

Greenstar FS CDi Regular

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

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

E
HW ON CH ON

N E

~
M

External Pump

Cylinder Zone Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 53

Greenstar FS CDi Regular Mid Position Valve (Y Plan)


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

Greenstar FS CDi Regular

L N E

= Live = Earth Mid Position Valve

N = Neutral E

N NS LS LR

LZ NZ

Room T/Stat
N

Green/Yellow Blue White Grey Orange

Cylinder T/Stat
C 1 2

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

E
HW OFF

External Pump

N L

Time Controller

Page 54

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

Greenstar FS CDi Regular 3 x 2 Port Valves (S Plan Plus)


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

Greenstar FS CDi Regular

L N E

= Live = Earth

N = Neutral E

N NS LS LR

LZ NZ

Room T/Stat Zone 1


N

N E

~
M

Cylinder T/Stat
C 1 2

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 2 ON

L
L N E

CH Zone 1 ON HW ON

N E

~
M

External Pump

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Worcester wiring guide Greenstar gas-fired boilers

Page 55

Greenstar FS CDi Regular 2 x Heating Zones


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

Greenstar FS CDi Regular

L N E

= Live = Earth

N = Neutral E

N NS LS LR

LZ NZ

Room T/Stat Zone 1


N N

Room T/Stat Zone 2

~
M

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

L
L N E

N E

~
M

External Pump

Heating Zone 2 Valve Time Controller

Page 56

Worcester wiring guide Greenstar gas-fired boilers

Greenstar FS CDi Regular 2 x 2 Port Valves & Underfloor Heating


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

Greenstar FS CDi Regular

L N E

= Live = Earth

N = Neutral E

N NS LS LR

LZ NZ

Room T/Stat Zone 1


N

N E

~
M

Cylinder T/Stat
C 1 2

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

L
L N E

HW ON

N E

~
M

Cylinder Zone Valve


L N E

External Pump

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 57

Greenstar FS CDi Regular Zoned Radiator & Underfloor Heating


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

Greenstar FS CDi Regular

L N E

= Live = Earth

N = Neutral E

N NS LS LR

LZ NZ

Room T/Stat Radiators Zone


N

N E

~
M

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

E L N E

N L

Demand

External Pump

Time Controller Single Channel

Underfloor Controls Wiring Centre

Page 58

Worcester wiring guide Greenstar gas-fired boilers

Greenstar FS CDi Regular Single Hot Water Zone (Vented 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

Greenstar FS CDi Regular

L N E

= Live = Earth

N = Neutral E

N NS LS LR

LZ NZ

Cylinder T/Stat
C 1 2

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

N L

External Pump

Time Controller Single Channel

Worcester wiring guide Greenstar gas-fired boilers

Page 59

Greenstar FS CDi Regular Single Heating Zone


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

Greenstar FS CDi Regular

L N E

= Live = Earth

N = Neutral E

N NS LS LR

LZ NZ

Room T/Stat
N

230V Mains Voltage Double Pole Fused Spur


L N E

10

L
L N E

N L

External Pump

Time Controller Single Channel

Page 60

Worcester wiring guide Greenstar gas-fired boilers

Greenstar FS CDi Regular Grundfoss Pump Plan


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

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.

Greenstar FS CDi Regular

N NS LS LR

LZ NZ

230V Mains Voltage Double Pole Fused Spur


L N E
N

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 (N/U)


2

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

N/U = Not Used

UPP 15-50 PUMP PLAN - WIRING CENTRE CONNECTIONS

Worcester wiring guide Greenstar gas-fired boilers

Page 61

Greenstar FS CDi Regular Smartfit Control Pack


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

Greenstar FS CDi Regular

N NS LS LR

LZ NZ

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE ACCESSORY PORT

L N E

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

CYLINDER SENSOR

External Pump

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Page 62

Worcester wiring guide Greenstar gas-fired boilers

Greenstar FS CDi Regular Cascaded boilers 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

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.

Wiring from Zone/s Controls

IMPORTANT NOTE: The Relay should be mounted within a suitable electrically safe housing.
NO NC NC NO

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C Coil Live

C Coil Neutral

Header Limit Thermostat


N C

Greenstar FS CDi Regular

N O

230V AC Double Pole Relay

Example relay shown is a Double Pole Mains Voltage Relay. This isolates the Boilers electrically in case of a fault condition.

Greenstar FS CDi Regular

N NS LS LR

N NS LS LR

LZ NZ

LZ NZ

230V Mains Voltage Double Pole Fused Spur


L N E

L N E

L N E

Shunt Pump

Shunt Pump

Worcester wiring guide Greenstar gas-fired boilers

Page 63

Greenstar FS CDi Regular Frost Protection


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

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 FS CDi Regular

L N E

= Live = Earth

N = Neutral E

230V Mains Voltage Double Pole Fused Spur


L N 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

Switch Live from Wiring Centre

Frost Stat

L N E

External Pump
Page 64 Worcester wiring guide Greenstar gas-fired boilers

Greenstar HF CDi combi 2 x Heating Zones


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

Greenstar HF CDi
L N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

L N E

= Live = Earth

N = Neutral E

230V HW interface Installer Module


Safety isolation

N
NC

Room T/Stat Zone 1


N N

Room T/Stat Zone 2

~
Heating Zone 1 Valve

10

CH Zone 1 ON

CH Zone 2 ON

N E

HW ON

~
Heating Zone 2 Valve

N L

Time Controller 3 Channel

Worcester wiring guide Greenstar gas-fired boilers

Page 65

Greenstar HF CDi combi Zoned Radiator & Underfloor Heating


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

Greenstar HF CDi
L N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

L N E

= Live = Earth

N = Neutral E

230V HW interface Installer Module


Safety isolation

N
NC

Room T/Stat Radiators Zone


N

N E

~
Radiators Zone Valve

10

CH Rads ON

L
HW Heat Bank ON

N L

Demand

Underfloor Controls Wiring Centre Time Controller

Page 66

Worcester wiring guide Greenstar gas-fired boilers

Greenstar HF CDi combi separate Time Controller & Room Thermostat


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

230V Mains Voltage Double Pole Fused Spur


L N E

Greenstar HF CDi
L N NS LS LR

230V HW interface Installer Module


Safety isolation

Room T/Stat

N
NC

Series Connector Not supplied. Once wired in make connector safe in electrical cover.

Time Controller

Worcester wiring guide Greenstar gas-fired boilers

CH ON

HW Heat Bank ON

Page 67

Greenstar HF CDi combi Programmable Thermostat


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

Programmable Thermostat 230V Mains Voltage Double Pole Fused Spur


L N E 230V HW interface Installer Module
Safety isolation

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.

Time Controller Hot Water Heat Bank

Page 68

Worcester wiring guide Greenstar gas-fired boilers

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.

L N 230V Mains Voltage Double Pole Fused Spur


L N E 230V HW interface Installer Module
Safety isolation

= Live Room T/Stat = Earth

N = Neutral E

Greenstar HF CDi
L N NS LS LR

Header Limit Thermostat N

C N C

N
NC

10

HW Heat Bank ON

CH ON

L N E

Time Controller

System Pump

Worcester wiring guide Greenstar gas-fired boilers

Page 69

Greenstar HF CDi combi Frost Protection


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

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

230V Mains Voltage Double Pole Fused Spur


L N E

Frost T/Stat

230V HW interface Installer Module


Safety isolation

N
NC
FR FS NP LP

Page 70

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Si Combi 2 x 2 Port Valves (S Plan)


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

L N E Greenstar Si Combi
N

= Live = Earth

N = Neutral E

Room T/Stat Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E
HW ON CH ON

N E

~
M

N L

Cylinder Zone Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 71

Greenstar Si Combi Mid Position Valve (Y Plan)


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

L N E Greenstar Si Combi
N

= Live = Earth
N E

N = Neutral E

Mid Position Valve


Green/Yellow Blue White Grey Orange

Room T/Stat

Cylinder T/Stat
C

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller

Page 72

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

HW OFF

Greenstar Si Combi 3 x 2 Port Valves (S Plan Plus)


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

L N E Greenstar Si Combi
N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 2 ON

CH Zone 1 ON HW ON

N E

~
M

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Worcester wiring guide Greenstar gas-fired boilers

Page 73

Greenstar Si Combi 2 x Heating Zones


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

L N E Greenstar Si Combi
N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Room T/Stat Zone 2


N

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

N E

~
M

N L

Heating Zone 2 Valve Time Controller

Page 74

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Si Combi 2 x 2 Port Valves & Underfloor Heating


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

L N E Greenstar Si Combi
N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1


N E

~
M

Cylinder T/Stat
L N NS LS LR

C 1 2

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

HW ON

N E

~
M

N L

Cylinder Zone Valve


L N E

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 75

Greenstar Si Combi Zoned Radiator & Underfloor Heating


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

L N E Greenstar Si Combi Room T/Stat Radiators Zone


N

= Live = Earth
N E

N = Neutral E

~
M

N NS LS LR

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH ON

L
L

Demand

Time Controller Single Channel

Underfloor Controls Wiring Centre

Page 76

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Si Combi separate Time Controller & Room Thermostat


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

Series Connector Not supplied. Once wired in, make connector safe in electrical cover. Room T/Stat

Greenstar Si Combi

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Time Controller

Worcester wiring guide Greenstar gas-fired boilers

CH ON

Page 77

Greenstar Si Combi Programmable Thermostat


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

Greenstar Si Combi

Programmable Thermostat

N NS LS LR

C NC NO

230V Mains Voltage Double Pole Fused Spur


L N E

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

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Si Combi Smartfit Control Pack


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

Greenstar Si Combi

N NS LS LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

ACCESSORY PORT CYLINDER SENSOR

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Worcester wiring guide Greenstar gas-fired boilers

Page 79

Greenstar Si Combi Cascaded boilers 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

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

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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

230V Mains Voltage Double Pole Fused Spur


L N E

Page 80

Worcester wiring guide Greenstar gas-fired boilers

Greenstar Si Combi Frost Protection


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

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.

Frost T/Stat Greenstar Si Combi


FR FS NP LP

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E
Worcester wiring guide Greenstar gas-fired boilers Page 81

Greenstar i Junior Combi 2 x 2 Port Valves (S Plan)


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

L N E Greenstar i Jnr Combi


N

= Live = Earth

N = Neutral E

Room T/Stat Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E
HW ON CH ON

N E

~
M

N L

Cylinder Zone Valve Time Controller

Page 82

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i Junior Combi Mid Position Valve (Y Plan)


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

L N E Greenstar i Jnr Combi


N

= Live = Earth
N E

N = Neutral E

Mid Position Valve


Green/Yellow Blue White Grey Orange

Room T/Stat

Cylinder T/Stat
C

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

HW OFF

Page 83

Greenstar i Junior Combi 3 x 2 Port Valves (S Plan Plus)


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

L N E Greenstar i Jnr Combi


N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 2 ON

CH Zone 1 ON HW ON

N E

~
M

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Page 84

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i Junior Combi 2 x Heating Zones


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

L N E Greenstar i Jnr Combi


N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Room T/Stat Zone 2


N

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

N E

~
M

N L

Heating Zone 2 Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 85

Greenstar i Junior Combi 2 x 2 Port Valves & Underfloor Heating


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

L N E Greenstar i Jnr Combi


N

= Live = Earth

N = Neurtal E

Room T/Stat Zone 1


N E

~
M

Cylinder T/Stat
L N NS LS LR

C 1 2

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

HW ON

N E

~
M

N L

Cylinder Zone Valve


L N E

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Page 86

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i Junior Combi Zoned Radiator & Underfloor Heating


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

L N E Greenstar i Jnr Combi Room T/Stat Radiators Zone


N

= Live = Earth
N E

N = Neutral E

~
M

N NS LS LR

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH ON

L
L

Demand

Time Controller Single Channel

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 87

Greenstar i Junior Combi separate Time Controller & Room Thermostat


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

Series Connector Not supplied. Once wired in, make connector safe in electrical cover. Greenstar i Jnr Combi Room T/Stat

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Time Controller

Page 88

Worcester wiring guide Greenstar gas-fired boilers

CH ON

Greenstar i Junior Combi Programmable Thermostat


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

Greenstar i Jnr Combi

Programmable Thermostat

N NS LS LR

C NC NO

230V Mains Voltage Double Pole Fused Spur


L N E

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.

Worcester wiring guide Greenstar gas-fired boilers

Page 89

Greenstar i Junior combi Smartfit Control Pack


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

Greenstar i Jnr Combi

N NS LS LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

ACCESSORY PORT CYLINDER SENSOR

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Page 90

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i Junior combi Cascade boilers 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

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

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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 jnr Combi

Greenstar i Jnr Combi

N NS LS LR

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Worcester wiring guide Greenstar gas-fired boilers

Page 91

Greenstar i Junior combi Frost Protection


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

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.

Frost T/Stat Greenstar i Jnr Combi


FR FS NP LP

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E
Page 92 Worcester wiring guide Greenstar gas-fired boilers

Greenstar i System 2 x 2 Port Valves (S Plan)


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

L N E

= Live = Earth

N = Neutral E

Greenstar i System
N

Room T/Stat Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

E
HW ON CH ON

N E

~
M

N L

Cylinder Zone Valve Time Controller

Worcester wiring guide Greenstar gas-fired boilers

Page 93

Greenstar i System Mid Position Valve (Y Plan)


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

L N E

= Live = Earth

N = Neutral E

Mid Position Valve


N E
Green/Yellow Blue White Grey Orange

Greenstar i System
N

Room T/Stat

Cylinder T/Stat
C

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller

Page 94

Worcester wiring guide Greenstar gas-fired boilers

HW ON

CH ON

HW OFF

Greenstar i System 3 x 2 Port Valves (S Plan Plus)


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

L N E Greenstar i System
N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 2 ON

CH Zone 1 ON HW ON

N E

~
M

N L

Cylinder Zone Valve


N

Time Controller 3 Channel


N

~
M

Heating Zone 2 Valve Room T/Stat Zone 2

Worcester wiring guide Greenstar gas-fired boilers

Page 95

Greenstar i System 2 x Heating Zones


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

L N E Greenstar i System
N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Room T/Stat Zone 2


N

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

CH Zone 2 ON

N E

~
M

N L

Heating Zone 2 Valve Time Controller

Page 96

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i System 2 x 2 Port Valves & Underfloor Heating


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

L N E Greenstar i System
N

= Live = Earth

N = Neutral E

Room T/Stat Zone 1 Cylinder T/Stat


C 1 2

N E

~
M

N NS LS LR

Heating Zone 1 Valve

230V Mains Voltage Double Pole Fused Spur


L N E

10

CH Zone 1 ON

HW ON

N E

~
M

N L

Cylinder Zone Valve


L N E

Time Controller Twin Channel

Demand

Underfloor Controls Wiring Centre

Worcester wiring guide Greenstar gas-fired boilers

Page 97

Greenstar i System Zoned Radiator & Underfloor Heating


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

L N E Greenstar i System

= Live = Earth

N = Neutral E

Room T/Stat Radiators Zone


N

N E

~
M

N NS LS LR

Radiators Zone Valve

230V Mains Voltage Double Pole Fused Spur


L N E

L = Live
L N E 4 5 6 7 8 9 10

N = Neurtal E = Earth

CH ON

N L

Demand

Time Controller Single Channel

Underfloor Controls Wiring Centre

Page 98

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i System Single Hot Water Zone (Vented 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

L N E

= Live = Earth Cylinder T/Stat


C 1 2

N = Neutral E

Greenstar i System

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller Single Channel

Worcester wiring guide Greenstar gas-fired boilers

Page 99

Greenstar i System Single Heating Zone


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

L N E

= Live = Earth Room T/Stat

N = Neutral E

Greenstar i System

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

10

N L

Time Controller Single Channel

Page 100

Worcester wiring guide Greenstar gas-fired boilers

Greenstar i System Smartfit Control Pack


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

Greenstar i System

N NS LS LR

SMARTFIT ROOM UNIT

230V Mains Voltage Double Pole Fused Spur


L N E
N L L SL PL N N L

Smartfit Layout: Example shown S Plan configuration


MAINS BOILER PUMP
SMARTFIT FROST PROTECTION ROOM UNIT S PLAN Y PLAN POLARITY FREE ACCESSORY PORT

HW VALVE (S)

CH VALVE (S)

3 PORT VALVE (Y)

CYLINDER SENSOR

HW VALVE (S) CH VALVE (S) CYLINDER T/STAT

Worcester wiring guide Greenstar gas-fired boilers

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.

Below you will find an electrical diagram for this arrangement.


Optional: Third Party Room Thermostat: Using the Worcester Internal DT20 Timer an External Third Party Room Thermostat must be connected to the boiler on the External Controls section of ST10 (NS, LS & LR). OPTIONAL: THIRD PARTY ROOM THERMOSTAT N CALL COM
Blue Green\Yellow

230V MAINS SUPPLY N E L


Brown

DUAL THERMOSTAT SAFETY LIMIT THERMOSTAT

Connector Block

(made safe)

CYLINDER THERMOSTAT

Brown

ST8
9 8

NOTE: Leave the link if using Worcester Internal Digital RF units.

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

Worcester wiring guide Greenstar gas-fired boilers

9 8 7

DIVERTER VALVE MOTOR PLUG

Greenstar i System Cascade boilers 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

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

Junction Box/Wiring Centre


L N E Switched Live/ Demand

C N O N C

Header Limit Thermostat 230V AC Double Pole Relay

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

230V Mains Voltage Double Pole Fused Spur


L N E

Worcester wiring guide Greenstar gas-fired boilers

Page 103

Greenstar i System Frost Protection


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

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.

Frost T/Stat Greenstar i System


FR FS NP LP

N NS LS LR

230V Mains Voltage Double Pole Fused Spur


L N E

Earth to Wiring Centre Neutral Feed to Wiring Centre Live Feed to Wiring Centre Switch Live from Wiring Centre

Page 104

Worcester wiring guide Greenstar gas-fired boilers

Worcester wiring guide Greenstar gas-fired boilers

Page 105

Worcester wiring guide Greenstar gas-fired boilers

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

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Training Tel: 01905 752526


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technical.enquiries@uk.bosch.com
Monday Friday 7.00am 8.00pm Saturday 8.30am 4.00pm

www.worcester-bosch.co.uk
Calls to the listed 0844 numbers are charged at up to 3 pence per minute from BT landlines. Calls from mobiles and some networks may vary. Calls to and from Bosch Thermotechnology Ltd. may be recorded for training and quality assurance purposes.

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