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Greenfloor heating series

Technical and Specification Information

Worcester and you, making a difference

Working together for many years, heating

professionals and Worcester have been

making a real difference in hundreds of

thousands of homes across the UK. We are

recognised as a market leader in high

efficiency, condensing boiler technology

and are also committed to providing

renewable energy solutions.

As part of the Bosch Group, our products

are designed and manufactured to provide

the high levels of quality and reliability

which are synonymous with the Bosch

name throughout the world.

We’re a leading British company,

employing more than 1,800 people at our

headquarters and manufacturing plants in

Worcester and at Clay Cross in Derbyshire,

including a nationwide network of over 300

Service Engineers and over 80 technically-

trained Field Sales Managers.

As part of Europe’s largest supplier of

heating products, Worcester, Bosch Group

has the UK-based resources and support

capability to offer you the value-added

solutions we feel you deserve.

“At Worcester we recognise the vital role

you, our customer, has in the specification

and installation of ‘A’ rated, energy efficient

appliances in homes across the UK. We will

continue to invest in our products, people,

facilities and added value services such as

training, to give you the support you require

in providing a total solution for your

customers’ comfort.”

Carl Arntzen,

Managing Director, Worcester, Bosch Group

Worcester, Bosch GroupTechnical Help line

32

Contents Page

Worcester Greenfloor heating 4 - 8

Greenfloor pipe fixing methods 9

Floor constructions 10 - 11

Greenfloor controls 12

Product compatibility 13

Installation requirements 14 - 16

General requirements 17 - 18

Components 19 - 21

Specification and Design Service 22 - 23

Greenfloor heating series

components and accessories 24 - 27

Worcester training 28 - 30

After-sales 31

54

Worcester Greenfloor heatingGlobal responsibility for nature and the environment

As part of the Bosch group, Worcester is committed to

environmental protection. With product development being

prioritised in the interests of people’s safety, the economical

use of resources and environmental sustainability.

In just a few short years, Britain’s domestic heating and

hot water industry has changed dramatically.

With approximately 25% of the UK’s carbon dioxide

emissions being produced by home energy consumption,

75% of which is for the provision of heating and hot water,

such change is not only inevitable but crucial.

Words and expressions such as “renewable energy”,

“sustainable technology” and “carbon footprint” have

become part of everyday conversation and have been

fuelled by extreme weather and stark television images

of melting polar ice caps.

Worcester, Bosch Group, whilst continuing to satisfy the

daily demands for heating and hot water comfort, has taken

a lead in developing solutions which reduce the impact on

the environment by reducing CO2 emissions – not only for

today but well into the future.

As part of this philosophy we are proud to introduce

high efficiency Greenfloor heating systems. Part of the

Total System Solution offering from Worcester, Greenfloor

heating systems deliver efficient heating in their own right

as well as facilitating the use of low carbon technologies

such as air source and ground source heat pumps and

condensing boilers.

Greenfloor heating is suitable for both new build and

refurbishment applications, offering a number of major

benefits over traditional radiator systems. By operating at

lower temperatures, underfloor heating helps to increase

the efficiency of the boiler or heat pump and reduces

overall running costs. Unlike radiator systems underfloor

distributes heat more evenly, increasing user comfort and

helping to reduce dust and the risk of house mites.

Greenfloor provides a complete underfloor heating

package that’s robust and reliable. The range includes

PE-Xc pipe with a choice of different pipe fixing methods

and manifolds for between 2 and 16 zones. These

are complemented by controls and a full range of

other accessories.

The pipe fixing methods are designed to make installation

quick and easy and can be used with traditional sand and

cement screed, wet screed or as a dry construction system

to suit the requirements of each property.

PE-Xc Pipe, protected againstthermal ageing and stress fracture

Features Benefits

Flexible and durable

Pre-insulated pipe positioning panels Quick and easy installation

Stainless steel manifolds Robust and durable

Full suite of wireless and wiredcontrol systems

Suits any type of installation

Uses radiant heat

Requires lower working temperatures

Less circulation of dust than withradiators, cleaner air for home

Maximises the efficiency ofcondensing boilers and heat pumps

Eliminates the need for radiators

Complements Worcester gas- and oil-fired boilers, ground source andair to water heat pumps

Creates space on walls and allowsunrestricted layout within a room

Complete heating and hot watersolutions from one source

Greenfloor features and benefits

Heat from a radiator travels up and around thewalls and ceiling of a room first, losing much ofits useful heat in the process...

...while the heat from underfloor heating is evenlydistributed from the surface of the floorthroughout the whole living space.

76

Greenfloor heating

Worcester’s Greenfloor heating system uses a water-filled

pipe system that turns the floor into a large surface area

radiator. The pipe system gently warms the space above it

through a combination of radiant energy and heat conduction.

In a modern, well-insulated space where heat loss factors

have been taken into consideration, underfloor heating can

act as the primary heating source and, in most cases, no

other space heating methods will be required.

Underfloor heating operates with lower water temperatures

than traditional radiator systems. This makes it the perfect

complement for Worcester’s ground source and air to water

heat pumps. As well as space heating, Worcester heat

pumps are able to provide a constant supply of hot water

throughout the year.

The low return water temperature of underfloor heating

also makes it suitable for use with Worcester condensing

boilers, ensuring they remain at their optimum efficiency,

with significant energy savings.

As there are no radiators to take up space, Worcester

Greenfloor systems also provide maximum flexibility within

the property. They can also be used with a wide range of

floor coverings, including parquet, carpeting, marble or tiles.

Underfloor heating is a system where every component is

important to overall performance. Worcester Greenfloor

systems provide a comprehensive selection of high quality

system components, while offering considerable flexibility

to meet all of a project’s needs.

System components

Greenfloor heating systems comprise a number of elements:

• PE-Xc system pipe

• Stainless steel manifolds

• Manifold cabinets

• Pump and mixing stations

• Pipe fixing methods

• Controls.

All Greenfloor systems are supplied complete with all

components and connections. Any specialist tools that

are necessary are also available from Worcester.

Greenfloor PE-Xc system pipe

The Greenfloor PE-Xc system

pipe is oxygen impermeable

and highly flexible for ease

of installation. The pipe is

available in two sizes to

suit the panel system

(see table below).

System pipe is available in coils, with a reel available to ease

unwinding, reduce waste and avoid the need for couplings.

Pipe and pipe fixing method compatibility

Pipe positioning panel 14 x 2mm 16 x 2mm

Stapler panel systems 14 x 2mm 16 x 2mm

Dry construction system 14 x 2mm –

Timber suspended floor 14 x 2mm 16 x 2mm

Pipe 14 x 2mm 16 x 2mm

PE-Xc Yes Yes

Coil length (standard) 200m 200m

Coil length (long) 750m 650m

Max. operating pressure 6 bar 6 bar

Max. operating temperature 90ºC 90ºC

Min. bend radius 70mm 80mm

Greenfloor stainless steel manifolds

All Greenfloor manifolds are manufactured from stainless

steel and include flow meters for accurate system

commissioning. A full range of accessories is available

including ball valves and connectors.

The pre-assembled stainless steel manifolds serve 2-16

zone applications. They are supplied with integrated valves

providing a filling and draining facility and automatic air

vents. In the event of additional zones being required,

manifolds can be joined together. The flow rate can be

accurately set on flow meters for safe and rapid setting

of the values provided by the Worcester Design Service.

The return manifold provides threaded connections for

installation of electronic actuators.

Manifold cabinets

Surface VSS-A VSS-A VSS-A VSS-Amounted 560 700 1000 1300Width 560mm 700mm 1,000mm 1,300mm

Height 700mm 700mm 700mm 700mm

Depth 150mm 150mm 150mm 150mm

Recessed VSS-U VSS-U VSS-U VSS-U560 700 1000 1300

Width 560mm 700mm 1,000mm 1,300mm

Height780-880mm 780-880mm 780-880mm 780-880mm

(adjustable)Depth

115-165mm 115-165mm 115-165mm 115-165mm(adjustable)

Manifold cabinets

Greenfloor manifold cabinets are constructed from 1mm

galvanised sheet steel. The recessed type allow a flush

finish to a plastered wall and feature pre-punched side

openings for manifold connections and pipe penetrations

at the top and bottom. They are also height adjustable

to align with the screed thickness. A surface mounted

version is also available. Both the recessed and surface

mounted cabinets are lockable to prevent unauthorised access.

Height 350mm

Depth 62mm

Material Stainless steel

Flow meters Yes

Flow & return heat source 1"

Flow & return to underfloorzones (PE-Xc pipe)

3/4"

Note: for a two zone system, the manifold width is

200mm. For each additional zone added, the manifold

width increases by 50mm. The maximum number of

zones is 16.

98

Greenfloor pump and mixing stations

Greenfloor offers a number of pump and mixing stations to

satisfy the needs of each individual installation.

FRS pump and mixing station

The FRS standard pump and mixing station features a fixed

value thermostatic injection valve, which is commissioned

on site by the installer to the specification provided by the

Worcester Design Service. The flow water temperature will

be maintained constantly at a safe and efficient level. The

FRS also includes a high limit thermostat to protect the

heated floor area from excessive temperatures using a

circulating pump and temperature gauge. Each installation

of an FRS will also require an FRS connection set, available

from Worcester, to allow an easy and speedy connection to

the Greenfloor stainless steel manifold.

Alternatively, a choice of advanced controls featuring

weather compensation is available.

VRS pump and mixing stations

The VRS weather compensated pump and mixing stations

are available to suit up to both a 7kW and 10kW installation

and fit directly to the Greenfloor stainless steel manifold.

The VRS station features a modulating circulating pump,

electronic mixing valve and an intelligent controller. This

feature, through input gathered by the supplied flow

temperature and outdoor sensors, adjusts the output

temperature based upon external conditions.

KMS pump and mixing stations

The KMS remote pump and mixing stations feature the

same proven components and method of operation as

the VRS pump and mixing stations. The KMS provides

the flexibility of mounting the station away from the

Greenfloor manifold and is available to suit up to both

15kW and 25kW installations.

All Greenfloor pump and mixing stations are provided

with comprehensive installation, commissioning and

user instructions. Further support on planning

and specifying the system can be provided by the

specialist Worcester Design Services team.

Single room extensions

The RMS pump and mixing station is designed to offer a

simple underfloor heating control solution for single rooms.

The RMS connects into the existing flow and return circuit

of the central heating system and features a circulation

pump and a temperature limiting valve on the return side.

It is possible for the circulation pump to be electrically

supplied via a proprietary room thermostat to provide an

interlock as well as to aid energy efficiency. Please note

that the RMS single room pump and mixing station relies

upon the existing central heating system’s controls to be

‘calling for heat’ to achieve warming of the floor. To achieve

a greater level of independent control, an FRS standard

pump and mixing station should be selected.

Greenfloor offers a range of pipe fixing methods

to suit every project.

Greenfloor pipe

positioning panels

Greenfloor pipe positioning

panels are ideal for use in

new and existing buildings

and can be used with cement

or pumped liquid screed.

The channels on the panels

ensure that optimum spacing of the pipe coils

are achieved. Pipe is fixed using a press-stud action

which enables fixing without clamps. The panels

are available with and without insulation.

Greenfloor staple panels

Greenfloor staple panels are

easy to assemble and very

cost-efficient. They are

supplied as a rolled panel and

manufactured from foamed

polystyrene with a fully

bonded, tear-proof and

waterproof woven fabric

coating. The imprinted installation grid allows for system-

compatible pipe spacing, as well as quick and easy pipe fixing

when using our Greenfloor clip rails or staples.

Greenfloor dry

construction system

The Greenfloor dry construction

system provides the ideal

solution for dry construction

in buildings of all ages. They

are particularly popular with

timbered floors where a

water-based screed is undesirable. The system is based

on working with dry construction panels while using steel

spreader plates into which the pipe is pressed. Easy to work

with, the system enables serpentine or spiral installations and can

accommodate even the most complex of room geometries.

Greenfloor timber

suspended floor system

Greenfloor clip rail and

staples provide a simple cost

effective solution. It is ideal

for when fixing pipe to floor-

grade insulation between the

joists of a timber suspended

floor. Tongue & groove or

chipboard flooring can then be laid directly across

the joists.

Pipe positioning panels 30 11 Light

Length 900mm 900mm 900mm

Width 1,447mm 1,447mm 1,447mm

Depth 48mm 29mm 18mm

Thermal insulation (Rλ) 0.75m2k/W 0.37m2k/W None

Sound insulation 28dB None None

Unit of delivery 10.4m2 10.4m2 10.4m2

110mm/ 110mm/ 110mm/Installation centres 165mm/ 165mm/ 165mm/

220mm 220mm 220mm

Staple panels 35mm roll 30mm roll

Width 1,000mm 1,000mm

Depth 35mm 30mm

Thermal insulation (Rλ) 0.78m2k/W 0.67m2k/W

Sound insulation 29dB 29dB

Unit of delivery 12m2 12m2

Dry construction system Panel Straight Curvedplate plate

Length 1,000mm 750mm 245mm

Width 625mm 120mm 125mm

Depth 25mm 0.5mm 0.5mm

Thermal insulation (Rλ) 0.56m2k/W N/A N/A

Sound insulation None N/A N/A

Unit of delivery 13.1m2 50 pieces 25 pieces

Installation centres 125mm/N/A 125mm

250mm

Greenfloor pipe fixing methods

FRS standard pump and mixing station

Timber suspended floor system Clip rail

Length 1,000mm

Width 40mm

Height 25mm

Unit of delivery 100m

Installation centres 50mm

1110

Flooring

Flooring underlay

Staple panel

Concrete base

Clip rail

Sub floor

Clip rail fixing pins

Greenfloor PE-Xc pipe

Pipe stapleEdging

insulationstrip

Screed

Greenfloor offers a choice of fixing methods making it suitable for all types of floor construction in new build

and existing properties. It is most frequently used with ceramic, wood or laminate floor coverings, but can also

be used with carpets and vinyls.

Flooring

Flooring underlay

Screed

Pipe positioning panel

Concrete base

Sub floor


Edginginsulation

strip

Flooring

Flooring underlay

Dry screed system foil

Dry construction panel

Wooden floor


Heat conducting plate

Edginginsulation

strip

Greenfloor pipe positioning panel system Greenfloor dry construction panel system

Greenfloor staple panel system with clip rail

Flooring

Flooring underlay

Clip rail

Joist

Support batten

Floor grade insulation

Clip rail fixing pins


Pipe staple

Flooring boards

Greenfloor timber suspended floor system

Floor constructions

13

Greenfloor controls are optimised for use with

Greenfloor heating systems. The range of products

includes wiring centres and components for individual

room temperature control.

Room thermostats

Single room controls allow the temperature in each room to

be set individually. The temperature is controlled by the

thermostat in relation to variable factors such as solar heat

gains, electrical devices and people. They are available as

230V wired controls or as wireless (RF) versions. Single

room thermostats are available as wall mounted models.

Wired programmable room thermostats are available as

flush mounted models.

Wiring centres

Greenfloor wiring centres provide a quick, simple and safe

means of wiring together room thermostats and actuators.

The wired unit can be used with up to six 230V room

thermostats, or programmable room thermostats. It can

also operate up to 14 actuators. There is the facility to

connect a time control which enables a night set-back

mode and an interlock to

stop the manifold circulating

pump from operating. It also

turns off the heat source

(when all valves are closed).

The wireless unit will receive signals from up to eight

wireless thermostats and can be wired to a maximum of

16 actuators. The unit is supplied complete with a 7 day

programmer that allows each zone to be programmed

independently and works harmoniously with Worcester’s

wireless (RF) room thermostat. To stop the manifold

circulating pump running and turning off the heat source,

the unit incorporates an interlock.

Actuators

The 230V actuators are

supplied by the Greenfloor

wiring centres and control

the water flow through each

zone, according to the room

thermostat’s demand signal.

They consume as little energy

as just 2 Watts.

Greenfloor controls

Control Roomthermostat

Programmableroom thermostat

Wiring centre Actuator

Wired 230V option Yes Yes Yes Yes

Wireless (RF) option Yes No Yes Yes

230V wiring centre

12

Product compatibility

Greenfloor heating is designed to work with all Greenstar gas and oil-fired boilers and appropriate renewable technologies.

Gas-fired boilers

Regular

Greenstar Ri series

Greenstar CDi Regular series

Greenstar FS CDi series

System

Greenstar i System series

Greenstar 30CDi System

Combi

Greenstar i Junior series

Greenstar Si Series

Greenstar CDi series

Greenstar Highflow CDi series

Oil-fired boilers

Regular

Greenstar Danesmoor WM series

Greenstar Camray series

Greenstar Camray Utility series

Greenstar Utility series

Greenstar Camray External series

System

Greenstar Camray System series

Greenstar Camray Utility System series

Greenstar Camray External System series

Combi

Greenstar Heatslave series

Greenstar Heatslave External series

Renewable technology

Ground source heat pumps

Greenstore System Ground Source Heat Pump series

Greenstore Combination Ground Source Heat Pump series

Air to water heat pumps

Greensource Air to Water Heat Pump series

Boilers September 2011

1514

Pipe fixing methods

Before a suitable Greenfloor pipe fixing method

can be selected, consideration must be given to

the following factors:

• The desired finished floor level and the available

depth for installation

• The heat output required from the floor to accommodate

the heat loss of the room and building

• The type of floor that Greenfloor will be installed within

• The desired floor finish.

Wet screed floors

Screed

Greenfloor pipe positioning panels and Greenfloor staple

panels are designed for use with either a standard sand

and cement screed or a pumped liquid screed. Typically

a 75mm screed depth is used.

Greenfloor pipe positioning panels

Greenfloor pipe positioning panels offer flexibility in

achieving a balance of the finished floor level against

the available installation depth. The panels are available

with either 30mm or 11mm of polystyrene insulation.

Alternatively an option with no insulation provides the

ease and convenience of the panel fixing method and

relies on the floor grade insulation installed on site.


panels offer a number of

advantages over other pipe

fixing methods, while allowing

an experienced installer a one

man installation. Working

with a 200m coil, Greenfloor

PE-Xc system pipe can simply

be walked into the pre-formed castellated sections of the

panel. Greenfloor pipe positioning panel installations are

also much easier to adjust should last minute changes be

required to the layout of the installation. There are no clips

to release, no damage to the panels and the pipe can easily

be relaid to the revised requirements. Greenfloor pipe

positioning panels deliver a highly professional finish to the

installation procedure, prior to pressure testing and the

screed being laid.

Greenfloor staple panels

Greenfloor staple panels are made of polystyrene insulation

and are coated with a fully bonded, tear and waterproof

woven fabric. This has a number of advantages, particularly

in avoiding the situation with floor grade insulation where

the staples can pull out.

The Greenfloor staple panel also provides an installation grid

at 50mm intervals for easy spacing of the Greenfloor PE-Xc

system pipe. This is applied directly to the staple panel

using staples and a stapler available from Worcester.

Greenfloor staple panels are available in a choice of

two installation thicknesses, 30mm and 35mm. It is

recommended to fix the Greenfloor PE-Xc system pipe

with Greenfloor staples every 300mm. More staples

may be necessary on bends.

The pipe spacing will be specified as part of the package

of information supplied by the Worcester Design Service.

Once the Greenfloor PE-Xc system pipe is installed, pressure

testing must be carried out prior to the screed being laid.

Greenfloor staples & Greenfloor clip rail

Both of these products offer an alternative method of

installing Greenfloor. A particularly low installation cost can

be achieved by simply fixing the Greenfloor PE-Xc system

pipe to the floor grade insulation installed on site.

Greenfloor staples, installed using the Greenfloor stapler or

Greenfloor clip rail, or a combination of the two, provides a

robust fixing method prior to the screed being laid.

We recommend fixing the Greenfloor PE-Xc system pipe

with Greenfloor staples every 300mm, while more staples

may be necessary on bends.

Greenfloor clip rails should be fixed to the floor grade insulation

using the self adhesive backing. This should be done prior

to Greenfloor rail fixing pins being pushed into the

insulation through the clip rail. This will provide a robust

and secure fixing.

Greenfloor clip rails should be fixed at no more than

1,000mm spacing between clip rails and no more than

500mm spacing from wall edges. They should be installed

at 90° to the coldest external wall.

After applying the Greenfloor PE-Xc system pipe, pressure

tests must be completed prior to the screed being laid.

Installation requirements

Dry screed floors

Greenfloor dry construction

panels offer an alternative to

the traditional approach of

installing Greenfloor PE-Xc

system pipe within 75mm

of wet screed. The dry

construction panel system

is designed to be installed

directly over an existing floor surface; this may be designed

as part of a new construction or a retrofit at a later date.

Greenfloor dry construction panels can also offer a solution

where an existing floor is not able to withstand the weight

or loading of a traditional wet screed, for example on

timber suspended floors.

The dry construction panels are laid over the existing floor

surface and feature an interlock system to ensure secure

installation of each panel to the next. Once the installation

of the dry construction panels is complete, Greenfloor heat

conducting plates are installed.

The Greenfloor heat conducting plates allow the heat from

the PE-Xc system pipe to radiate over a wider area to

provide an even heat output. They are available in both

straight and curved sections.

The curved sections allow for a 180° bend at the edge

of the installation area prior to installing the next

straight section.

On completion of the installation of the Greenfloor

dry construction panels and heat conducting plates,

the Greenfloor PE-Xc 14mm system pipe can be installed.

Once the system pipe is installed, the Greenfloor dry

screed system foil is placed over the whole area.

This provides an intermediate layer to minimise the

risk of movement or expansion noise against the

finished floor surface.

For pressure testing directions see page 17.

Timber suspended floors

Greenfloor offers a simple and effective solution for timber

suspended floors which is particularly suitable for retrofit

installations. Timber battens are fixed to run the length of

the joists to provide a platform upon which the floor grade

insulation can be installed. Greenfloor staples or clip rails

can then be used to secure the Greenfloor PE-Xc pipe.

Installation centres can be as close as 100mm to ensure

maximum heat output is available for a comfortable,

efficient and effective heating system.

This style of installation is only recommended for use in

timber suspended floors at 1st floor level and above.

Ground floor installations should, wherever practical,

employ a wet screed installation. This allows for maximum

efficiency and avoids the risk of the ventilated area below

drawing heat away from the floor surface. In all cases, the

installer must plan for maximising thermal insulation and

minimising drafts.

Greenfloor timber suspended floor installations must

successfully pass the same test criteria as a

Greenfloor dry screed floor installation.

For pressure testing directions see page 17.

Flooringboards

Supportbatten

Clip rail staple

Pipe staple

Cliprail

Joist Floor gradeinsulation


FlooringFlooringunderlay

1716

Insulation to Building Regulations requirements

In all instances, all floors must be insulated to the latest

Building Regulations requirements. The thermal resistance

of the pipe positioning, staple or dry construction panels

may be calculated as part of the building’s insulation

programme or seen as an extra over the minimum

compliance standard already planned.

Pressure testing

Once the PE-Xc system pipe is installed and connected

to the Greenfloor stainless steel manifold, the installation

must be pressure tested using the following procedure.

• Ensure the Greenfloor installation is isolated from the

heat source using the valves between the pump and

mixing station and the stainless steel manifold.

• Flush and fill each loop individually using a mains

cold water supply by ensuring only the manual

isolating valve and flow meter, for the current

loop, are open when being flushed.

• Once all loops are flushed of air and filled, connect

a suitable pressurisation pump to one of the fill and

drain points on the manifold.

• Open each of the loops fully using the manual isolating

valves and flow meters.

• Increase the pressure using the pump to 6 bar. An initial

decrease can be expected as the Greenfloor PE-Xc system

pipe expands. Following this decrease the pressure

should be adjusted back to 6 bar. No other decrease

should be seen. This test pressure must be successfully

witnessed for at least 1 hour.

• After successful completion of the pressure test at 6 bar,

the wet screed or floor finish can be laid. The pressure

test should be maintained throughout the laying of the

screed or floor finish. This protects the system pipe from

deformation and allows any damage incurred to be

immediately noticed.

Laying wet screed

• The screed should be laid

as soon as possible after

successful pressure testing

of the Greenfloor installation.

• This should be supplied and

installed in accordance with

British Standards and the

flooring manufacturer’s

instructions.

• As wet screed cures, it releases heat. As a result a slight

increase in pressure may be observed.

• Once laid, all screeds require a period of time to cure.

Curing periods are typically 21 days, but British Standards

and the manufacturer’s instructions must be followed.

For the first 3-4 days the screed must not be walked on.

Any pressure could introduce a weak spot to the screed

and the potential for cracking in the future.

• After the initial period has passed the screed can be

walked on.

• The screed must then be covered with both a polythene

barrier to maintain moisture levels and a protective

plywood layer to prevent damage. At all times the screed

supplier’s instructions must be followed.

• At the end of the curing period, the system pressure

should be adjusted to the normal working pressure of

1.5 bar by draining off via the fill and drain point.

• The isolating valves between the pump and mixing station and

the stainless steel manifold can then be opened to connect

the heat source circuit with the Greenfloor installation.

• The heat source can then be turned on to aid the

drying process.

• The temperature in the Greenfloor installation should be

limited to 25°C for 3 days, then increased for a further

4 days to approximately 40°C.

Screed type Dry construction panel

0.2mm – system foil

Dry 0.5mm – heat conducting plate

25mm – dry construction panel

25.7mm in total

Screed type Pipe positioning panel – 30mm

75mm – screed

Wet 30mm – pipe positioning panel

105mm in total

Screed type Pipe positioning panel – 11mm

75mm – screed


86mm in total

Screed type Pipe positioning panel – Light

75mm – screed


75mm in total

Screed type Staple panel – 30mm

75mm – screed

Wet 30mm – staple panel

105mm in total

Screed type Staple panel – 35mm

75mm – screed

Wet 35mm – staple panel

110mm in total

Installation depths

Greenfloor dry construction panel system

Greenfloor pipe positioning panel system

Greenfloor staple panel system

Greenfloor staple and clip rail systems

Below are the required depths for your chosen floor fixing method in addition to the allowance for insulation in accordance

with the current Building Regulations (excluding final floor finish).

Timber suspended floor or concrete base

Dry constructionpanel



Edging insulation strip

Dry screed system foil

Heatconducting plate

Concrete base Insulation


FlooringScreed Flooringunderlay


Sub floor

Pipe staple

Clip rail staple

Cliprail

Flooringboards

Supportbatten

Clip rail staple

Pipe staple

Cliprail

Joist Floor gradeinsulation



Concrete base Insulation


FlooringScreed Flooringunderlay


Sub floor

Pipe positioning panel

Timber suspended floor application shown.

General requirements

1918

Greenfloor PE-Xc system pipe

Greenfloor PE-Xc system

pipe is available in two

different diameters and

two different lengths.

There is a choice of 14mm

dia. and 16mm dia. pipe,

each with a 2mm side wall.

The selection of the

diameter depends on each particular installation and will be

specified as part of the package of information provided

by the Worcester Design Service. This is dependent upon

factors such as total pipe length and pressure loss

throughout the installation.

Domestic installers will find the 200m long coils the most

practical and easiest to work with. If installing regularly, for

example on construction sites, it may be more practical to

specify the larger coils which are available – 14mm dia. as a

750m coil or 16mm dia. as a 650m coil. These much larger

coils will reduce the amount of off-cuts. The coil is best

handled when using a pipe reel and stand which are available

from Worcester, and enables the pipe to be supported and

easily uncoiled.

Greenfloor PE-Xc system pipe is guaranteed for a period

of 25 years.

Greenfloor stainless steel

manifolds

Greenfloor stainless steel

manifolds are available

in a range of sizes to

accommodate applications

from 2 to 16 zones.

It is also possible to

connect two manifolds

together. For example

if an extension to the

Greenfloor installation

is required, or to accommodate unforeseen circumstances

at installation stage.

The number of ports required on the manifold depend

on a number of factors including:

• The number of rooms in the property

• The size of the rooms

• The heat loss of the room and building

• The heat output required from the floor

• Limiting any one pipe run to no more than 120m,

from the manifold and back.

Greenfloor stainless steel manifolds feature flow

connections on the lower manifold section.

Incorporated flow meters allow each zone to

be accurately commissioned.

The zone specifications and the optimum number of ports

will be provided in the package of information provided by

the Worcester Design Service.

The outlets of the manifold are 3/4" and easily connect with

Greenfloor PE-Xc system pipe using 3/4" to 14mm or 16mm

adaptors, according to the diameter of the pipe specified.

The upper manifold section contains the return

connections, again using 3/4" adaptor fittings, the

Greenfloor PE-Xc system pipe can be easily connected.

Each port on the return manifold includes a 30mm

threaded connection which incorporates a manual isolating

valve and is expected to be replaced with a 230V actuator.

This enables full control over each zone using either a wired

or wireless control platform and wiring centre.

Each manifold section also features a fill and drain

point with a sealing cap provided, an automatic air

vent and 1" connections to the chosen Greenfloor

pump and mixing station.

Greenfloor manifold cabinets

A Greenfloor manifold

cabinet may be specified

and selected to offer a

neat and tidy finish to

the installation.

Available as either flush

mounted, which can be

recessed into a wall prior

to final plastering taking

place, or surface mounted,

which fits directly to a

finished wall surface.

• It is suggested the screed is left to thoroughly dry for a

further 7 day period. However this may be reduced so

long as the installer of the finished floor is satisfied that

any remaining moisture levels are within the specification

of the finished floor product.

• The Greenfloor installation should be switched off and

the screed allowed to cool for 3 days before installation

of the finished floor product commences.

Accommodating expansion

All installations must be provided around the perimeter with

a means of accommodating the expansion of the screed or

the dry construction components. This takes the form of

the Greenfloor edging insulation strip.

Wet screed expansion

Large areas of screed floor

(over 40m2) may also require

regular Greenfloor expansion

joint sections to physically

separate the screed. These

are self adhesive and fix easily

to the floor fixing method. If


panels are being used, a

Greenfloor rounded section should be installed

to provide a level platform upon which to install

the expansion joint section.

Wherever a screed expansion joint is added, the Greenfloor

PE-Xc system pipe should be protected by a Greenfloor

expansion protection tube to a distance of 300mm in

each direction.

Further information on wet and dry screed expansion

can be found in the British Standards and Building

Regulations as well as from the screed suppliers.

Floor finishes for dry screed installations

• The finished floor must be installed immediately after

pressure testing is complete to protect the installation.

• Laminate floor finishes with interlocking joints must be a

minimum of 7mm thick.

• Plywood or chipboard floor finishes can be used but

should be a minimum of 15mm thick with glued tongue

and groove edges.

• Alternatives to plywood or chipboard fi nishes offering a

lower resistance to heat output are also available.

Further information can be found at your local builder’s

merchants.

Preparing for commissioning

• Before the Greenfloor installation is operated the system

pressure must be reduced to normal working pressure of

1.5 bar by draining off via the fill and drain point.

• The isolating valves between the pump and mixing

station and the stainless steel manifold can then be

opened to connect the heat source circuit with the

Greenfloor installation.

Components Greenfloor PE-Xc pipe and manifolds

2120

Greenfloor offers a number of combinations of controls

and Greenfloor pump and mixing stations to suit individual

installation needs.

Comprehensive wiring instructions are supplied with

each bespoke installation design provided by the

Worcester Design Service, in addition to those supplied

with the product. These are available to download from

our website at www.worcester-bosch.co.uk/ufhwiring

Greenfloor controls – wireless (RF)

The Greenfloor wireless

wiring centre provides a very

easy to install control system

without the restrictions of

running cables to each

individual room thermostat.

The Greenfloor wireless

wiring centre features a 7 day programmer which enables

each of the zones connected to be controlled completely

independently. Within each zone a Greenfloor surface

mounted wireless room thermostat is fitted and through

a simple pairing process is set to control the appropriate

230V actuator outputs within the wiring centre.

The wiring centre is capable of receiving signals from

a maximum of 8 surface-mounted wireless room

thermostats and is able to provide output to a maximum

of 16 actuators. The wiring centre also provides two

separate volt-free interlock relays, one to control the

heat source and one to control the Greenfloor pump

and mixing station’s circulation pump.

In larger installations it is possible to use more than one

wiring centre. The wiring centres are to be wired in

harmony to control the heat source and the Greenfloor

pump and mixing station’s circulation pump.

Greenfloor controls – 230V wired

The Greenfloor 230V wiring

centre provides an easy to

install control system where

running cables to each

individual room thermostat is

not a barrier, for example in

new build and major

renovation installations.

Clearly identified and spring loaded connections mean

installing cables can be completed efficiently.

The Greenfloor 230V wiring centre is capable of receiving

inputs from a maximum of 6 230V room temperature

devices and is able to provide output to a maximum of

14 actuators. The wiring centre also provides an interlock

relay to control the heat source and the Greenfloor pump

and mixing station’s circulation pump.

Greenfloor controls – recessed 230V

programmable room thermostat

The Greenfloor recessed 230V

programmable room thermostat

features 3 factory set programmes,

selectable and adjustable at time

of commissioning and operates on

a 7 day basis. This enables individual

days to be programmed differently

if necessary. The programmable room thermostat also

provides a 230V output when a reduced temperature

economy mode is entered. This instructs the Greenfloor

wiring centre that all dependent zones should also enter

reduced temperature economy mode. Practically, this means

that typically a single programmable room thermostat can be

used per floor. For example, when a surface mounted 230V

room thermostat is being used in each room, offering

individual temperature control, it works to the same time

patterns as the lead programmable room thermostat.

Greenfloor controls – surface mounted

230V room thermostat

The Greenfloor surface mounted room

thermostat allows for temperature

control within each zone and is able to

accept the 230V economy mode signal

from a programmable room thermostat.

It is possible to use any combination of 230V room

temperature devices so long as the installation complies with

current Building Regulations. Further advice will be provided

in the specification package supplied by the Worcester

Design Service bespoke to each installation’s needs.

Greenfloor pump and mixing stations

Greenfloor offers a number of pump

and mixing stations to suit individual

installation needs.

The Greenfloor FRS standard and VRS

pump and mixing stations are

designed to be installed directly onto

the Greenfloor stainless steel manifold.

The Greenfloor FRS standard pump and mixing station can

satisfy a maximum designed heat output of 8kW

and features a fixed temperature control output.

The Greenfloor VRS pump and mixing stations are available

in two heat outputs. One to satisfy 7kW maximum output

and the larger model to provide a 10kW maximum heat

output. Both feature intelligent weather compensated flow

temperature output.

The Greenfloor KMS pump and mixing

stations do not fit directly to the

Greenfloor stainless steel manifold.

Instead they offer installation flexibility

by being installed in a remote location,

such as near to the heat source

or within a plant room. They can be

installed in any position between the

heat source and the Greenfloor

stainless steel manifold.

The Greenfloor KMS pump and mixing stations are able to

offer the greatest heat outputs of any Greenfloor pump and

mixing station. Available in two heat outputs, a 15kW and

25kW maximum heat output, both feature intelligent

weather compensated flow temperature output.

Regulations, standards and further advice

Further information regarding the design, specification and

installation best practice principles of underfloor heating

can be found in, but is not limited to the following

documents, standards and regulations.

Documents

• The CIBSE underfloor heating design and installation

guide (2004)

• The CIBSE domestic heating system design guide (2004)

• The BPEC warm water underfloor heating for mechanical

services engineers – design course, handbook

• The BPEC warm water underfloor heating for mechanical

services engineers – installation course, handbook.

Building Regulations

• England & Wales

– Part L (Energy Efficiency)

– Part E (Sound)

• Republic of Ireland

– Part L (Conservation of fuel & energy)

– Part E (Sound)

• Northern Ireland

– Technical Booklet F (Conservation of fuel & energy)

– Technical Booklet G (Sound)

• Scotland

– Technical Standards Section 6 (Energy)

– Technical Standards Section 5 (Sound)

British Standards

Full British Standards can be found on our website

at www.worcester-bosch.co.uk/ufhstandards

Pump and mixing station installed at manifoldPump and mixing station

installed remote of manifold

Fixed value flow temperature Weather compensated flow temperature

Wireless

Wireless wiring centre

FRS standard pump

and mixing station


VRS 7 weather compensated

pump and mixing station

OR




KMS 15 remote pump

and mixing station

OR

KMS 25 remote pump

and mixing station

Wired

230V wiring centre

FRS standard pump

and mixing station

230V wiring centre



OR



230V wiring centre

KMS 15 remote pump

and mixing station

OR

KMS 25 remote pump

and mixing station

ComponentsGreenfloor controls, pump and mixing stations

2322

Worcester offers a fully bespoke specification and

system design service to support the Greenfloor

underfloor heating product range.

Specification

To request a specification, simply copy and complete

the specification request form opposite or go to

www.worcester-bosch.co.uk/ufhdesign and

submit your drawings.

You will then receive a complete specification and

component list for your project. We aim to provide

this within two working days.

Design

Should you require a full design service, we will require

you to submit the design request form attached to

your specification and provide proof of purchase of

the Greenfloor items for that project prior to us carrying

out the work.

You will then receive pipe layout drawings, circuit lengths,

pressure losses, flow rate settings for each circuit and a

full materials specification. We aim to provide this within

10 working days.

Specification and Design Service

Tel: 0844 892 4010 email: [email protected]

2524

Stainless steel manifold

Worcester Part No. 2-way – 7 738 300 2353-way – 7 738 300 2364-way – 7 738 300 2375-way – 7 738 300 2386-way – 7 738 300 239 7-way – 7 738 300 2408-way – 7 738 300 2419-way – 7 738 300 242 10-way – 7 738 300 24311-way – 7 738 300 24412-way – 7 738 300 24513-way – 7 738 300 24614-way – 7 738 300 24715-way – 7 738 300 24816-way – 7 738 300 249

Screw connection14mm – 3/4"(pack of 10)

Worcester Part No. 8 104 9240

Screw connection16mm – 3/4"(pack of 10)


Double nipple3/4" – 1/2"(pack of 6)

Worcester Part No. 7 747 201 400

Double nipple3/4" – 3/4"(pack of 6)


Pipe positioning panellight – 1.3m2

(10m2 pack)


Pipe positioning panelfor doors/connections –

30mm (5m2 pack)


Pipe positioning panelfor doors/connections –

11mm (5m2 pack)


Pipe positioning panel30mm, 1.3m2

(10m2 pack)


Pipe positioning panel11mm, 1.3m2

(10m2 pack)


Pipe positioning panelRounded section joint seal

25m


Pipe positioning panelcutting tool


Staple panelRoll 30mm (12m2 pack)


Staple panelRoll 35mm (12m2 pack)


Stapler


PE-Xc Pipe 14x2 Coil 200m








Pipe reel stand


Pipe reel


Ball valve set 1"


Double screw connection


Greenfloor heating series components and accessories

Manifold cabinet 560mm

Surface mounted



Surface mounted



Flush mounted


Manifold cabinet 1,300mm

Surface mounted



Surface mounted



Flush mounted



Flush mounted



Flush mounted


2726

Pipe bend guide(pack of 50)


Expansion joint section(14x1.8m pieces)


Expansion joint protection 14mm

(25m roll)


Expansion joint protection 17mm

(25m roll)


Rail fixing pins(pack of 500)


Clip rail(100x1m pieces)


Edging insulation strip( 50m roll)


FRS standard pump & mixing station

up to 8kW


FRS connection set


Pipe staples(pack of 300)


Dry construction panel(13.1m2 pack)


Heat conducting plate – straight section

(pack of 50)


Heat conducting curved section

(pack of 25)


Dry screed system foil (100m2)


Wiring centre for wireless controls


Recessed 230Vprogrammable room

thermostat


Surface mounted wireless room thermostat


Surface mounted 230V room thermostat


KMS 15 remote pump & mixingstation – up to 15kW


KMS 25 remote pump & mixingstation – up to 25kW


VRS 7 weathercompensated pump &

mixing station – up to 7kW


230V actuator


230V wiring centre


VRS 10 weathercompensated pump &

mixing station – up to 10kW


RMS single room pump& mixing station


28 29

Worcester training coursesOne stop shop training

We are here to provide you with training and assistance for all areas of your business, not just product training.

Call us on 01905 752526 to order a full training course brochure.

Boiler training courses

Greenstar CDi gas-fired condensing combi boilers

Models covered Greenstar 27/30/37/42CDi Duration: 1 day

Greenstar i Junior & Si gas-fired condensing combi boilers

Models covered Greenstar 24/28i Junior and Greenstar 25/30Si Duration: 1 day

Greenstar Highflow CDi & FS CDi regular floor standing gas-fired condensing combi and regular boilers

Models covered Greenstar Highflow 440/550CDi and Greenstar FS 30/42CDi Regular Duration: 1 day

Greenstar system & regular gas-fired condensing boilers

Models covered Greenstar 12/15/18/24Ri, Greenstar 30/40CDi Regular, Greenstar FS 30/42CDi Regular, Greenstar 30CDi Systemand Greenstar 12/15/18/24i System

Duration: 1 day

Greenstar Danesmoor, Heatslave & Camray high efficiency condensing oil-fired boilers – pre-OFTEC training

Models covered Greenstar Danesmoor series, Greenstar Heatslave series and Greenstar Camray series Duration: 1 day

Greenstar controls

Models covered MT10, MT10RF, DT20RF, DT20, DT10RF, TD200, RT10, FR10, FR110, FW100 and ISM1 Duration: 1 day

Renewable training courses

Greenskies solar hot water system

Covering Installation, commissioning and servicing Duration: 2 days

Greenskies advanced solar

Covering Worcester solar control range and pump stations Duration: 1 days

Greenstore ground source heat pumps

Covering Installation, commissioning and system design Duration: 2 days

Greensource heat pumps – air to water

Covering Installation, commissioning and system design Duration: 2 days

Greensource heat pumps – air to air

Covering Installation, commissioning and system design Duration: 1 day

Greenfloor heating

Covering Installation, commissioning and servicing Duration: 1 day

Greenstream MVHR

Covering Installation, commissioning and system design Duration: 1 day

The very best training programmes from Worcester Worcester has always placed great emphasis on technical

support and training for installers and service engineers.

Advances in heating technology, including the increasing use

of renewables, make the need for training greater than ever.

To ensure the highest levels of competence and expertise in the

installation of all Worcester products, the company runs intensive

training courses for installers, commissioning engineers and

operatives involved with servicing and fault finding.

Courses available

Our training facilities offer a number of courses suitable

for the installer and commissioning engineers, and more

in-depth courses for the servicing and fault finding engineers.

Training centres throughout the UK

To enable us to meet the growing demand for training we

have invested in additional facilities at the award-winning

training academy at our Worcester headquarters. In addition

to the original academy there is now a new 400m2 unit, 25%

of which is devoted to an open-plan domestic training area

with life-size single-storey brick buildings. These feature

working Greenskies solar thermal systems which enable

installers to get up onto the roof of the building to get more

realistic training. There are bays full of all Greenstar gas-fired

appliances, so installers can really get to grips with the

importance of system design. The additional space will also

contain dedicated training areas for our renewable and future

products. The training centre will also run certified CODNC01

and COCN1 courses. CODNC01 equips installers with the

relevant qualifications for the changeover from domestic to

commercial gas work. COCN1 allows existing commercial

installers to renew their qualification.

Further academies are located at West Thurrock in Essex,

Bradford and Clay Cross in Derbyshire, all offering our full

suite of courses. Please phone 01905 752526 for more

information about a course near you. Each course is run

by specialist trainers and is superbly equipped to deliver

a combination of classroom theory and practical hands-on

experience that’s second to none.

College-linked Learning

As well as offering training at our own centres, Worcester

has established close partnerships with many colleges

around the UK, equipping them with our latest products.

Call us on 01905 752526 to find out when we will be

running the course of your choice at a college in your area.

Belfast

Bradford

Clay Cross

Worcester

West Thurrock

Dundee

Dublin

Aberdeen

Dunfermline

Burnley

Durham

Salisbury

Tredegar

Camborne

Johnstone

Mobile training

To complement our training venues across the country,

we can also bring training to you.

We have mobile vehicles fully equipped with operational

Greenstar gas-fired boilers, dry strip-down models and even

a Greensource air to air heat pump, ensuring that quality

training in a comfortable environment can be achieved on

your doorstep!

If it's oil training you require, our 7.5 tonne mobile oil

vehicle is available throughout the country for hands-on

product training and OFTEC assessments.

Distance learning/web based learning

Worcester has produced a selection of Distance Learning

CD ROMs/DVDs which are packed with information.

Call 0844 892 9800 for your copies, or visit

www.worcester-bosch.co.uk for information

on Web Based Learning.

Get on course for a more profitable future now.

Call now for more information 01905 752526

29

As part of the worldwide Bosch Group, Worcester strives to

maintain the highest possible standards of after-sales care.

In addition to the no-nonsense parts and labour

guarantee applicable to all Worcester products, you and

your customers have the assurance that every Worcester

product is manufactured to both the appropriate British

and European standards.

Worcester Contact Centre

Should you require support, our fully trained Contact

Centre staff, based at our head office in Worcester, are

ready to take your calls. Whatever your query our contact

centre operators along with our nationwide team of

engineers are ready to help you.

Boiler Protection Options

Worcester offers boiler protection including service and

maintenance contracts. Please call the Worcester Contact

Centre for further details.

If you do not offer annual service and maintenance

contracts please refer your customers to the Worcester

Contact Centre:

Tel: 08457 256 206

Fax: 01905 757 536

Opening Times

Monday – Friday: 7.00am – 8.00pm

Saturday: 8.00am – 5.00pm

Sunday: 9.00am – 12 noon

A complete after-sales service

All the technical advice you needSpares

Genuine replacement parts for all supported Worcester

products are readily available from stock, on a next day

delivery basis. For more information please call your local

stockist. You can find a spares stockist on our website.

Customer Technical Support

The Worcester Technical Helpline is a dedicated phone

line – committed to providing a comprehensive service to

complement the brand name and quality of our products.

Our experienced team of technical experts provides

answers to queries of a technical nature across the entire

Worcester range.

Worcester also has a pre-sales team, who provide

assistance in selecting a heating system to suit a particular

application, along with full guidance on installation. For

more information please contact the Technical Helpline

or alternatively visit our website where literature can be

downloaded at www.worcester-bosch.co.uk.

Technical

Tel: 0844 892 4010

Fax: 01905 752 741

Opening Times

Monday – Friday: 7.00am – 8.00pm

Saturday: 8.30am – 4.00pmPlease note to attend OFTEC courses you must have a minimum of 12 months’ experience installing/servicing oil boilers. For inexperienced candidates, our GreenstarDanesmoor, Heatslave and Camray course offers pre-OFTEC training. For experienced oil technicians training is not a pre-requisite for OFTEC assessment.

Industry focused training courses

BPEC warm water underfloor heating installation

Covering Basic principles & advantages of underfloor heating, floor systems and finishes, operation, installation, testing and post installation activities

Duration: 2 days

BPEC ventilation

Covering Installation, commissioning, inspection and testing Duration: 2 days

Hot water systems & safety

Covering All G3 Regulations for the installation, servicing and commissioning of unvented cylinders. This course is certified by Logic Certification.

Duration: 1 day

Chemical water treatment

Covering Water treatment of domestic heating systems in accordance with BS 7593: 2006 Duration: 1 day

Construction skills F-Gas training/assessment certification

Covering Qualifies for Construction Skills Certification & Registration (valid for 5 years) and Voluntary ACRIB Registration

Duration: 4 days

OFTEC training and assessment

OFTEC 101

Covering Domestic/light commercial pressure jet commissioning and servicing Duration: 3 days

OFTEC 105e

Covering Domestic/light commercial pressure jet boiler installation Duration: 1 day assessment

OFTEC 101 & 105e

Covering Domestic/light commercial pressure jet installation, commissioning and servicing Duration: 3 days

OFTEC 600a

Covering Oil tank installation and associated controls Duration: 1 day assessment

OFTEC 101/105e/600e

Covering Domestic/light commercial pressure jet boiler installation, commissioning, servicing and oil tank installation and associated controls

Duration: 4 days

Mobile OFTEC

All above covered throughout the country on the mobile training vehicle as well as in all our centres

Domestic ACS training and assessment

Initial CCN1 + 4 appliances + CPA1

Covering Designed for candidates whose qualifications expired more than 12 months ago Duration: 5 day

Reassessment CCN1 + 4 appliances + CPA1

Covering Re-assessment for candidates whose CCN1 qualification expires in less than 12 months Duration: 4 days

3130

www.worcester-bosch.co.uk

Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.

This leaflet is accurate at the date of printing, but 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.

Part No. 8 716 116 329 A 11/11

Worcester, Bosch Group,

Cotswold Way, Warndon,

Worcester, WR4 9SW

BB

T2319

Engineer Appointments

Email: [email protected]

or telephone 0844 892 3000

Enquiries



Guarantee Registration

To register your Worcester guarantee,

please visit our website or

telephone 0844 892 2552

PAPERS MADE WITH100% CHLORINE FREE

BLEACHED PULPTM

Customer Service

Sales

Tel: 01905 752640

Fax: 01905 456445

Spare Parts

Tel: 01905 752576

Fax: 01905 754620

Technical Helpline



Training

Tel: 01905 752526

Fax: 01905 752535

Literature


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