Bosch 12-18, 25-32kW, 18-25 User Manual

GREENSTAR HEATSLAVE EXTERNAL 12/18, 18/25, 25/32kW

FLOOR STANDING EXTERNAL OIL FIRED CONDENSING COMBINATION BOILER USING BALANCED FLUE SYSTEM

FOR OPEN VENT AND SEALED CENTRAL HEATING SYSTEMS WITH DOMESTIC MAINS FED HOT WATER

THE APPLIANCE IS FOR USE WITH KEROSENE ( 28 SECOND

OIL) ONLY

GB

INSTRUCTION MANUAL

INSTALLATION COMMISSIONING & SERVICING

INSTALLATION & SERVICING INSTRUCTIONS

SYMBOLS USED IN THIS MANUAL:

Domestic hot water

Central heating

Room thermostat

Frost thermostat

Wait time period

Programmer/timer OFF

Programmer ON CH only

Programmer ON DHW only

Programmer ON CH and DHW

Cold water main supply

Electricity supply

IMPORTANT HANDLING INSTRUCTIONS: It is advised that more than one person is involved in the transfer of the packaged appliance from the van to the point of installation.

It is advised that no attempt should be made to move the packaged appliance without the use of a suitable truck.

At all times the correct method for handling heavy objects should be strictly observed.

GENERAL HANDLING GUIDELINES:

•Lift only a manageable weight, or ask for help.

•When lifting, bend the knees, and keep the back straight and feet apart.

•Do not lift and twist at the same time.

•Lift and carry items close to the body.

•Wear protective clothing and gloves to protect from any sharp edges.

1

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL(S) STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR MODEL OF APPLIANCE.

THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY STATUTORY OBLIGATION.

THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD TO PROSECUTION.

COMPLYING WITH THE BUILDING REGULATIONS:

This heating appliance forms part of the controlled services for the building. It is law that all controlled services for buildings must comply with building regulations. You must be able to satisfy your Local Authority Building Control Body (LABC) that the work carried out concerning the installation and commissioning of this heating appliance has been carried out to a satisfactory standard.

OFTEC operate a competent persons scheme and registered installers are able to certify that their work complies with building regulations. Under the scheme;

OFTEC must be informed about every installation.

OFTEC will issue a building regulations compliance certificate to the householder and will notify the LABC.

OFTEC provide controlled document forms CD10 and CD11 for use during installation and commissioning respectively.

Other organisations operate self-certification schemes e.g. NAPIT and BESCA Ltd. and it may be possible for installers who are members of these organisations to self certify their work.

Alternatively you must submit a building control notice to the LABC before installing any boiler. The LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations.

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

DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.

PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM AND THE USER MANUAL WITH THE OWNER OR WITH THE APPLIANCE AFTER INSTALLATION OR SERVICING. THE SERVICE INTERVAL RECORD CAN BE FOUND ON THE BACK PAGE OF THIS MANUAL.

ABBREVIATIONS USED IN THIS MANUAL:

ØDiameter

CH	Central Heating
DHW	Domestic Hot Water
TRV	Thermostatic Radiator Valve
IP	Ingress Protection
CF	Conventional flue
BF	Balanced flue
N/A	Not allowed
SEDBUK	Seasonal Efficiency of Domestic Boilers in the United Kingdom
OFTEC	Oil Firing Technical Association for the Petrolium Industry
IEE	Institute of Electrical Engineers
LABC	Local Authority Building Control Body
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
Check List		Hardware/Literature pack
Item			Qty
Greenstar Heatslave External Installation/Servicing Instructions			.........1
Users Instructions............................................................................................			1
Hardware Pack.................................................................................................			1
100mm Ø Services Duct................................................................................			1
Condensate Trap Kit........................................................................................			1
Warranty Return Envelope.............................................................................			1
Cabinet Key.......................................................................................................			1

INSTALLATION & SERVICING INSTRUCTIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

CONTENTS

SAFETY & REGULATIONS

		IMPORTANT INFORMATION AND SYMBOLS	1
		SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS	3
APPLIANCE INFORMATION
		GENERAL INFORMATION	4
		TECHNICAL DATA	5
		LAYOUT & COMPONENTS	6
PRE-INSTALLATION
		CLEANING PRIMARY SYSTEMS	7
		MAINS SUPPLIES	8
		OIL SUPPLY	9
		WATER SYSTEMS & PIPEWORK	10-11
		CONDENSATE & PRESSURE RELIEF PIPEWORK	12
		BOILER LOCATION & CLEARANCES	13
		CABINET MOUNTED LOW LEVEL FLUE TERMINAL POSITIONS	14
		HIGH LEVEL FLUE TERMINAL POSITIONS	15
		EXTERNAL OILFIT BALANCED FLUE OPTIONS	16
		CABINET MOUNTED HORIZONTAL BALANCED FLUE OPTIONS	17
INSTALLATION
		UNPACKING THE BOILER	18
		PIPEWORK & FLUE POSITIONS	19
		BOILER INSTALLATION	20
		FLUE INSTALLATION	21
		COMBUSTION CHAMBER	22
		PIPEWORK CONNECTIONS	23-24
		OIL BURNER AND PUMP	25
		REFITTING COMPONENTS	26
		ELECTRICS	27-28
COMMISSIONING
		PRE-COMMISSIONING CHECKS - APPLIANCE	29
		FILLING THE SYSTEM	30
		STARTING THE APPLIANCE	31-34
		WATER TREATMENT	35
		FINISHING COMMISSIONING - APPLIANCE	36
SERVICING & SPARES
		INSPECTION AND SERVICE	37-40
		SHORT PARTS LIST 12/18	41
		SHORT PARTS LIST 18/25	42
		SHORT PARTS LIST 25/32	43
FAULT FINDING & DIAGNOSIS
		FAULT FINDING	44-45
		FAULT FINDING LOGIC FOR SATRONIC CONTROL BOX	46
		FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX	47
		ELECTRICAL SCHEMATIC	48
COMMISSIONING & SERVICE RECORDS
		COMBUSTION RECORD	49
		SERVICE INTERVAL RECORD	50

SAFETY &	REGULATIONS
APPLIANCE	INFORMATION
PRE -	INSTALLATION
INSTALLATION
COMMISSIONING
SERVICING	& SPARES
FAULT FINDING	& DIAGRAMS

2

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

CONTENTS

SAFETY &

REGULATIONS

SAFETY PRECAUTIONS

OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:

Extinguish any naked flames.Isolate the electrical supply.Isolate the fuel supply to the boiler.Rectify fault.

HEALTH & SAFETY:

The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU Directives.

COMBUSTIBLE AND CORROSIVE MATERIALS:

Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance.

The combustion air must be kept clear of chemically aggressive substances which can corrode the appliance and invalidate any warranty.

FITTING & MODIFICATIONS:

Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with these instructions and the relevant Installation Regulations.

Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

SERVICING:

Advise the user to have the system regularly serviced by a competent, qualified engineer (such as OFTEC registered personnel) using approved spares, to help maintain the economy, safety and reliability of the appliance.

INSTALLATION REGULATIONS

Failure to install appliances correctly could lead to prosecution.

The appliance should be installed by a competent person. The person installing the appliance should be aware of the Health and Safety at Work Act and take appropriate action to ensure that the regulations are adhered to. In order to give optimum efficiency and trouble free operation the appliance must be commissioned by a qualified OFTEC engineer.

The compliance with a British Standard does not, in itself, confer immunity from legal obligations. In particular the installation of this appliance must be in accordance with the relevant requirements of the following British Standards and regulations in respect of the safe installation of equipment:

BS 5410: part 1: Code of practice for Oil Fired Boilers.

BS 799: part 5: Specification for Oil Storage Tanks.

BS 7593: Code of Practice for treatment of water in domestic hot water central heating systems.

B S 5449: part 1: Specification for forced circulation hot water central heating for domestic premises.

BS 5955: part 8: Specification for the installation of thermoplastic pipes and associated fittings for use in domestic hot and cold water services and heating systems.

BS 7291: Thermoplastic pipes and associated fittings for hot and cold water for domestic purposes and heating installations in buildings.

BS 7074: part 1: Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems.

BS 7671: IEE Wiring Regulations, current edition. BS 1362: Specification for general purpose fuse links for domestic and similar purposes.

The Building Regulations Part J and L1 England and Wales; Part F and Part J Section III Scotland; Part L and Part F Northern Ireland.

Local water company bye-laws.

The Control of Pollution (Oil) Regulations. OFTEC Standards.

Where no specific instruction is given, reference should be made to the relevant codes of practice.

3

SAFETY PRECAUTIONS

& INSTALLATION REGULATIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

GENERAL INFORMATION

											STANDARD PACKAGE:
				640mm
	770mm										A - Floor standing oil fired condensing boiler for
										A	open vent and sealed domestic central heating
											and mains fed hot water.
											B - Literature pack.
											C - Condensate trap kit.
											D - 100mmØ services duct.
											E - Cabinet key

950mm

B

C

D

E

APPLIANCE

INFORMATION

Check List
Item	Qty
Greenstar Heatslave External Installation/Servicing Instructions	........1
Users Instructions ..........................................................................................	1
100mm Ø Services Duct...............................................................................	1
Condensate Trap Kit.......................................................................................	1
Warranty Return Envelope ............................................................................	1
Cabinet Key.......................................................................................................	1

4

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

GENERAL INFORMATION

TECHNICAL DATA

APPLIANCE

INFORMATION

DESCRIPTION	UNITS	12/18		18/25		25/32
Central Heating
Primary water capacity (total)	litres	69		69		72
Maximum static head	metres	30		30		30
Minimum static head	metres	1		1		1
Available pump head (20°C difference) at max. output	metres water	4.7		4.0		4.2
Max. permissible sealed system operating pressure	bar	2.5		2.5		2.5
in accordance with WRAS guidelines
Flow restrictor	colour	Lime		—		—
Domestic Hot Water
Optimum flow rate (±15%)	litres/min	15		18		22
Minimum inlet pressure (dynamic) for optimum flow rate	bar	1.5		1.2		0.9
Maximum hot water rise for 90 litres draw off (@optimum flow rate)	°C	40		40		40
Flue
Exit flue gas mass flow	kg/hr	29		40		51
Pipework connections
Fuel line (compression)	mm	10		10		10
CH flow	mm	22		22		28
CH return	mm	22		22		28
Water main inlet	mm	15		15		15
DHW outlet	mm	22		22		22
Open vent (optional)	BSP	1		1		1
CH drain/optional feed and expansion	BSP	3/	4	3/	4	3/	4
Condensate (polypropylene)	mm	21.5		21.5		21.5
Electrical
Electrical power supply voltage	AC...V	230		230		230
Frequency	Hz	50		50		50
Max. power consumption	W	240		240		263
Thermostats
CH control thermostat range (cut in/cut out)	°C	55/81		55/81		55/81
DHW control thermostat range (cut in/cut out)	°C	55/72		55/72		55/72
CH & DHW control thermostat differential	°C	5		5		5
Boiler high limit thermostat set point	°C	92		92		92
Boiler manual reset overheat thermostat set point	°C	105		105		105
Flue reset overheat thermostat set point	°C	110		110		110
General Data
Maximum hearth temperature	°C	<100		<100		<100
SEDBUK (Band A)	%	90.2		90.1		90.3
Appliance protection rating	IP	45		45		45
Weight (excluding packaging)	kg	195		195		206
Emissions class for NOx and CO	class	3		3		3
Typical NOx emissions figure	mg/kW hr	75		70		75

5

TECHNICAL DATA

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

44

43

i)

iv)

44

ii)

43

i)

42b

ii)

iii)

iv)

v)

42a

12

10 11

8 9

7

6

5

4

3

2

1

40 41

39

38

37 35/36 34

33

32

31

30

29

LAYOUT & COMPONENTS

iii)

v)

14

15

16

	25 24	23 22
26

27

28

The diagram opposite excludes the top, front and RH side casing panels.

1.CONTROL BOX ASSEMBLY

2.DIVERTER VALVE

3.PRESSURE GAUGE

4.AUTO AIR VENT

5. CH CONTROL AND MANUAL RESET OVERHEAT THERMOSTAT PHIAL

6.CASING SIDE PANEL

7.CIRCULATING PUMP

8.AUTO-RESET HIGH LIMIT THERMOSTAT PHIAL

9. DHW FLOW SWITCH

10.PRESSURE RELIEF VALVE

11.DHW HEAT EXCHANGER

12.FLUE GAS SAMPLING POINT

13 13. FLUE OVERHEAT THERMOSTAT PHIAL

14. CASING SUPPORT PANEL

15. FLUE MANIFOLD ACCESS COVER

16. AIR INLET PIPE AND CASING

17. SECONDARY HEAT EXCHANGER BLEED POINT (ONE ON EITHER SIDE)

18. SECONDARY HEAT EXCHANGER

18

19.SECONDARY HEAT EXCHANGER DRAIN

20.EXPANSION VESSEL

21.OPTIONAL OPEN VENT/AIR VENT

1722. DRAIN AND OPTIONAL FEED AND EXPANSION

1923. CONDENSATE OUTLET

24.PRIMARY HEAT EXCHANGER

25.TRAY

26.OIL ISOLATION VALVE

27.CONDENSATE TRAP

28.CONDENSATE TRAP BRACKET

29.COMBUSTION CHAMBER ACCESS DOOR

30.HEATSLAVE TANK DRAIN

31.HEATSLAVE TANK

32.MODE SWITCH

33.BOILER MODE INDICATOR

34.LOCKOUT INDICATOR

35.OVERHEAT RESET BUTTONS (boiler & flue temperature)

36.LOCKOUT RESET BUTTON

37.SERVICE CONNECTION

38.CH TEMPERATURE CONTROL

39.DHW TEMPERATURE CONTROL

40.DATA LABEL

41.FROST THERMOSTAT SENSORS

42a. BENTONE STERLING BURNER (12/18 & 18/25)

i) CONTROL BOX 20 ii) MOTOR

21iii) AIR INTAKE CASING

iv)OIL PUMP

v)COMBUSTION HEAD

42b. RIELLO RDB 2.2 BURNER (25/32)

i)CONTROL BOX

ii)MOTOR

iii)AIR INTAKE CASING

iv)OIL PUMP

v)COMBUSTION HEAD

43.CLIP - AIR INTAKE HOSE

44.AIR INTAKE HOSE

APPLIANCE

INFORMATION

6

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

LAYOUT & COMPONENTS

IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation.

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

INSTALLATION

PRE -

CLEANING PRIMARY SYSTEMS

IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for t he use of wat er treatment with the appliance will invalidate the appliance warranty.

BEFORE CLEANING THE SYSTEM:

ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER.

FLUSH THE EXISTING SYSTEM WITH A POWER FLUSHING MACHINE OR WITH A CHEMICAL CLEANER BEFORE INSTALLING NEW COMPONENTS.

CLEANING THE PRIMARY SYSTEM:

Cleanse the system in accodance with BS 7593.

Fill the system with cold mains water to the recommended pressure and check for leaks.

Open all drain cocks and drain the system.

Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer's instructions.

Circulate the flushing agent before the boiler is fired up.

Run the boiler and system at normal operating temperature in accordance with the manufacturer's instructions.

Drain and thoroughly flush the system to remove the flushing agent and any debris.

7

CLEANING PRIMARY SYSTEMS	INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
	8 716 113 389b (09/07)

IMPORTANT: The appliance provides a permanent external electrical supply for servicing and must therefore be fed via a circuit breaker incorporating earth leakage protection.

MAINS WATER EXPANSION VESSEL:

A - Mini expansion vessel, part No. 7 716 102 105

B - Mains water inlet
C - Non-return valve
D - Boiler					D
				A
B			C

MAINS SUPPLIES

ELECTRIC SUPPLY:
•	Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2 (24 x
	0.2mm) temperature rated to 90°C.
•	Protection IP45.
•	External 5A fuse to BS 1362.
•	The appliance must be earthed.
•	Please refer to IEE regulations for cross
	bonding requirements.
•	It must be possible to isolate the appliance
	from the electric supply with at least a 3mm
	contact separation in both poles supplying
	the appliance.
•	Wiring between the appliance and the	INSTALLATION
	-PRE

electrical supply must comply with IEE wiring regulations and any local regulations which may apply for fixed wiring to a stationary appliance.

• Any system connected to the boiler must not have a separate electrical supply.

WATER SUPPLY:

The following are general requirements and if necessary the advice of the local water company should be sought before fitting the appliance.

•The appliance cold water supply should be the first connection off the water main where possible.

Water Mains Pressure:

Minimum dynamic mains water pressure for optimum performance.

12/18kW	18/25kW	25/32kW
1.5 bar	1.2 bar	0.9 bar

•Maximum mains fed water pressure 10 bar. If necessary, fit a pressure reducing valve.

IMPORTANT: Non-return, back flow prevention devices (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances.

•Where the water main supply has a nonreturn, back flow prevention valve fitted, a mini expansion vessel (A) must be connected to the mains water inlet pipe (B) between the non-return valve (C) and the boiler (D) as shown opposite.

Use in hard water areas:

Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the heat exchanger is limited by the control circuit.

In areas where the temporary water hardness exceeds 200ppm, consideration may need to be given to the fitting of a scale prevention device. In such circumstances, the advice of the local water authority should be sought.

8

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

MAINS SUPPLIES

PRE - INSTALLATION

9

A	- Oil storage tank	H	- Oil supply pipe
B	- Isolating valve	J	- Oil pump
C	- Oil strainer & water seperator	K	- Full base (plastic tanks)
D	- Fire valve to BS5410	L	- Non-return valve
E	- External casing	M	- De-aerator
F	- Fire valve sensor	N	- Oil filter (16µm max filtration size)

G- Oil burner

NOTE: All dimensions are in metres unless stated otherwise.

The maximum pipe run figures are based on using copper pipe with an inside diameter of

2mm less than the Ø.		.
	1m min

a)

			A								F		300mm min.	max.(13ft)
K
														4m
				B	C		H		B D	B N	G		J
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM												E
HEAD	10mmØ	12mmØ				HEAD		10mmØ		12mmØ
0.5	12	30					2.5		62	100
1.0	25	69					3.0		74	100
1.5	37	91					3.5		87	100
2.0	49	100					4.0		99	100
										1m min	.
b)								B	D			F	G
						L
			A											max.
														(11.5ft)
			B	C		L	H			B	N		J
150mm					K									3.5m
												E
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
HEAD	10mmØ	12mmØ				HEAD		10mmØ		12mmØ
0	50	100					2.0		26	66
0.5	44	100					2.5		20	50
1.0	38	95					3.0		14	37
1.5	32	80					3.5		8	22
													F
									M				G
c)
														max.
			A
														(11.5ft)
			B	C	H		B		D		J
					K					1m min	.	E		3.5m
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
HEAD	FUEL FLOW RATE			10kg/h			HEAD		FUEL FLOW RATE				10kg/h
	2.5kg/h	5kg/h	10kg/h						2.5kg/h	5kg/h	10kg/h
	8mmØ	8mmØ	8mmØ	10mmØ					8mmØ	8mmØ	8mmØ 10mmØ
0	100	55	26	100			2.0		60	30	14		65
0.5	95	45	23	100			2.5		45	25	11		50
1.0	80	40	20		90		3.0		35	15	8		35
1.5	70	35	17		75		3.5		25	10	5		20

The table and illustration above is a guide only and does not in any way override the deaerator manufacturers instructions.

OIL SUPPLY

This appliance is suitable for kerosene (28 second oil) only, no other fuel must be used.

OIL SUPPLY:

•Plastic or steel tanks should be installed to BS 5410. A steel tank should conform to BS 799: part 5 and have a slope of 1 in 24

away from the outlet valve with a sludge cock at its lower end.

•Do not use galvanised steel tanks or pipework for the oil supply system.

•Do not use soldered joints on the oil supply pipework.

a) Single pipe gravity feed system:

The oil storage tank (A) must be positioned so that the oil level does not exceed 4 metres above the level of the burner oil pump (J) and in addition the oil level must be at least 300mm above the oil pump (J). Where the maximum oil level in the oil storage tank exceeds 4 metres, a head breaking device must be installed between the tank (A) and the burner oil pump (J).

b)Double pipe sub-gravity feed system:

Maximum suction height 3.5 metres. Non-return valves must be fitted to the inlet and return oil line between the oil pump (J) and oil storage tank (A).

c)Single pipe suction lift with de-aerator

Maximum suction height 3.5 metres. The oil tank (A) must be positioned below the oil pump

(J). Create an inlet and return loop between the de-aerator (M) and oil pump (J).

A non-return valve must be incorporated within the de-aerator or fitted to the oil line between the oil storage tank (A) and the de-aerator (M).

A top feed oil tank fitted with a de-aerator using an internal non-return valve should have any non-return valves fitted in the base of the tank to the suction line removed to assist purging air from the oil line.

Pipework

Use copper pipe of the correct diameter according to the information shown opposite. Use flexible hoses to connect to the oil pump (J).

Lay the oil supply pipe (H) as straight and level as possible to avoid air pockets and unnecessary friction losses. Route away from the boiler access door or other hot surfaces.

Install a manual isolating valve (B) to the oil supply pipe (H), as close to the oil storage tank (A) as possible.

Fit an oil strainer and water seperator (C) to the oil supply pipe, near the oil storage tank. Fit an additional oil filter (N, 16µm max filtration size) close to the boiler, but not inside the boiler casing.

Fit a fire valve in accordance with BS 5410. The fire valve (D) must be fitted externally at least 1 metre from the appliance with the fire valve sensor (F) located within the appliance case.

A capillary type valve provides a neat and simple installation. Alternatively, a fusible link or electrical system may be used.

Under no circumstances should a combination isolating/fire valve be used as the sole fire protection device.

OIL SUPPLY

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

COMMISSIONING INSTALLATION

TYPICAL OPEN VENT SYSTEM
E	S
1000mm min.
F H	R
	T	L
G	R
	L	L
C
	D
A - Appliance expansion vessel	F - Feed & expansion 15mmØ min
B - Extra expansion vessel	G - Appliance
C - Automatic bypass valve	H - Open vent 22mmØ min
D - Drain cock	L - Lockshield valve
E - Feed & expansion cistern	P - Pressure relief discharge

				R
TYPICAL SEALED SYSTEM			T	L
	A
	G			R
		B
			L	L
P	U	C
			D

R

TL

R

TL

D

R - Radiators S - Static head T - TRV

U - To filling system

R

TL

R

TL

D

WATER SYSTEMS & PIPEWORK

IMPORTANT: The boiler should not be allowed t o operat e wit h a ret urn temperature of less than 40°C when the system is up to operating temperature.

PRIMARY SYSTEM PLASTIC PIPEWORK:

•Plastic pipework must not be used for the DHW system.

•Any plastic pipework used for the CH system must have a polymeric barrier, comply with BS 7921 and installed to BS 5955 with 1000mm (minimum) length of copper or steel pipe connected to the boiler.

•Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx. 50°C with 1000mm (minimum) length of copper or steel pipe connected to the boiler.

PRIMARY SYSTEM/CONNECTIONS/VALVES:

•Do not use galvanised pipes or radiators.

•All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar.

•Radiator valves should conform to BS 2767:10.

•All other valves should conform to BS 1010.

•On new installations TRVs must be used on all radiators except the radiator where the room thermostat is sited, this must be fitted with lockshield valves and left open. All installations should have TRVs fitted to radiators within the sleeping accommodation.

•An automatic bypass valve must be connected between the heating flow and return where TRVs are used on all radiators, fitted to give at least a 3m circuit when activated.

•Drain cocks are required at all the lowest points on the system.

•Air vents are required at all high points on the system.

OPEN VENT PRIMARY SYSTEM:

•In order to comply with BS 5449 the feed and expansion pipe and the open vent pipe, (or the combined feed and vent pipe), must be connected to the BSP outlet/s on the right hand side of the primary heat exchanger.

•The feed and expansion cistern (E) must be positioned to provide a static head (S) of at least 1 metre above the highest point in the heating system to the water level in the feed and expansion cistern (E).

•Ensure adequate space is left in the expansion cistern for expansion of the system water.

•No valve shall be fitted in the open vent pipe

(H) or the feed and expansion pipe (F).

•The open vent pipe (H) must be at least 22mmØ.

SEALED PRIMARY SYSTEM:

•Where the system volume is more than 180 litres at 0.5 bar or exceeds 2.65bar at maximum heating temperature an extra expansion vessel (B) must be fitted as close as possible to the appliance in the central heating return.

•Pressurise the extra expansion vessel (B) to the same figure as the expansion vessel built into the appliance.

PRE - INSTALLATION

10

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32	WATER SYSTEMS & PIPEWORK
8 716 113 389b (09/07)

PRE -	INSTALLATION
INSTALLATION
COMMISSIONING

			Water main
Heating return			supply
	Non return	Non return
Hose	valve	valve
return
Stop			Stop
cock	Test cock		cock
Temporary hose

		Make up
Heating return	Auto air		vessel
	vent
	Non return		1000mm above
	valve
			the highest point
			of the system
	Stop
	cock
	Fill Point

WATER SYSTEMS & PIPEWORK

FILLING PRIMARY SEALED SYSTEMS:

•Filling the system must comply with one of the methods shown opposite.

•The filling point must be at low level and must never be a permanent direct fixing to the mains water supply.

•Filling loops must be WRAS approved.

SHOWERS/BIDETS:

•If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti-siphon device must be fitted to the shower hose.

•Only thermostatically controlled showers are suitable for use with this appliance.

•Bidets with direct hot & cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays.

DOMESTIC HOT WATER:

•Plastic pipework must not be used for the DHW system.

•Taps and mixing valves must be capable of sustaining a pressure up to 10 bar in accordance with the Water Regulations as they will be operating at mains water pressure.

•Hot water temperature and flow rate are affected by the size and insulation of pipework making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent setting is required.

•If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets.

11

WATER SYSTEMS & PIPEWORK	INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32
	8 716 113 389b (09/07)

	a
	C
	B
	A
	75mm	D
	min.
b	c
C	E
A	C
	A
450 min.		D
Invert
d	(Unsuitable for clay soil types)
C	500mm min.
A	F
		25mm
		min.
		G
	I	400mm
		min.
	H
	200mm min.

J

K

CONDENSATE &

PRESSURE RELIEF PIPEWORK

CONDENSATE PIPEWORK:

•All national and, where appropriate, local regulations for the discharge and neutralisation of condensate should be followed.

•The condensate pipe must be a minimum of 21.5mmØ polypropylene pipe.

•The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route and not exceed 3 metres outside the building. If a run greater than 3m is required, 32mmØ polypropylene pipe must be used.

•The pipework must follow one of the options shown opposite:

a - Internal waste drainage system b - Soil/vent stack

c - External drainage system

d - External condensate absorption point

•Condensate pipework must not be connected to rainwater downpipes.

•Use waterproof pipe insulation in exposed positions and for external pipework

IMPORTANT: Condensate pipework must not leak and the condensate trap must be filled with water before the boiler is started to prevent the possibility of potentially harmful flue products escaping via the condensate route.

A - Condensate from the boiler condensate trap (supplied) which has a 75mm minimum water seal.

B - Sink.

C - 21.5mm Ø polypropylene condensate pipe.

D - Gully.

E - Internal soil and vent stack.

F - 300mm x 100mm Ø sealed plastic tube.

G - Ground level.

H - Drainage holes 50mm from base of tube (12mm Ø at 25mm centres) facing away from building.

I - Limestone chippings.

PRESSURE RELIEF PIPEWORK:

IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe.

Care should be taken when siting the outlet pipe so that it does not cause an obstruction or discharge above a window, entrance or other public access where it could cause a hazard.

•The pressure relief drain pipe (K) should be at least 15mm diameter copper pipe and run

downwards away from the boiler and discharge away from any electrics or other hazard, preferably to an external drain or soakaway.

•Pipe (K) should be finished with a partial bend, near the outlet to face the external boiler casing (as shown) to help prevent freezing.

PRE - INSTALLATION

J - External boiler casing.

K - Pressure relief pipe.

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

12

CONDENSATE &

PRESSURE RELIEF PIPEWORK

PRE - INSTALLATION

		BOILER LOCATION &
		CLEARANCES
	600mm
		WARNING:
		This appliance should not be installed where
		there is a potential for excessive ground
		water coverage.
		This boiler is only suitable for installing
		externally at a suitable location onto a fixed
		permanent rigid surface c apable of
		supporting the boiler weight.
600mm		2500mm*
		There must be a sufficient hard standing
	FRONT	around the appliance to allow for servicing.
		surface to ensure that condensate does not
		The boiler must be installed on a flat level
		enter the primary heat exchanger.
		Tarmac and wood hardstandings are not
		recommended.
600mm	BASE
(min)
	2500mm*	CLEARANCES: Min service & flue clearances
		Above	600mm
		Front	600mm
		RH/LH flue outlet on opposite side		10mm
		RH flue outlet on rear		85mm
		LH flue outlet on rear		10mm
		Rear = flue outlet on side		150mm**
		Rear = rear flue outlet		2500mm*
		It is strongly recommended that the flue
		terminal faces away from walls to reduce
10mm	Plan	the possibility of wetting occuring.
		85mm
	view	*This can be reduced to 1200mm if there is at
		least 2500mm clearance on both sides of the
	FRONT	flue.
		** 200mm if a high level terminal is used exiting
		through the rear panel.
	600mm
	150mm**	150mm**

2500mm*					10mm	10mm				2500mm*
	Plan						Plan
	view						view
	FRONT						FRONT
	600mm						600mm

13

BOILER LOCATION &

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

CLEARANCES

Minimum dimensions of flue terminal positions for oil fired appliances:

TERMINAL POSITION		B(H)
A 1	Directly below an opening, air brick, opening windows, etc	600mm
B 1	Horizontally to an opening, air brick, opening window, etc	600mm
C Below a plastic/painted gutter, drainage pipe or eaves if		75mm
	combustible material protected
D 2	Below a plastic/painted gutter, drainage pipe or eaves without	600mm
	protection to combustible material
E	From vertical sanitary pipework	300mm
F	From an external or internal corner or from a surface or boundry	300mm
	alongside the terminal
G	Above ground or balcony level	300mm*
H 1	From a surface or boundary facing the terminal with 2500mm	1200mm
	clearance to both sides of the terminal
H 2	From a surface or boundary facing the terminal with less than	2500mm
	2500mm clearance to either side of the terminal
I 1	From a terminal facing the terminal with 2500mm clearance to	1200mm
	clearance to both sides of the terminal
I 2	From a terminal facing the terminal with less than 2500mm	2500mm
	clearance to either side of the terminal
K	Horizontally from a terminal	750mm

CABINET MOUNTED LOW LEVEL

FLUE TERMINAL POSITIONS

•	Flue terminals must be positioned to avoid
	combustion products entering into buildings.
•	The flue must be fitted and terminated in
	accordance with the recommendations of
	BS5410.
•	The flue must not cause an obstruction.
•	Discharge from the flue outlet must not be a
	nuisance.
•	Flue gases have a tendency to plume and in
	certain weather conditions a white plume of
	condensation will be discharged from the flue
	outlet which could be regarded as a
	nuisance, for example, near security lighting.
•	There should be no restriction preventing the	-PRE	INSTALLATION
	clearance of combustion products from the
	terminal.
•	The air inlet/outlet duct and the terminal of
	the boiler must not be closer than 25mm to
	any combustible material. Detailed
	recommendations on protection of
	combustible materials are given in BS 5410:1
•	A protective terminal guard must be fitted if
	the terminal is 2m or less above a surface
	where people have access.
	Stainless steel terminal guard.
	Part No: 7 716 190 050

B(H) Balanced Horizontal flue

1 An opening means an openable element, such as an openable window, or a permanent opening such as a permanently open air vent.

Notwithstanding the dimensions above, a terminal should be at least 300mm from combustible material, e.g. a window frame.

2A way of providing protection of combustible material would be to fit a heat shield at least 750mm wide.

boundary			C, D
	F
I			B
		A
H	E		F	J
		G		F	K
boundary

•The following additional guidelines (from part L Exceptions Guidance Document) are recommended when determining the flue outlet position:

•Avoid discharging flue gases into car ports or narrow passageways.

•*Minimum distance of the flue terminal from above ground is 2100mm where directed to a public footpath, private access route or a frequently used area and 2500mm from a car parking area.

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE EXTERNAL 12/18-18/25-25/32 8 716 113 389b (09/07)

14

CABINET MOUNTED LOW LEVEL

FLUE TERMINAL POSITIONS

PRE - INSTALLATION

15

Minimum dimensions of flue terminal positions for oil fired appliances:

HIGH LEVEL FLUE TERMINAL

TERMINAL POSITION B(H) B(V)

POSITIONS

A1 2

Directly below an opening, air brick, opening window, etc

600mm

N/A

B1 2

Horizontally to an opening, air brick, opening window, etc

600mm

N/A

•

Flue terminals must be positioned to avoid

combustion products entering into buildings.

C

Below a plastic/painted gutter, drainage pipe or eaves if

75mm

N/A

•

The flue must be fitted and terminated in

combustible material protected

accordance with the recommendations of

D3

Below a plastic/painted gutter, drainage pipe or eaves without

600mm

N/A

BS 5410.

protection to combustible material

•

The flue must not cause an obstruction.

•

Discharge from the flue outlet must not be a

E

From vertical sanitary pipework

300mm

N/A

nuisance.

F

From an external or internal corner or from a surface or boundry

300mm

N/A

•

Flue gases have a tendency to plume and in

alongside the terminal

certain weather conditions a white plume of

condensation will be discharged from the flue

G

Above ground or balcony level

300mm*

N/A

outlet which could be regarded as a

H

From a surface or boundary facing the terminal

600mm**

N/A

nuisance, for example, near security lighting.

•

There should be no restriction preventing the

J

From a terminal facing the terminal

1200**mm

—

clearance of combustion products from the

K

Vertically from a terminal on the same wall

1500mm

N/A

terminal.

•

The air inlet/outlet duct and the terminal of

L

Horizontally from a terminal on the same wall

750mm

—

the boiler must not be closer than 25mm to

M

Above the point of highest intersection with the roof

—

600mm

any combustible material. Detailed

recommendations on protection of

N

From a vertical structure on the side of the terminal

—

750mm

combustible materials are given in BS 5410:1

•

A protective terminal guard must be fitted if

O

Above a vertical structure less than 750mm from the side of the terminal

—

600mm

the terminal is 2m or less above a surface

P

From a ridge terminal to a vertical structure on the roof

—

—

where people have access.

The guard must be spaced equally (minimum

Q

Above or to the side of any opening on a flat or sloping roof

—

300mm

50mm) around the flue and fixed to the wall

R

Below any opening on a sloping roof

—

1000mm

with plated screws.

Stainless steel terminal guard.

Key: — Not applicable, N/A Not allowed, B(H) Balanced Horizontal flue, B(V) Balanced Vertical flue.

Part No: 7 716 190 050

Notes:

1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or

The following additional guidelines (from part

entering into buildings.

2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc.

L Exceptions Guidance Document) are

3. Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and

recommended when determining the flue

extending 300mm higher and wider than the tank is provided between the tank and the terminating position.

outlet position:

4. Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastics or has a

combustible or painted surface, then a heat shield of at least 750mm wide should be fitted.

•

Avoid discharging flue gases into car ports

5. If the lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has

or narrow passageways.

access, the terminal should be protected by a guard.

6. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the

• *Minimum distance of the flue terminal from

case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire

above ground is 2100mm where directed to a

retardant material and close wire in the vicinity of the flue.

7. It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R.

public footpath, private access route or a

8. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the

frequently used area and 2500mm from a

manufacturer of the plastic components.

car parking area.

• **Minimum distance of the flue terminal to a

P

facing wall, fence, building or property

Q

boundary is 2500mm.

Q

Q

Q

Q

Q

O

Q

boundary

M

N

Flat roof

Pitched roof

R

F

J

C, D

B

H

A

F

K

E

F

L

boundary

G

HIGH LEVEL FLUE TERMINAL

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR HEATSLAVE 12/18-18/25-25/32

8 716 106 252d (08/07)

POSITIONS