Technical and Specification Information Greenstar Heatslave II Internal Series Greenstar Heatslave II External Series Greenstar Heatslave II oil-fired condensing combi boiler range NEW Greenstar Sense & System Filter 1 Worcester and you. Making a difference. As part of the Bosch Group, Worcester is able to provide comprehensive support products are designed and manufactured to and advice from designing system layouts provide customers with the highest levels of through to installation. quality and reliability which are synonymous with the Bosch name. Worcester is dedicated to providing high performance, energy efficient heating Worcester is a part of Europe’s largest and hot water systems for a wide range supplier of heating products and with our of installations. Our oil manufacturing UK-based resources as well as the Bosch heritage stretches back to the foundation of Group's global infrastructure, we can offer the company in 1962 and during this period you the value-added solutions you deserve. we have built a reputation for manufacturing Worcester employs a nationwide network of products which offer the end user the Service Engineers and technically trained highest levels of quality and reliability. Field Sales Managers, supported by an experienced technical services team which 2 The reception and main entrance at our Worcester headquarters Contents Page The Greenstar condensing combi boiler range 4-5 Why choose Worcester? 6 Heatslave II designed with installation and servicing in mind 7 Key features of the range 8-9 “At Worcester we recognise the vital role you Optional plug-in controls 10 - 11 play in the specification and installation of ErP easy as ABC 12 - 13 energy efficient appliances in homes across Inside story – Greenstar Heatslave II 14 - 15 Inside story – Greenstar Heatslave II External 16 - 17 Site preparations and guidance 18 - 22 order to deliver only the best solutions to your Installation requirements 23 - 27 customers’ requirements.” NEW Greenstar System Filter 28 - 29 Condensate pipework 30 - 31 The Worcester CondenseSure siphon 32 - 33 Horizontal and vertical flue terminal positioning 34 - 35 Horizontal fluing options (internal models) 36 - 37 Vertical fluing options (internal models) 38 - 39 Horizontal fluing options (external models) 40 Plume management positioning and system options 41 - 43 Conventional flue 44 Oilfit flexible flue liner 45 - 46 Accessories 47 - 49 Worcester training 50 - 52 After-sales 53 the UK. We will continue to invest in our products, people, facilities and added value services to ensure you have all you require in Carl Arntzen, Managing Director, Bosch Thermotechnology Ltd. 3 The Greenstar Heatslave II combi boiler range Worcester has always understood that, as the market The latest generation Heatronic 4i controls bring advanced leader for heating and hot water, it is our responsibility to and precise control to both the internal and external pave the way for future standards of quality, reliability and models, giving the installer and homeowner a vast range innovation. This common purpose and vision has been of features, allowing the heating system to be as efficient held for over 50 years, with Worcester pioneering domestic and flexible as possible. They also enable integration with oil-fired boilers since 1962. The Greenstar oil-fired range our range of intelligent plug-in controls, enabling further has been expertly designed using the latest cutting-edge efficiency gains to be made. boiler technology to deliver exceptional performance over a wide range of applications. The appliance is manufactured Every appliance is operationally tested before it leaves at Clay Cross in Derbyshire with Bosch production the factory as part of Worcester's rigorous quality processes and systems. control procedure. The Greenstar Heatslave II ranges utilise valuable feedback Highly efficient condensing technology that our installers and users have provided to inspire a The secondary condensing heat exchanger of the range of boilers which provide flexibility for the installer Greenstar range extracts more energy from the oil and, and ease of use for the consumer. when compared with a non-condensing boiler, can cut heating and hot water bills by over £400 a year†. All On-demand hot water Greenstar condensing boilers are able to deliver this An instantaneous supply of hot water is available from the energy-saving performance by extracting additional latent plate heat exchanger which rapidly transfers heat from heat from the exhaust gases – a highly efficient use of the Heatslave II's thermal store. DHW flow rates of up to energy which significantly reduces carbon dioxide emissions 22 l/min can be achieved and the 18/25 and 25/32 models into the atmosphere. are suitable for properties with more than two bathrooms. †Source: Energy Saving Trust: Based on replacing a G-rated oil-fired boiler with an A-rated oil-fired condensing boiler and a full set of controls in a typical 3 bedroom semi-detached home with an average oil price of 6.02p/kWh. 4 Kitchen courtesy of Alno Kitchens. The Greenstar Heatslave II combi range at a glance Heatslave II 12/18 18/25 25/32 7 731 600 047 7 731 600 048 7 731 600 049 ErP Seasonal space heating energy efﬁciency class A / 91% A / 90% A / 91% ErP Water heating energy efficiency class B B B Part no. 89.4% 89.2% 89.0% Min 12kW 18kW 25kW Max 18kW 25kW 32kW 15l/min 18l/min 22l/min 855 x 520 x 600mm 855 x 520 x 600mm 855 x 520 x 600mm 9 9 9 9 9 9 Riello RDB Riello RDB Riello RDB 12/18 18/25 25/32 7 731 600 050 7 731 600 051 7 731 600 052 ErP Seasonal space heating energy efﬁciency class A / 91% A / 90% A / 91% ErP Water heating energy efficiency class B B B 89.4% 89.2% 89.0% 12kW 18kW 25kW SAP efﬁciency Output kW DHW ﬂow rate Dimensions (h x w x d) Conventional ﬂue Room sealed ﬂue Oil burner Heatslave II External Part no. SAP efﬁciency Output kW DHW ﬂow rate Dimensions (h x w x d) Balanced ﬂue Oil burner Min Max 18kW 25kW 32kW 15l/min 18l/min 22l/min 950 x 640 x 770mm 950 x 640 x 770mm 950 x 640 x 770mm 9 9 9 Riello RDB Riello RDB Riello RDB 5 Why choose Worcester oil? Given the competitive nature of the heating industry, Worcester know that installers have an important decision to make when it comes to selecting the best product for their customers. Many installers are loyal to the Worcester brand and recognise the By appointment to Her Majesty The Queen Boiler Manufacturer Worcester, Bosch Group T/A Bosch Thermotechnology Ltd. importance of the technical support and training Worcester offers. At Worcester, we pride ourselves on the hard work that goes on behind the scenes to make sure you and your customers benefit from much more than the best in high-efficiency boilers and renewable technologies. For example, within the product reliability department, every Worcester Greenstar oil boiler is tested. The testing procedure ensures that every boiler has been put through its paces in the most extreme of conditions to ensure they are robust enough to stand up to the highest of demands and toughest of environments. We collect information on each individual component when we field trial our appliances, whilst also systematically noting any feedback from the service engineer who worked on the boilers. This information, along with responses from installers, is constantly processed to ensure all technical observations can be acted upon as a matter of urgency. It is this commitment that ultimately “ 9 out of 10 professional installers would choose Worcester for their own home”* ensures Worcester products remain the best they can be. Did you know? • For testing purposes Worcester has its own formula to on-site, Worcester has more quality control engineers contains iron dust, quartz sand, hemp fibre and other than salesmen. contaminants which are commonly found in system • • As part of the global Bosch Group, Worcester has water samples. access to world leading resources, including a corporate Test boilers are positioned on a shaker table for 3 hours research department and access to the very latest before being set to vibrate across a range of frequencies manufacturing and product development processes. to simulate 3,000 miles of worldwide transport. • Parts in the hydraulic circuit complete 300,000 water • Each new Worcester appliance design is ‘field trialled’ for at least 1 winter period. To benefit from winter pressure cycles to ensure optimum performance conditions all year round, outside of the British winter, is achieved. products are tested overseas. • We have received a Royal Warrant in recognition of supplying goods to Her Majesty, the Queen, an honour we have held since 1992. 6 • With over 100 people in the quality control team replicate contaminated heating system water. This mix • Every boiler receives an end of line full functional test before it leaves the factory. • One in four oil boilers installed in the UK is a Heatslave. *Source: Worcester Customer Satisfaction Index 2011 Greenstar Heatslave II designed with installation and servicing in mind In addition to our own extensive testing and research, we Simple servicing also listen and respond to installers as part of our product The Heatslave II range has serviceability at its heart. development programme. Based on installer feedback, the Greenstar Heatslave II As a result of such feedback, we have brought about the has been created to make servicing as simple and quick as following distinct features that benefit the installer. possible, with the layout enabling an annual service to take place completely from the front of the boiler. Easy installation The first thing that you will notice is that the Greenstar Heatslave II models are up to 50kg lighter than the previous Greenstar Heatslave. Look inside and you'll see there is now a cross-firing burner, simplifying oil supply and the expansion vessel is mounted at the front on a hinge, allowing fluing to the left. The hydraulic connections have been positioned on a diagonal plane at the left rear of the boiler enabling quick and easy installation. The expansion vessel moves 90º to allow full unhindered access to the burner, and the primary heat exchanger designed with ErP in mind, contains a one-piece primary baffle which is manufactured in high-temperature-resistant stainless steel, making them easy to clean and quick to service. Further improvements include an oil line which is run through the cabinet, as well as an oil isolation valve which mounts on an easy-to-access bracket on the right hand side of the primary heat exchanger. There is space on the bracket for the installation of a second oil isolation valve if you are utilising a twin pipe system. Finally, the Greenstar Heatslave II retains the internal condensate trap from the previous models, which utilises a simple condensate pipe connection. The height of the trap removes the need for a condensate pump in most instances. The existing, simple-to-remove, mesh baffle design has continued to be utIlised in the secondary heat exchanger. The components on the modular hydraulic block will be familiar to those servicing our gas-fired boilers. They offer improved reliability and are easy to replace. 7 Key features of the range On the primary On the secondary heat exchanger* heat exchanger* Greenstar Heatslave II boiler range Greenstar Heatslave II External Greenstar internal models are ideally suited for installation Where space in the home is at a premium a Greenstar around the home. Heatslave II External boiler is the ideal solution. The Greenstar Heatslave II internal boilers feature: Whilst offering many of the operating features of Heatslave II internal models, Heatslave II External boilers also feature: • • Cross-firing burner • A robust, durable external cabinet that blends in with the Renowned Worcester reliability garden and allows for a long life expectancy • • Same class-leading footprint as previous Heatslave models, • IP45 Ingress Protection – protecting the boiler from water, Installer-optimised hydraulic connections creating less disturbance in replacement installations • Front access for routine servicing, including a pivoting expansion vessel for ease of access to the combustion chamber and one-piece baffles • Pre-wired electrical mains connection • Easily accessible oil inlet valve • Reduced boiler weight • Modern cabinet design • The option to add a range of digital programmers, including RF options, to give fully automatic control, eliminating the need for external wiring of a programmer • • A pre-wired mains lead with a plug allows easy isolation of the boiler during maintenance • A built-in frost thermostat which protects the appliance from freezing • An internal pull-out control panel which contains the boiler heating and hot water temperature controls as well as a lockout indicator, mode indicator and mode switch • The same performance features as the internal counterparts • All External combi boilers are now supplied complete with flue. Weather and load compensation options enabling the boiler flow temperature to be varied in accordance with Efﬁciency and environmental features demand, allowing greater efficiency and comfort • Excellent energy performance • A design which has the ErP Directive in mind • ErP ‘A’ rated for heating and ErP ‘B’ rated for • A pre-heated thermal store which provides the user with instant hot water • Unique pull-out control panel with LCD display and diagnostic information • The Heatronic 4i boiler control unit intelligently responds to heating and heat water demands, reducing burner firings and transferring surplus heat from central heating demands to the thermal store • • 5 year guarantee on Worcester primary heat exchanger*. 10 year guarantee on the plate heat exchanger* 8 dust and external elements hot water • The opportunity to improve SAP performance with weather compensation • 30ºC minimum heating return temperature for maximum condensing efficiency • ECO hot water mode • Accepts pre-heated hot water from low carbon heating technologies such as solar thermal and biomass. *Subject to conditions Operation Applications The Greenstar Heatslave II is supplied as standard suitable • The outputs offered by the range ensures installation for sealed primary water systems. The appliance contains flexibility, making Greenstar oil-fired boilers ideally suited an expansion vessel, 3bar pressure relief valve, pressure to many sizes of domestic property gauge and an automatic air vent. • The Greenstar Heatslave II will accept pre-heated DHW to 60ºC from sources such as solar and biomass. They are ideally matched to our range of Greenskies solar thermal panels. Greenskies Solar-Lifestyle and Solar-Lito Greenstar Heatslave II External model Oil These appliances are for use on 28 sec kerosene fuel only. Fluing The indoor appliance can be used with Hot water mode either a room sealed concentric flue or With the appliance in a standby condition, i.e. the heatbank conventional (open) flue. A flexi-flue liner kit is available to at a temperature set by the hot water thermostat, when a enable the appliance to be flued via a chimney. The room demand for hot water is required the flow switch will sealed flue ensures quiet operation. energise the pump and circulate primary hot water around the boiler and the plated water to water heat exchanger. The external appliances utilise a balanced flue system in The burner will automatically light to maintain the order to minimise the risk of lockouts caused by heavy winds. temperature of the heatbank. A standard flue kit is included with every external boiler. When hot water is no longer required, the appliance will A plume management kit is available for both internal and continue to operate until the heatbank has returned to external boilers. temperature. Priority is always given to the production of domestic hot water. Greenstar Oilfit – the easy-fit fluing solution • Multiple fluing options with the ability to flue internal floor There are two hot water modes on the appliance. In the standing boilers from the top, rear or side and external standard mode the burner fires soonest to keep the thermal boilers from the rear and side store temperature high, maximising hot water comfort. In ECO mode the thermal store temperature is allowed to fall more before the burner fires, saving fuel. • Conventional flue for internal models via the adaptor kit or flexi-flue chimney liner kit • Room sealed flue lengths using 80/125mm dia. flue up to 8m vertically and 6m horizontally. Plume kit lengths to 5m Central heating mode When central heating is required, the diverter valve will open and the pump will energise in order to circulate primary water around the heating system. The burner will automatically light and the radiators will heat up to the • Quick-to-install push-fit connections and telescopic options which form a gas-tight seal and in most cases eliminate the need to cut the flue • Easy-fit installation that requires no special tools when fitting flue extensions, elbows and adaptors. temperature set by the heating control thermostat. Installation of a Greenstar Oilfit RS flue system 9 Keeping you and your customers in control The Greenstar Heatslave II features the revolutionary Heatronic 4i control unit which provides accurate and intelligent control of the appliance. The control unit is discretely housed in a drawer with upward-facing controls for ease of adjustment. The Greenstar Heatslave II pull-out fascia with the intuitive in-built display. Easy-to-read and monitor Weather and load compensation The clear screen means system parameters, such as hot To save energy and improve heating comfort, the Heatslave water flow rate and heating flow temperatures, can be II will accept compensating room and outdoor temperature easily monitored by the installer during commissioning. controls. For weather compensation, an outdoor sensor can be combined with the Heatronic 4i’s in-built weather Easy reset compensation functionality. Load compensation is Most boiler lockouts can be reset from a single button on the provided by wiring the Greenstar Sense I intelligent room control unit. This is also the reset for burner lockouts, so the thermostat to the boiler. end user has no need to access the inside of the boiler. Service menu The simple-to-use engineers’ menu can check the operations of various boiler components without the need to remove the boiler front cover. Any problems can be easily identified with diagnostic codes, narrowing the potential causes of the problem. ECO hot water mode The Heatronic 4i has two hot water modes. Standard mode prioritises maintaining the temperature of the slave tank, maximising hot water performance. In ECO mode, to save fuel, the temperature drop of the slave tank is increased, meaning the burner fires less frequently to reheat the tank, thus saving fuel. 10 As part of the Bosch Group, Worcester is committed to new product development, economical use of heating systems and environmental protection. As part of this commitment, Worcester has a range of heating controls designed to enhance the integral efficiency of our Greenstar Heatslave II range. Greenstar Comfort controls Greenstar Comfort plug-in twin channel programmer – Part no. 7 733 600 003 • Simple menu navigation • Heating programme visualisation bar • 7-day time control for heating and hot water. G Greenstar Comfort I RF wireless room thermostat an plug-in twin channel programmer – Part no. 7 733 600 001 and A the features of Comfort PLUS… All • No wiring required • Reliable RF signal. EFFICIENCY +1% Greenstar Comfort II RF wireless programmable room thermostat G and plug-in RF receiver – Part no. 7 733 600 002 All the features of Comfort & Comfort I PLUS… • 6 adjustable heating temperatures per day • Set programme at the room thermostat • Remote access to boiler diagnostic codes. EFFICIENCY +1% Greenstar Comfort Wall Plate Kit – Part no. 7 733 600 039 • This kit allows a plug-in Comfort programmer or RF receiver to be wall mounted and hard wired to the boiler. This is an ideal solution for external boilers. NEW Greenstar Sense controls – load and weather compensation To maximise savings and heating comfort, the Heatslave II can be paired with a weather sensor or the Sense I intelligent room thermostat. Sense I – Intelligent room thermostat – Part no. 7 738 110 054 • Load compensation EFFICIENCY • Boiler output automatically adjusted to precisely meet the heat demand of the property at maximum efficiency • Maximises the condensing boiler’s operation • For use with a 230V programmer. Not compatible with Worcester Comfort controls. +1% Outdoor weather sensor – Part no. 7 716 192 764 • Monitors external temperatures to offer weather compensation in combination with the in-built heat curves of the Greenstar Heatslave II • The appliances inbuilt weather compensation is activated when the sensor is connected. For use with a 230V programmer. Not compatible with Worcester Comfort controls. A 230V room thermostat is required in addition. EFFICIENCY +1.5% Controls at a glance Outdoor weather sensor 1 9 Hard wired Radio frequency Plug-in Weather compensation Optimum start Programmable room thermostat Room thermostat Auto switch – BST/GMT 7 day 24 hour Hot water Central heating Wall mounted Fascia mounted Boiler flow temp compensation 9 9 9 9 9 9 9 9 9 EFFICIENCY N/A N/A I 1% I 1% I 1% III 1.5% MODEL Heatslave II External Sense I 9 9 9 9 9 9 9 9 9 CONNECTION TYPE Heatslave II Comfort II RF 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 TEMPERATURE CONTROL Efficiency benefit Comfort I RF 9 TIME CONTROL ErP Class Comfort MOUNT Intelligent Control option Digital TYPE 9 9 9 92 92 91 91 91 92 92 Should be used with Comfort wall plate kit. 2 Must be used with an external propriety 230V timer. 11 What is ErP? The ErP Directive, which is a new regulation set by the European Union, is designed to drive improvements in the efficiency and performance of heating and hot water products. Its purpose is to ensure that end users are aware of the level of energy efficiency inherent within their appliances. As such, the Directive will help improve the overall efficiency of the housing stock, while enabling homeowners to reduce their energy bills. The ErP regulations cover boilers, combination boilers, heat pumps and other heating appliances up to 400kW. What is Energy Labelling? The Energy Labelling involves a label which we are familiar with today on washing machines and televisions at the point of sale. The Energy Labelling Product A regulations introduce Europe-wide energy labelling Model name requirements for boilers, combination boilers, water heaters and other heating products up to 70kW and hot water cylinders under 500 litres. CH efficiency band DHW efficiency band How will the labelling scheme work? The new Energy Labelling Directive will introduce new efficiency classes from A++ to G alongside the existing SEDBUK rating for boilers in the domestic and light commercial sectors. Most condensing boilers will fall within the A band, which requires them to achieve more than 90% seasonal efficiency, while renewable technologies such as heat pumps will likely be in the A+ or A++ bands (depending on flow temperature). 12 Sound power level Maximum heating output What about systems that contain What about controls? different products? The ErP Directive covers all products that In these circumstances, there is a responsibility to consume energy, such as boilers, heat pumps, provide a package label when combining a heating solar thermal etc. It also includes controls, appliance with a temperature control and/or solar which are defined using ‘classes’. These run device, cylinder or a supplementary heating from Class I (a simple on/off room stat) through appliance (for example, a two-boiler cascade with to Class VIII (multi-sensor room control for use a combined total output of under 70kW). with modulating heating appliances). The person who puts that package together will Each control class equates to a certain percentage need to produce a package document known as uplift in system efficiency e.g. a class III weather a fiche (data table) and label that provides the sensor and room thermostat will add 1.5% combined energy efficiency rating rather than efficiency to the heating system. Details of the ratings of each individual component. controls class for each Worcester control can be found on page 11. For example, this could be the merchant’s responsibility if they supply a complete package under one part number or the installer if the items are bought individually under separate part numbers. In either circumstance, Worcester will provide an online tool that makes calculating the overall package efficiency of a Worcester system effortless. ErP easy as ABC with Worcester The Energy Labelling obligation under the Energy Related Products (ErP) Directive came into force on the 26th September 2015. Worcester has a number of measures in place to support you including: An online label generator which creates product and heating system labels ErP will be covered in all Worcester training courses ErP experts – our technical and customer support teams can answer all your questions. ErP Technical Support: 0330 123 3641 Email: ErPemail@example.com 13 Inside story – Greenstar Heatslave II internal condensing combi boiler series Pressure relief valve Heating and DHW connections Primary heat exchanger Flue connection point DHW plate heat exchanger Expansion vessel Scroll up Digital display ECO DHW mode Reset Optional programmer Pressure gauge Domestic hot water temperature control Service menu Confirm Central heating temperature control Scroll down Greenstar Heatslave II fascia with optional Greenstar Comfort plug-in twin channel programmer fitted Flue gas sample point DHW plate heat exchanger Auto air vent Flue manifold with access to secondary heat exchanger ErP compliant modulating pump Diverter valve Primary heat exchanger access door Hydraulic unit drain Condensate trap Oil isolation valve and breaker (hidden) Heat bank Burner Expansion vessel (removed from bracket) 14 Technical data Boiler Greenstar Heatslave II 12/18 Greenstar Heatslave II 18/25 Greenstar Heatslave II 25/32 Height 855mm 855mm 855mm Width 520mm 520mm 520mm Depth 600mm 600mm 600mm 124kg 126kg 128kg A / 91% A / 90% A / 91% ErP Water heating energy efﬁciency class B B B ErP Water heating efficiency – declared load profile XL XL XL 89.4% 89.2% 89.0% 62 litres 63 litres 64 litres Available pump head (20°C difference) at maximum output 4.7m 4.0m 4.2m Maximum permissible sealed system operating pressure in accordance with WRAS guidelines 2.5bar 2.5bar 2.5bar Maximum ﬂow rate for a 40ºC ∆T over a 90 litres draw off 15 ltr/min* 18 ltr/min* 22 ltr/min* Minimum inlet pressure (dynamic) for maximum ﬂow rate 1.5bar 1.2bar 1.6bar Exit ﬂue gas mass ﬂow 29kg/hr 40kg/hr 51kg/hr Fuel line (compression) 10mm 10mm 10mm CH ﬂow 22mm 22mm 28mm CH return 22mm 22mm 28mm Water main inlet 15mm 15mm 15mm DHW outlet 22mm 22mm 22mm 21.5mm polypropylene 21.5mm polypropylene 21.5mm polypropylene 230V AC 230V AC 230V AC Frequency 50Hz 50Hz 50Hz Maximum power consumption 184W 209W 233W Part load power consumption† 44W 47W 48W CH control range 50/82°C 50/82°C 50/82°C Heat store control range Weight – lift ErP Seasonal space heating energy efﬁciency class SAP efﬁciency Primary water capacity (total) Condensate connection Electrical power supply voltage 55/84ºC 55/86ºC 55/88ºC Boiler manual reset overheat set point 105ºC 105ºC 105ºC Flue reset overheat thermostat set point 110ºC 110ºC 110ºC 95ºC 95ºC 95ºC <100ºC <100ºC <100ºC 12 - 18kW 18 - 25kW 25 - 32kW Riello RDB2.2** Riello RDB2.2** Riello RDB2.2** 9 (optional) 9 ( optional) 9 (optional) 9 ( optional) 9 (optional) 9 ( optional) Maximum vertical room sealed balanced ﬂue (125mm dia.) inc. terminal 8,000mm 8,000mm 8,000mm Maximum horizontal room sealed balanced ﬂue (125mm dia.) 6,000mm 6,000mm 6,000mm Plume management maximum length 5,000mm 5,000mm 4,000mm CF Flexiflue (100mm dia.) 12,000mm 12,000mm 12,000mm IP 20 IP 20 IP 20 55dB(A) 56dB(A) 54dB(A) Tank manual reset overheat thermostat set point Maximum hearth temperature Output to central heating Oil burner Plug-in timer Weather/load compensation Appliance protection rating Noise output level *Restricted DHW flow rate. **Suitable for kerosene (28 sec oil) only. †Power consumption excluding pump. 15 Inside story – Greenstar Heatslave II External condensing combi boiler series Pressure relief valve Heating and DHW connections Secondary heat exchanger DHW plate heat exchanger Expansion vessel Scroll up Digital display ECO DHW mode Optional programmer Pressure gauge Reset Service menu Domestic hot water temperature control Confirm Scroll down Central heating temperature control Greenstar Heatslave II External fascia with optional Greenstar Comfort plug-in twin channel programmer fitted Flue overheat reset Flue gas sample point DHW plate heat exchanger Auto air vent Flue manifold and secondary heat exchanger access Low energy circulating pump Diverter valve Hydraulic unit drain Condensate trap Primary heat exchanger access door Heat bank Burner Expansion vessel (removed from bracket) 16 Technical data Boiler Greenstar Heatslave II External 12/18 Greenstar Heatslave II External 18/25 Greenstar Heatslave II External 25/32 Height 950mm 950mm 950mm Width 640mm 640mm 640mm Depth 770mm 770mm 770mm 151kg 154kg 158kg A / 91% A / 90% A / 91% ErP Water heating energy efﬁciency class B B B ErP Water heating efficiency – declared load profile XL XL XL 89.4% 89.2% 89.0% 62 litres 63 litres 64 litres 4.7m 4.0m 4.2m 2.5bar 2.5bar 2.5bar Maximum ﬂow rate for a 40ºC ∆T over a 90 litres draw off 15 ltr/min* 18 ltr/min* 22 ltr/min* Minimum inlet pressure (dynamic) for optimum ﬂow rate 1.5bar 1.2bar 1.6bar Exit ﬂue gas mass ﬂow 29kg/hr 40kg/hr 51kg/hr Fuel line (compression) 10mm 10mm 10mm CH ﬂow 22mm 22mm 28mm CH return 22mm 22mm 28mm Water main inlet 15mm 15mm 15mm DHW outlet 22mm 22mm 22mm 21.5mm polypropylene 21.5mm polypropylene 21.5mm polypropylene 230V AC 230V AC 230V AC Frequency 50Hz 50Hz 50Hz Maximum power consumption 184W 209W 233W Part load power consumption† 44W 47W 48W CH control range 50/82ºC 50/82ºC 50/82ºC Heat store control range Weight – lift ErP Seasonal space heating energy efﬁciency class SAP efﬁciency Primary water capacity (total) Available pump head (20°C difference) at maximum output Maximum permissible sealed system operating pressure in accordance with WRAS guidelines Condensate connection Electrical power supply voltage 55/84ºC 55/86ºC 55/88ºC Boiler manual reset overheat thermostat set point 105ºC 105ºC 105ºC Flue reset overheat thermostat set point 110ºC 110ºC 110ºC 95ºC 95ºC 95ºC <100ºC <100ºC <100ºC 12 - 18kW 18 - 25kW 25 - 32kW Riello RDB2.2** Riello RDB2.2** Riello RDB2.2** 9 (optional) 9 9 (optional) 9 9 (optional) 9 5,000mm 5,000mm 4,000mm IP 45 IP 45 IP 45 N/A N/A N/A Tank manual overheat reset thermostat set point Maximum hearth temperature Output to central heating Oil burner Plug-in timer Weather load/compensation Plume management maximum length Appliance protection rating Noise output level *Restricted DHW flow rate. **Suitable for kerosene (28 sec oil) only. †Power consumption excluding pump. 17 Site preparations and guidance (internal models) Siting of appliance Installation and service clearances Greenstar Heatslave II oil-fired appliances are not suitable The minimum clearances shown below should be allowed for external installation unless a suitable enclosure is for installation and servicing. provided. The floor must be firm and level. The floor on which the boiler is to be mounted should be capable of Installation clearances supporting an overall weight of approximately 140kg. 720mm 1,200mm All models have a hearth temperature of below 100°C, 300mm removing the need for a constructional hearth. The appliances should be positioned on a non-combustible solid base as near to the flue location point as possible. Care should be taken to ensure that the appliance is level. 1,155mm Flue system 100mm Greenstar Heatslave II appliances can be connected to either a conventional flue system or a multi-directional, 100mm 600mm room-sealed balanced flue. In either case, the conventional flue adaptor or the appropriate RS flue kit needs to be specified. Maintenance/service clearances 1,200mm 530mm 300mm (maintenance) 10mm (service) 1,155mm 5mm 600mm Installation of a Greenstar Oilfit RS flue system 18 5mm A removal work surface may be installed over the boiler Compartment installation Follow the requirements of BS 5410 and note: • Minimum clearances must be maintained • An access door is required to install, service and maintain the boiler as well as any ancillary equipment, Conventional flue† – minimum air vent area (cm2) for appliances installed in a compartment Internal ventilation* kW High level (D) Low Level (C) 12/18 198 18/25 275 25/32 352 i.e. condensate trap • If fitting the boiler into an airing cupboard use a noncombustible material to separate the boiler from the airing space. If the material is perforated, the holes must not External ventilation** High level (D) Low Level (C) 279 99 198 413 138 275 528 176 352 exceed 13mm. Room-sealed flue† – minimum air vent area (cm2) for appliances installed in a compartment Compartment ventilation • Ventilation must be provided for boilers fitted into compartments as described in BS 5410 Internal ventilation* External ventilation** kW High level (D) Low Level (C) (C) and another at high level (D) onto the same wall using 12/18 198 198 99 99 the same air (E) for circulation 18/25 275 275 138 138 25/32 352 352 176 176 • A minimum of 2 air vents must be fitted, one at low level • Free air must not be taken from a room or internal space containing a bath or shower and must not communicate with a protected area such as a hall, stairway, landing, corridor, lobby, shaft, etc. • Air vents must allow access for clean, free air and must be sited to comply with the flue terminal High level (D) Low Level (C) *Internal air to and from a space/room inside the building. **External air to and from directly outside the building. †Due to changes to BS 5410 and modern building design, these figures no longer incorporate the adventitious ventilation allowance. Air supply CF (conventional flue) position requirements • Air ducting runs must not exceed 3 metres. • Low level air vents must be within 450mm from the floor • A warning label must be added to the vents with a statement to the effect: “Do not block this vent. An adequate supply of free air must be delivered to the boiler for combustion purposes through a permanent inlet, such as an air brick, into the area where the boiler is situated. Combustion air must not be taken from bathroom or bedroom areas. Do not use for storage”. Minimum area of air inlet for combustion* kW Area 12/18 99cm2 18/25 138cm2 25/32 176cm2 *Due to changes to BS 5410 and modern building design, these figures no longer incorporate the adventitious ventilation allowance. Internal ventilation External ventilation Compartment ventilation A Compartment B Boiler C Low level vent D High level vent E Air supply 19 Important: bathroom locations and clearances Casing dimensions • The boiler must not be installed in zones 0, 1 or 2 • Any switch or appliance control using mains electricity Greenstar Heatslave II must not be within reach of a person using the bath 520mm 600mm or shower • Electrical switches, fused spurs and socket outlets must not be situated in the bathroom. Refer to the latest IEE wiring regulations. 855mm 600mm 600mm 750mm 1 2 1 2 2,250mm Pipework connections A to G (below) show the flue and pipe outlets (mm): 2,250mm Note: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections. 0 Greenstar Heatslave II 454 337 145 E E 600mm 35 65 750mm A C 94 D 121 770 726 2,250mm 2 1 1 2 19 639 609 582 415 0 FRONT VIEW Key Description A CH flow B DHW flow C DCW mains water inlet Heatslave II 12/18 & 18/25 Heatslave II 25/32 22mm dia. plain 28mm dia. plain ended copper ended copper 22mm dia. plain ended copper 15mm dia. D CH return 22mm dia. plain 28mm dia. plain ended copper ended copper E Flue outlet Flue outlet F Pressure relief pipe G Condensate outlet Oil 20 SIDE VIEW Flue and pipe connections 600mm radius a bathroom. 52 G 667 2,250mm Conventional flued boilers must not be fitted in F B 15mm dia. plain ended copper 21.5mm dia. polypropylene 15mm copper compression Site preparations and guidance (External models) Siting of appliance Casing dimensions Greenstar Heatslave II External appliances are suitable for 640mm external installation only. Appliances should be installed 770mm at a suitable location onto a fixed, permanent and rigid surface. There must be sufficient hard-standing around the appliance to allow for servicing. Appliances must be installed on a flat, level surface to ensure that condensation does not enter the primary heat exchanger. Appliances 950mm should not be installed where there is a potential for excessive ground water coverage. Tarmac and wood hard-standings are not recommended. Flue system For all external boilers, consideration should be given to the location of the appliance and its flue outlet in relation Installation and service clearances to windows, doors and air vents. Greenstar Heatslave II The minimum clearances shown below should be allowed appliances can be connected to the Greenstar Oilfit plume for installation and servicing. It is strongly recommended management system. that the flue terminal faces away from walls to reduce the possibility of “wetting” occurring. Care should be taken to ensure that pipework leaving the appliance and entering the building should not be exposed. The appliance should be sited as close to the dwelling as possible. Side view, rear flue Top view, rear flue 600mm 2,500mm FRONT 600mm 2,500mm 85mm Plan view 45mm FRONT 600mm min. 600mm BASE Top view, left flue Top view, right flue 50mm 50mm 10mm 2,500mm Plan view FRONT 10mm Plan view FRONT 21 Pipework connections Flue and pipe outlets (mm): Note: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections. Rear Left side 670 260 100 490 Services Flue Flue Services 800 95 Condensate Condensate 650 800 650 PRV PRV Oil 327 435 124 90 105 55 658 679 698 81 Fire valve capillary & drain access 161 715 Right side 670 490 Services Flue Condensate 794 650 437 528 PRV 230 105 94 Oil 55 658 669 705 715 Fire valve capillary & drain access Pipework connections Description Heatslave II External 12/18 & 18/25 Heatslave II External 25/32 CH flow/heating vent 22mm dia. plain ended copper 28mm dia. plain ended copper DHW flow 22mm dia. plain ended copper 22mm dia. plain ended copper Mains water inlet 15mm dia. plain ended copper 15mm dia. plain ended copper CH return 22mm dia. plain ended copper 28mm dia. plain ended copper Condensate outlet Pressure relief pipe Oil connections 22 21mm polypropylene 15mm dia. plain ended copper 15mm dia. plain ended copper 10mm dia. copper compression Installation requirements Installation regulations Sealed system installation The appliance should be installed by a competent person The Greenstar Heatslave II oil-fired appliances are designed who is aware of the Health and Safety at Work Act. They for sealed systems, incorporating a pre-plumbed expansion should take appropriate action to ensure that the regulations vessel, pressure relief valve set to 3bar, automatic air vent are adhered to. In order to give optimum efficiency and and pressure gauge. The charge pressure of the built-in trouble-free operation, the appliance must be commissioned 12 litre expansion vessel is 0.5bar as dispatched, which is by a qualified OFTEC engineer. equivalent to a static head of five metres. At 1bar pressure the vessel will provide 107 litres expansion capacity, and as In particular, the installation of this appliance must be in the boiler has a primary water capacity of between 62 and accordance with the relevant requirements of the following 64 litres, therefore additional system expansion capacity British Standards and regulations in respect of the safe may be required. The system should be filled to between installation of equipment: 1 and 2bar through a WRAS approved temporary hose connection to the mains water supply. The compliance with a British Standard does not, of itself, confer immunity from legal obligations. Underfloor heating • Plastic pipework used for underfloor heating must be BS 5410: part 1 & 2: 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 correctly controlled with a thermostatic blending valve, limiting the temperature of the circuits to approximately 50ºC. A 20ºC temperature differential must also be maintained at the appliance. domestic hot water central heating systems. Primary system/connections/valves BS 5449: part 1: Specification for forced circulation hot water central heating for domestic premises. • Do not use galvanised pipes or radiators • Any plastic pipework used for the CH system must have a polymeric barrier, complying with BS 7921 and installed BS 5955: part 8: Specification for the installation of thermoplastic pipes and associated fittings for use in to BS 5955 with 1,000mm (minimum) length of copper or steel pipe connected to the boiler domestic hot and cold water services and heating systems. • All system connections must be capable of sustaining a BS 7291: Thermoplastic pipes and associated fittings for • Radiator valves should conform to BS 2767:10 • All other valves should conform to BS 1010 • An automatic bypass valve must be connected between pressure up to 3bar 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. the heating flow and return where TRVs are used on all radiators. It should be fitted to give at least a 3 metre circuit when activated • Drain cocks are required at all of the lowest points on the system • Air vents are required at all of the high points on Full British Standards requirements can be found on the the system. British Standards website. The Building Regulations England, Wales, Scotland and Northern Ireland. Local water company bye-laws. The Control of Pollution (Oil) Regulations. OFTEC Standards. 23 Water supply Plastic pipework The following are general requirements and if necessary the Any plastic pipework used for the DHW system must have advice of the local water company should be sought before a polymeric barrier, complying with BS 7921 and installed fitting the appliance. to BS 5955 with 1,000mm (minimum) length of copper or • The appliance cold water supply should be the first stainless steel pipe connected to the boiler. connection off the water main where possible. • Before installing plastic pipework, the pipe manufacturer’s literature should be consulted. Water mains pressure Minimum dynamic mains water pressure for maximum • To prevent the temperature and pressure exceeding the limits advised by the pipe manufacturer, a pressure performance. reducing valve must be used to prevent the incoming Mains water pressure 12/18 18/25 25/32 1.5bar 1.2bar 1.6bar Maximum mains fed water pressure 10bar. If necessary, fit a pressure reducing valve. water pressure exceeding 3bar (maximum). Also, a mini expansion vessel must be fitted to absorb the expanding water and a blending valve set to 60°C must be fitted before the DHW plastic pipework. • When selecting plastic pipework for use with domestic water supply, it should be ensured that it is compliant The appliance will accept pre-heated hot water to a with all current local and national legislation and temperature of 60°C regulations, including building regulations part G, BS 7291 - 1,2 & 3: 2006, BS 8000 - 15-15: 1990 and Non-return, back flow prevention devices (including those information. associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage Guarantee the boiler and other household appliances. Where the water Worcester oil-fired appliances are offered with main supply has a non-return, back flow prevention valve a 2 year* guarantee on parts and labour from fitted, a mini expansion vessel (part no. 7 716 192 105) the date of installation, providing the must be connected to the mains water inlet pipe between appliance is commissioned upon installation the non-return valve and the boiler. and the regular service requirements are met. The primary heat exchanger comes with a Use in hard water areas 5 year* guarantee and the secondary heat Normally there is no need for water treatment to prevent exchanger is guaranteed for 10 years*. scale formation as the maximum temperature of the heat exchanger is limited by the electronic 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. Hot water systems Taps and mixing valves must be capable of sustaining a pressure up to 10bar 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. • Only thermostatically controlled showers are suitable for use with this appliance. 24 *Terms and conditions apply. * * Oil supply A E H G J K B C B D N 4m Max. 300mm Min. F B Fig. 10 Single pipe system – Heatslave II E A F D H J G B 150mm K B N 3.5m Max. L B C Fig. 11 Two pipe system – Heatslave II B F J H K E G D C B C 3.5m Max. M A B Fig. 12 Single pipe lift system with de-aerator – Heatslave II Key A B C D E F G Oil storage tank Isolating valve Oil strainer and water separator Fire valve to BS 5410 External wall Fire valve sensor Oil burner H J K L M N Oil supply pipe Oil pump Full base (plastic tanks) Non-return valve De-aerator Oil filter (70µm max. filtration size) 25 Fig. 10 Single pipe system – Heatslave II External Fig. 11 Two pipe system – Heatslave II External Fig. 12 Single pipe lift system with de-aerator – Heatslave II External Key A B C D E F Oil storage tank Isolating valve Oil strainer and water separator Fire valve to BS 5410 External wall Fire valve sensor G H J K L M Oil burner Oil supply pipe Oil pump Full base (plastic tanks) Non-return valve De-aerator N Oil filter (70µm max. filtration size) The oil burner on the Greenstar oil-fired appliances is All oil pumps on Worcester appliances can easily be supplied with a single flexible fuel line from the oil pump converted to work on a two pipe system or a single pipe which is connected to the main oil supply line (via the oil suction lift system with de-aerator. The maximum suction isolation valve) within the appliance. This enables the height is 3.5m (details are within the Installation and burner to be removed without the need for disconnection of Servicing instructions which come with the appliance). the fuel line. More advice on fuel lines can be sought from OFTEC Book The maximum permissible head is 4 metres. If the head is greater, then a head breaking device must be incorporated into the oil supply line. 26 Three as well as Technical sheet TI/134. Maximum allowable run from tank to de-aerator Supply pipe The oil supply pipe itself would normally be annealed copper tube with a protective plastic coating which is easily Fuel flow rate 2.5 (kg/h) 5 (kg/h) 10 (kg/h) 10 (kg/h) Head 8mm dia. 0m 100m 55m 26m 100m 0.5m 95m 45m 23m 100m (via an access duct) and should be of the manipulative 1.0m 80m 40m 20m 90m type. Plastic pipe specifically for oil lines does exist and is 1.5m 70m 35m 17m 75m acceptable but must only be used underground. 2.0m 60m 30m 14m 65m 2.5m 45m 25m 11m 50m 3.0m 35m 15m 8m 35m 3.5m 25m 10m 5m 20m manipulated around bends and usually enables the fuel line to be run in a continuous length without joints. If joints must be used, they must be accessible, even if underground Galvanised pipe, fittings and soldered joints must not be used in oil lines. More advice on fuel lines can be sought from OFTEC Book Three as well as Technical sheet TI/134. 8mm dia. 8mm dia. 10mm dia. Table 3: Single pipe suction lift with de-aerator Supply pipe sizing The diameter of the oil supply pipe itself is determined by Oil tanks the distance from the oil tank to the appliance and the head For further information on oil tank location, please consult of oil whether it be positive or negative. the tank supplier. Tables 1 and 2 give the required diameter of supply pipe Oil filters when cross referenced with the head. Table 3 gives the Oil filters must always be incorporated in the oil supply line. diameter of the supply pipe when the use of a de-aeration One should be fitted on the outlet from the oil tank to filter device is made. deposits from within the tank or fuel, and one should be fitted near the appliance to filter deposits from within the Maximum allowable pipe run fuel line itself. They are supplied and fitted by the installing Head 8mm inside dia. pipe (10mm OD copper) 10mm inside dia. pipe (12mm OD copper) 0.5m 12m 30m draining down the fuel supply line. There must be sufficient 1.0m 25m 69m clearance below the filter to enable servicing operations 1.5m 37m 91m to be carried out easily. Filters must comply to OFTEC 2.0m 49m 100m 2.5m 62m 100m 3.0m 74m 100m A fire valve is an essential part of the oil supply system. It 3.4m 87m 100m must be supplied and fitted by the installing engineer and 4.0m 99m 100m is not part of the boiler’s components. Its purpose is to cut engineer and are not part of the boiler’s components. It should be possible to service them without the need for standard OFS E104. Fire valves off the flow of oil outside the building in the event of fire Table 1: Single pipe gravity feed system within the boiler area. The valve should be located on the Maximum allowable pipe run fuel line at the point of entry into the building. It must be Head 8mm inside dia. pipe (10mm OD copper) 10mm inside dia. pipe (12mm OD copper) activated by a remote sensor located over the burner. A clip 0m 50m 100m must comply with OFTEC standard OFS E101 and be rated -0.5m 44m 100m at 85°C or above to avoid nuisance tripping. -1.0m 38m 95m -1.5m 32m 80m -2.0m 26m 66m -2.5m 20m 50m -3.0m 14m 37m -3.5m 8m 22m is provided within the appliance for the sensor. Fire valves Table 2: Double pipe sub-gravity feed system 27 The NEW Greenstar System Filter NEW Available in 22mm and 28mm, the Worcester Greenstar System Filter has been specifically designed to combat the damaging effects of system debris and pollutants, allowing homeowners to protect their boiler or heat pump for a fraction of its cost. Inspired by installer feedback, the new filter has been designed to make installation and servicing simpler than ever before. In addition the performance has been improved resulting in a greater collection of debris from the system. Please note: CIBSE heating guide recommends, for a condensing boiler system, anything running continuously over 23kW is likely to require 28mm pipework and therefore a 28mm filter. However, this will be dependent on the system layout and pressure drop. NEW features and improvements Over-tightening prevention feature Isolation valve indicators The removable lid has been designed to prevent over- The isolation valves can be opened using a single 90º tightening and damage to the O-ring seal, eliminating the turn, with red and green indicators showing when the risk of leaks. filter is in operation. or Bi-directional flow Stronger magnet Engineered to allow a bi-directional flow, enabling it to be A larger powerful internal magnet safeguards the boiler and installed anywhere along the return circulation pipework wider system components. between the last radiator and the boiler. 28 28mm version now available Pipe cut template A larger version is now available for use in larger A cutting guide is supplied with the filter for use in heating systems. measuring exact lengths of pipe to cut at the point at which the filter is being installed. Easy to fit Easy to service Although the Greenstar System Filter shares its name with The Greenstar System Filter has been designed to make our high efficiency gas and oil-fired boilers, it can also be servicing and maintenance simple by using the special fitted to any typical domestic heating system. spanners supplied and a radiator bleed key. Installation The filter can be installed anywhere in a heating system, except between the boiler and on the feed and expansion pipes on an open vent system. To maximise the effectiveness it should be placed on the primary heating return before the boiler and after the last radiator. 6 6 2 1 4 7 3 M 5 3. Pump 7 4. Radiator 5 M OK Open vented system 2. Open vent tank 4 4 OK 1. Boiler 1 1 Sealed system* 5 OK 5. System filter 6. Cylinder Combi *When a system boiler has an internal diverter valve and two returns, the system filter should be put on the heating return and not the cylinder return. Product info Part numbers WARNING MAGNETIC FIELD. 7 733 600 236 (22mm) 7 733 600 237 (28mm) Powerful magnetic field Can be harmful to pacemaker wearers. 29 Condensate pipework Important points to consider when siting a condensate Condensate pump drainage pipe: Where “gravity discharge” to an internal termination is not • Where a new or replacement boiler is being installed, physically possible, or where very long internal runs would access to an internal “gravity discharge” point should be required to reach a suitable discharge point, condensate be one of the factors considered in determining should be removed using a proprietary condensate pump, boiler location of a specification recommended by the boiler or condensate • The condensate pipe must be a minimum of 22mm dia. pump manufacturer. plastic pipe • The condensate pipework must fall at least 52mm per The pump outlet pipe should discharge to a suitable metre towards the outlet and should take the shortest internal foul water discharge point such as an internal soil practicable route and vent stack, internal kitchen or bathroom waste pipe, • Ensure there are no blockages in the pipe run. washing machine waste pipe, etc. A suitable permanent connection to the foul waste pipe should be used. (see fig. 3 and 4) Internal connections In order to minimise risk of freezing during prolonged cold spells, the following methods of installing a condensate drainage pipe should be adopted, in order of priority. Wherever possible, the condensate drainage pipe should be Condensate discharge from boiler Universal connector Visible air break Sink or at plug hole basin with integrated 22mm dia. overflow routed and terminated so that the condensate drains away from the boiler under gravity to a suitable internal foul water 75mm min. discharge point such as an internal soil and vent stack. A suitable permanent connection to the foul waste pipe Condensate pump should be used. (see fig. 1) Condensate discharge from boiler Soil and vent stack 75mm sink waste trap Fig. 3 Condensate pump disposal (internal models) Universal connector Universal connector 22mm dia. Insulate & increase pipe size to 32mm 25mm min. Min. 450mm and up to three storeys 22mm dia. Condensate discharge from boiler Pipework transition Fig. 1 Disposal to soil vent stack (internal and external models). For external models increase pipe size and insulate pipework. Condensate pump Alternatively if the first option is not possible, an internal kitchen or bathroom waste pipe, washing machine waste Fig. 4 Condensate pump to external disposal (internal models) pipe, etc. can be used. (see fig. 2) Condensate discharge from boiler Visible air break at plug hole Universal 22mm dia. connector Sink or basin with integrated overflow For full technical information on pipe size, insulation 75mm min. and different condensate pipework methods, please 75mm sink waste trap see Installation, Commissioning and Servicing Instruction Manual. Fig. 2 Disposal to a waste pipe (internal models) 30 External connections Freezing conditions • Pipework length should be kept to a minimum and the Condensate discharge from boiler 22mm Pipework transition dia. 400mm min. route should be as vertical as possible 25mm min. • A CondenseSure auxiliary siphon may be used to reduce 500mm min. the risk of freezing • Where pipework is subjected to extreme cold or wind chill, a form of weather-proof insulation should be used. Condensate waste • Care should be taken when siting a soak away to avoid obstructing existing services. If no other discharge method is possible, then the use of 100mm dia. min. plastic pipe 100mm dia. Drainage holes 12mm dia. a suitable foul water discharge point, or purpose-designed Drainage holes 300mm Bottom of sealed tube UNSUITABLE FOR CLAY SOIL TYPES 25mm soak away, may be considered (see fig. 5). should be adopted: 100mm dia. min. plastic pipe Limestone chippings 25mm 25mm 50mm an externally-run condensate drainage pipe terminating at If this method is chosen, then the following measures Insulate & increase pipe size to 32mm Universal connector Fig. 5 Soak away (internal and external models). For external models increase pipe size and insulate pipework. • The external run should be kept as short as possible and not exceed 3m • A CondenseSure auxiliary siphon may be used to reduce the risk of freezing • The pipe should be run internally as far as possible Condensate discharge from boiler Universal connector before going externally and the pipe diameter should be Pipework transition increased to 32mm before it passes through the wall to the exterior. The pipe should be insulated using suitable Insulate & increase pipe size to 32mm waterproof and weather resistant insulation External air break • The external pipe should take the shortest and least exposed route to the discharge point, and should “fall” as steeply as possible away from the boiler, without External rain water pipe into foul water Air gap 22mm dia. horizontal runs in which condensate might stand • The use of fittings, elbows, etc., should be kept to a minimum and any internal “burrs” on cut pipework 43mm 90º male/female bend PVCu strap on fitting should be removed so that the internal pipe section is as smooth as possible. Fig. 6 Disposal into a rainwater down pipe (internal and external models). For external models increase pipe size and insulate pipework. Fitting an external air break • Refer to Fig 6. When a rainwater down pipe (which goes In addition to the condensate discharge options illustrated directly into a sewer that carries both rain water and on these pages and in the Installation, Commissioning and foul water) is used to dispose of condensate, an air Servicing Instruction Manual, the Worcester CondenseSure break must be installed. It should be fitted on the auxiliary siphon provides an innovative alternative for 43mm pipework, between the boiler condensate outlet the prevention of freezing for externally run discharge and the drainpipe. The installation should take place condensate (see pages 32-33 for details). outside the property to avoid flooding during adverse weather conditions. 31 The Worcester CondenseSure With climate change and extreme weather variations becoming increasingly common, and with very cold winters with temperatures as low as -20°C being experienced, practices such as externally run condensate discharge pipework are now being questioned. In these conditions the condensate pipe on a condensing oil-fired boiler can freeze. This can lead to a blocked condensate pipe, which will cause condensate to drain back into the boiler leading to corrosion of mild steel components and leakage of condensate. This can result in premature component failure, damage to property and burner failure. The CondenseSure auxiliary siphon has been designed to allow a more flexible approach to boiler siting. Tested to extreme temperatures The CondenseSure insulating jacket helps to retain the temperature of the condensate. The CondenseSure auxiliary siphon has been extensively tested under simulated extreme weather conditions, proving its effectiveness in preventing frozen condensate A universal fitting for new and existing installations at -15ºC for a sustained period of 48 hours. Although developed specifically for Worcester Greenstar gas- and oil-fired boilers, the Worcester CondenseSure CondenseSure principle of operation can also be fitted to any make of condensing boiler for Most oil-fired condensing boilers have a trap which both new and retrofit installations. The CondenseSure releases condensate as it is formed. A typical A-rated can provide a simple solution which eliminates the need condensing boiler will generate up to 2 litres of for re-siting both the new boiler and the system pipework condensate an hour (dependent on output and when replacing an existing non-condensing appliance. temperature) which is discharged as a continuous CondenseSure can easily be fitted to an existing trickle. With this frequency of discharge, the condensate condensing boiler to provide peace of mind in extreme pipework is never empty of condensate, consequently weather conditions. increasing the potential for freezing of the pipework in prolonged sub-zero temperatures. Features The CondenseSure siphon connects to the boiler No electrical supply needed condensate discharge outlet and collects the condensate Zero running costs and no wiring connection, so no into a larger volume before releasing it into the need for an electrician to install. discharge pipe. Compatible with all boilers Can be installed on new or existing installations and is With this expanded siphonic operation, the discharge from suitable for any gas- or oil-fired condensing boilers. the CondenseSure increases to every 15 to 20 minutes, Uses ‘free’ energy resulting in: By attaching the CondenseSure to the 22mm heating • Increased velocity and flow rate • Only 3 to 4 siphonic actions per hour, meaning the flow pipework the energy from the pipe is used to heat condensate pipework is empty for longer • Significantly decreased or even eliminated freezing potential. the condensate. Installation flexibility Can be installed under the boiler or remotely. No pipe insulation needed Cost-saving and aesthetically pleasing. 32 Ease of installation Fitting The CondenseSure has been designed for ease of installation and is suitable for most boiler applications. Although it can be clipped to a flow pipe under a wall hung boiler, on floor standing boilers the CondenseSure 4 can be wall-mounted away from the boiler, whilst still being connected to the condensate discharge pipe. 1 2 Condensate discharge from boiler Universal connector 3 External pipework 3000mm max. 2 2.5º fall min. CondenseSure 5 32mm OD pipe A typical installation using CondenseSure 1. Foam backing with double-sided tape CondenseSure installation parameters 2. Siphon mounting screws The CondenseSure will protect an externally run condensate 3. Siphon body discharge pipe from freezing for 48 hours at -15°C providing 4. Foam insert the following installation parameters are met: 5. Foam cover • • There is a fall on the discharge pipe of at least 2.5 degrees • The discharge pipe diameter is not less than 32mm The externally run pipe length does not exceed 3 metres in diameter. Whilst it is not necessary to insulate the pipework, it may be a consideration if longer lengths or lower external temperatures are expected. Additional installation considerations include: • • • • Keeping any external pipework as short as possible Minimising the number of bends and connections Removal of burrs after cutting any pipe Removal of surplus solvent from the interior of the pipe. There is no Part P requirement as the CondenseSure has no working parts to break down, does not use any energy and has no electrical connections. Product info Part number 7 716 192 746 33 Horizontal and vertical flue terminal positioning All measurements in millimetres P Q O Q Q M boundary R Pitched roof C,D F J A B H E G boundary Note • 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. • 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 access, the terminal should be protected by a guard. • Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire retardant material and close wire in the vicinity of the flue. 34 • It is essential that a flue or chimney does not pass • through the roof within the shaded area delineated by dimensions Q and R. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the manufacturer of the plastic components. N Q Q Q Q Flat roof F Terminal position Conventional flue Horizontal room sealed flue Vertical room sealed flue Directly below an opening, A 1) 2) air brick, opening window etc. Not allowed 600mm Not allowed B 1) 2) Horizontally to an opening, air brick, opening window, etc. Not allowed 600mm Not allowed C Below a plastic/painted gutter, drainage pipe or eaves if combustible material is protected Not allowed 75mm Not allowed D 3) Below a plastic/painted gutter, drainage pipe or eaves without protection to combustible material Not allowed 600mm Not allowed E From vertical sanitary pipework Not allowed 300mm Not allowed F From an external or internal corner or from a surface or boundary alongside a terminal Not allowed 300mm Not allowed G Above ground or balcony level Not allowed 300mm* Not allowed H From a surface or boundary facing a terminal Not allowed 600mm** Not allowed J From a terminal facing a terminal – 1,200mm** – K Vertically from terminal on the same wall Not allowed 1,500mm Not allowed L Horizontally from a terminal on the same wall – 750mm – M Above the point of highest intersection with the roof 600mm – 600mm N From a vertical structure on the side of the terminal 750mm – 750mm O Above a vertical structure less than 750mm from the side of a terminal 600mm – 600mm P From a ridge terminal to a vertical structure on the roof 1,500mm – Not allowed Q Above or the side of any opening on a flat or sloping roof 300mm – 300mm R Below any opening on a sloping roof 1,000mm – 1,000mm K F L Key to illustration *Minimum distance of the flue terminal from above ground is 2,100mm where directed to a public footpath, private access route or a frequently used area and 2,500mm from a car parking area. **Recommended minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2,500mm. 1) Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or entering into buildings. 2) Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc. 3) Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 minutes fire resistance and extending 300mm higher and wider than the tank is provided between the tank and the terminating position. 35 Greenstar Heatslave II combi boiler range horizontal fluing options (internal models) The Greenstar Heatslave II combi boiler range has a 125mm Greenstar Heatslave II components diameter telescopic horizontal room sealed flue system Part No. including a plume management kit. Description 125mm diameter Horizontal room sealed flue – rear exit flue lengths Flue diameter 125mm Greenstar Heatslave II series Standard telescopic flue kit (460 - 670mm) 7 716 190 062 Short telescopic flue kit (350 - 460mm) 7 716 190 033 1,000mm flue extension Minimum flue length Maximum flue length 7 716 190 064 160mm 7 716 190 097 600mm short flue extension Rear exit 6,000mm 7 716 190 034 90º bend Side exit 5,000mm* 7 716 190 035 45º bends (pair) High level 5,000mm** 7 716 190 101 Flue damper *Length includes 90°bend inside cabinet. **Length includes 2x90° bends, one within the cabinet and one before the telescopic flue kit. 7 716 190 050 Flue terminal guard 7 716 190 105 Infill plate kit for high level horizontal flues Note: The maximum flue length must be reduced by the following amounts for each additional bend used. 80/125mm flues The following criteria should be noted when planning 45º bend 90º bend the installation: 500mm 1,000mm • The concentric flue system must be inclined at 3º (52mm per metre) from the appliance, to allow condensate to drain back into the boiler • A white plume of condensation will be emitted from the terminal because the appliance operates at high efficiency. Care must be taken when selecting the flue terminal position • To achieve a maximum flue length, one of the extension flue kits will need to be cut so that the permitted maximum flue length is not exceeded • Note: The short flue extension (600mm) may be used as an alternative to the standard 1,000mm extension on 80/125mm flue installations as required up to the maximum flue lengths stated (Part No. 7 716 190 097). 36 Horizontal flue options 1-5 illustrate common flue installations. Other configurations of the flue system are possible up to, and not exceeding, the stated maximum flue lengths. Option 1: Standard rear flue assembly Option 4: Side flue extension Components Components Part No. 125mm Part No. 125mm 7 716 190 064 7 716 190 064 7 716 190 033 7 716 190 034 Minimum length (mm) & no. of components required Maximum lengths (mm) & no. of components required Greenstar Heatslave II series Greenstar Heatslave II series 125mm 460 1 125mm 5,000 1 up to 5 1 Maximum flue length includes 90°bend inside cabinet. Option 2: Extended rear flue assembly using a 90º bend Option 5: High level horizontal discharge Components Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034 Maximum lengths (mm) & no. of components required Components Greenstar Heatslave II series 125mm 5,000 1 up to 5 1 Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034 Maximum lengths (mm) & no. of components required Option 3: Extended rear flue assembly using two 45º bends Greenstar Heatslave II series 125mm 5,000 1 up to 5 2 Maximum flue length includes 2x90° bends, one within the cabinet and one before the telescopic flue kit. Components Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 035 Maximum lengths (mm) & no. of components required Greenstar Heatslave II series 125mm 5,000 1 up to 5 1 Note: The maximum flue length must be reduced by the following amounts for each additional bend used. 80/125mm flues 45º bend 90º bend 500mm 1,000mm 37 Greenstar Heatslave II combi boiler range vertical fluing options (internal models) The Greenstar Heatslave II combi boiler range has a 125mm Greenstar Heatslave II components diameter vertical room sealed flue system. Part No. Description 125mm diameter Vertical room sealed flue Flue diameter 125mm Greenstar Heatslave II series 7 716 190 103 Vertical flue kit 7 716 190 033 1,000mm flue extension (960mm) Minimum flue length 1,080mm 7 716 190 097 600mm short flue extension Maximum flue length 8,000mm 7 716 190 034 90º bend 7 716 190 035 45º bends (pair) Note: The maximum flue length must be reduced by the following amounts for each additional bend used. A flue damper is required for effective flue lengths greater than 6m. 80/125mm flues 7 716 190 101 Flue damper 7 716 190 105 Infill plate kit for high level horizontal flues 7 716 191 090 Flashing – flat roof 45º bend 90º bend 500mm 1,000mm 7 716 191 091 Flashing – pitched roof The following criteria should be noted when planning the installation: • To achieve a maximum flue length, one of the extension flue kits will need to be cut so that the permitted maximum flue length is not exceeded • The concentric flue system must be inclined at 3º (52mm per metre) from the appliance, to allow condensate to drain back into the boiler • Because the appliance operates at high efficiency, a white plume of condensation will be emitted from the terminal. Care must be taken when selecting the flue terminal position • Note: The short flue extension (600mm) may be used as an alternative to the standard 1,000mm extension on 80/125mm flue installations as required up to the maximum flue lengths stated (Part No. 7 716 190 097). 38 Vertical flue options 1-4 illustrate common flue installations. Other configurations of the flue system are possible up to, and not exceeding, the stated maximum flue lengths. Option 1: Vertical balanced flue system minimum height Components Option 3: Vertical balanced flue system with two 90º bends Components Part No. 125mm Part No. 125mm 7 716 190 103 7 716 190 103 7 716 190 033 7 716 190 034 Minimum lengths (mm) & no. of components required Maximum lengths (mm) & no. of components required Greenstar Heatslave II series Greenstar Heatslave II series 125mm 1,080 1 125mm Option 2: Vertical balanced flue system maximum height Components Part No. 125mm 6,000 1 up to 5 2 Option 4: Vertical balanced flue system side discharge Components 7 716 190 103 7 716 190 033 Part No. 125mm 7 716 190 103 7 716 190 033 7 716 190 034 Maximum lengths (mm) & no. of components required Maximum lengths (mm) & no. of components required Greenstar Heatslave II series Greenstar Heatslave II series 125mm 8,000 1 up to 7 125mm 6,000 1 up to 5 2 Note: The maximum flue length must be reduced by the following amounts for each additional bend used. A flue damper is required for effective flue lengths greater than 6m. 80/125mm flues 45º bend 90º bend 500mm 1,000mm 39 Greenstar Heatslave II External combi boiler range fluing options Low-level rear Greenstar Heatslave II External boilers include a low level Top view balanced flue kit. 175mm 240mm Greenstar Heatslave II External components Components Part No. Description 7 716 190 034 90º bend (internal) required for fluing to left or right 125mm diameter TOP VIEW 7 716 190 050 Flue terminal guard FRONT Components Part No. 125mm – 7 716 190 050 Maximum lengths (mm) & no. of components required Greenstar Heatslave II External series 125mm – Included Low-level right 1 Low-level left Top view Top view 175mm 175mm TOP VIEW FRONT FRONT Components Part No. 125mm TOP VIEW 240mm 240mm Components – 7 716 190 034 7 716 190 050 Part No. 125mm – 7 716 190 034 7 716 190 050 Maximum lengths (mm) & no. of components required Maximum lengths (mm) & no. of components required Greenstar Heatslave II External series Greenstar Heatslave II External series 125mm – Included 1 N.B. For left and right hand flue termination, a 90º bend is required. 40 1 125mm – Included 1 N.B. For left and right hand flue termination, a 90º bend is required. 1 Plume management terminal positioning All measurements in millimetres ±45° Flue exhaust outlet 2,500 Air intake 6 7 600 300 2 Balcony 150 600 200 100 1 Boundary 300 150 3 300 Window 25 600 Window 600 Window Door 150 4 200 150 5 Drainpipe Note Key to illustration • • Terminals must be positioned so as to avoid combustion 1. 600 mm distance to a boundary, unless it will cause All measurements are the minimum clearances required products entering the building • Support the flue at approximately one metre intervals a nuisance. BS 5410: Part 1 recommends that care is taken when siting terminals in relation to boundaries. 2. Internal/external corners the air intake can be reduced and at a change of direction. Use suitable brackets to 150mm providing the flue exhaust outlet has a and fittings. 300mm clearance. 3. Vertical sanitary pipe: 25mm to the flue air intake and 300mm to the flue exhaust outlet. 4. Clearance no less than 200mm from the lowest point of the balcony or overhang, installations in car ports are not recommended. 5. 1,200mm from an opening in a car port on the same wall i.e. door or window leading into dwelling. 600mm to a surface facing a terminal. 6. Using a plume management kit, the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 600mm clearance. Plume kits running horizontally must have a 10º fall back to the boiler for proper disposal of condensate. For details on specific lengths see relevant boiler Technical & Specification manual. 7. 2,500mm between air intake and facing terminal. 41 Plume management system options Greenstar Heatslave II (internal) series At least 1,500mm from any opening in the building V 45° Condensfit II™ plume management system components ™ Part No. Opening in the building i.e. air brick, window. Direction of flue products, the angle of the terminal bend must be more than 45° from the wall or structure Description 80mm diameter Plume terminal 7 716 190 092 Plume management kit 7 716 190 093 1,000mm extension 7 716 190 095 90º bend 7 716 190 094 45º bend (pair) Re-directing flue discharge from an 80mm dia. plume management outlet Standard plume management system The flue terminal outlet has built-in stops to limit rotation Plume management system measuring for horizontal fluing to allow condensate to run back into Note: All boilers have a maximum permissible the boiler for safe disposal. Do not attempt to force beyond plume management length – see table below. the limit stops. The first section of plume management flue up to the first elbow must rise by at least 173mm per metre (10º) from 500mm (min) (M) L (max) the terminal; subsequent sections must rise by 52mm per metre (3º). 0 50 5,000mm (max) (M) mm L (max) 50 0m mm 500 m ±80° Flue length (L) Max. number of bends Plume length (M) Max. number of bends Greenstar Heatslave II 12/18 & 18/25 160 - 2,000mm 2 500 - 5,000mm 2 500 - 4,000mm 2 Greenstar Heatslave II 25/32 160 - 2,000mm Terminal exclusion zone 2 Additional bends Adding bends to the plume management system reduces the actual plume management length. Each bend has an equivalent straight length and must be factored into the overall effective length. • 90° bend is equivalent to 1,000mm • 45° bend is equivalent to 500mm. 42 Plume management system with extensions Plume management system with extensions and two 45º bends Components Part No. 80mm 7 716 190 092 7 716 190 093 Maximum lengths (mm) & no. of components required Greenstar Heatslave II 12/18 & 18/25 80mm 5,000 1 5 1 4 Greenstar Heatslave II 25/32 80mm Components Part No. 80mm 7 716 190 092 7 716 190 093 7 716 190 094* Greenstar Heatslave II External series Maximum lengths (mm) & no. of components required Greenstar Heatslave II 12/18 & 18/25 80mm 4,000 1 4 1 Plume management on Greenstar Heatslave II 25/32 80mm 3,000 4,000 1 3 1 *Pack contains a pair of 45º bends Greenstar Heatslave II External boilers The plume management kit can be used on the Greenstar Heatslave II External models in conjunction Plume management system with extensions and 45º bend with the external low level horizontal flue kit. ±45° M Components Part No. 80mm Min. 150mm 7 716 190 092 7 716 190 093 7 716 190 094* Maximum lengths (mm) & no. of components required Greenstar Heatslave II 12/18 & 18/25 80mm 4,500 1 4 1 3 1 Greenstar Heatslave II 25/32 80mm 3,500 1 *Pack contains a pair of 45º bends Note: The plume management length must be reduced by the following amounts for each additional bend. Greenstar Heatslave II & Heatslave II External series 45º bend 90º bend 500mm 1,000mm Plume length (M) Maximum number of bends Greenstar Heatslave II External 12/18 & 18/25 500 - 5,000mm 2 Greenstar Heatslave II External 25/32 500 - 4,000mm 2 43 Conventional flue Open (conventional) flued appliances must not be installed To convert the appliance to a conventional flue system the in a bedroom, bathroom or bedsitting room. vertical flue adaptor needs to be specified: • The flue system must be in accordance with BS 5410 and Part No. the current Building Regulations. 7 716 190 104 • The flue must be constructed of materials suitable for use with condensing combustion products. • External flue systems must be of the insulated type. • Brick and masonry chimneys must be lined with a suitable non-combustible material and properly jointed Description Conventional flue 80/100mm and 100/103mm adaptor kit 7 716 190 065 130mm adaptor The flue must be constructed of materials suitable for the use of condensing combustion products. to withstand the effects of the working temperature (minimum rating of material 120°C) of the appliance and D any condensate which may form. E • All flue joints must be sealed to prevent the leakage of condensate and combustion products. • Ensure that joints are made so that the condensate runs away and is not collected within the joint. NOTE: The flue can be increased in size from the boiler take off point providing the joint is correctly sealed. Never reduce the flue diameter from the boiler take-off point. Conventional flue sizing Output Worcester flexi-flue diameter 3rd party flue diameter 12/18 100/103mm 100/103mm 18/25 100/103mm 100/103mm 25/32 100/103mm 130mm • Because the flue operates at a lower temperature on a C condensing boiler compared to that of a conventional appliance, the flue draught will be lower. Typically B the draught will be between 0.5mmwg and 4.4mmwg, measured with the flue warm but the burner not firing. A The actual figure will vary depending on weather conditions, flue height and position. • The flue should be vertical and contain as few bends as possible. A maximum of two 135° bends should be used. • The flue outlet must be extended beyond the eaves of the building and, where possible, above the apex. • Fit a suitable anti down-draught terminal where down draughts are experienced. 44 A Boiler D Anti down-draught terminal B Flue E Chimney C Maximum 2 bends at 135º Oilfit flexible flue liner Greenstar Heatslave II flexible flue liner components Part No. The Oilfit flexible flue liner allows installation into a position where a standard efficiency appliance had previously Description 100mm diameter been installed. It achieves this by enabling a Greenstar 7 716 190 076 Oilfit flexible flue liner kit (8m) condensing boiler to be open-flued up a chimney. The 7 716 190 077 Oilfit flexible flue liner kit (12m) continuous flexible flue is installed from the roof, providing 7 716 190 078 Oilfit flexible flue liner kit (15m) a condensate-proof lining for the chimney. 7 716 190 066 1,000mm extension kit* 7 716 190 067 500mm extension kit* A roof terminal, extension pieces and a flue adaptor are all 7 716 190 068 Telescopic extension* included within the kit. 7 716 190 069 45º bend* Conventional flexible flue liner kit 7 716 190 104 100mm dia. Oilfit flexible flue liner kit Conventional flue 80/100mm and 100/103mm adaptor kit 7 716 190 074 Wall cover plate kit 1 x chimney cowl 1 x terminal 1 x support collar 1 x support bracket assembly Model Flue diameter Maximum flue length Greenstar Heatslave II series 1 x centralising spacer 12/18 100mm 12,000mm 1 x flexible to rigid adaptor kit (includes liner & seal) 18/25 100mm 12,000mm 1 x flexible liner 25/32 100mm 12,000mm 1 x rigid to flexible adaptor kit (includes liner & seal) Part No. 7 716 190 076 (8m) Part No. 7 716 190 077 (12m) 45 Typical installations G Open (conventional) flued appliances must not be installed in a bedroom, bathroom or bed-sitting room. Before installation commences it must be checked that: • The chimney is structurally sound and free of obstructions • The chimney has been thoroughly swept to remove deposits since it was last used. The flexible flue pipe is only suitable for lining chimneys F E that conform to the Building Regulations and it should not L max be used as a chimney on its own or outside a masonry or flueblock chimney. All the flexible liner and adaptors must be within the chimney with rigid stainless steel flue pipe connecting to the boiler. D The first 600mm of the stainless steel flue pipe off the C boiler must be vertical with no bends or restrictions. ** B There must be at least a 25mm clearance between the stainless steel flue pipe and any combustible material. A The data label must be secured onto the chimney or chimney hearth using the plate provided. A Boiler D Fire stop plate/inspection plate E Centralising spacer If it is not possible to attach the plate to the chimney, B Stainless steel vertical section (min. 600mm) the plate can be attached, in a visible position, next to C Maximum 2 bends at 45° G Chimney cowl F Flexible liner the electricity consumer unit. Calculating the length: Do not attach the data plate or label to the flue system. L maximum = boiler maximum minus 1m*. (Each 45º bend has a 0.5m equivalent flue length) The terminal should not be modified and an extra cowl or cover must not be fitted. The boiler is designed so that any rain that enters the flue will be directed down to the condensate drain. 46 *If the chimney has an additional offset, then L will be reduced by an extra metre. **The top 45º bend may not be required if there is sufficient room in the chimney to turn the flexible liner through 45º within the chimney. The stainless steel section must be adequately supported. Greenstar Heatslave II accessories Comfort plug-in twin channel programmer Comfort I RF wireless room thermostat and plug-in twin channel programmer Comfort II RF wireless programmable room thermostat and plug-in RF receiver Sense I intelligent room thermostat^ Worcester Part No. 7 733 600 003 Worcester Part No. 7 733 600 001 Worcester Part No. 7 733 600 002 Worcester Part No. 7 738 110 054 Outdoor weather sensor Comfort wall mounting plate CondenseSure auxiliary siphon Greenstar System Filter (22mm) Worcester Part No. 7 716 192 764 Worcester Part No. 7 733 600 039 Worcester Part No. 7 716 192 746 Worcester Part No. 7 733 600 236 Greenstar System Filter (28mm) Worcester Part No. 7 733 600 237 Greenstar Oilfit internal flue system Greenstar Heatslave II Internal series Standard telescopic flue kit (125mm dia.) Short telescopic flue kit (125mm dia.) Vertical flue kit (125mm dia.) 1,000mm flue extension (125mm dia.) Worcester Part No. 7 716 190 064 Worcester Part No. 7 716 190 062 Worcester Part No. 7 716 190 103 Worcester Part No. 7 716 190 033 ^For use with external proprietary 230V programmer. 47 Greenstar Oilfit internal flue system – continued Greenstar Heatslave II Internal series 600mm flue extension (125mm dia.) 45º bend (pair) (125mm dia.) 90º bend (125mm dia.) Conventional flue 80/100mm & 100/103mm adaptor kit Worcester Part No. 7 716 190 097 Worcester Part No. 7 716 190 035 Worcester Part No. 7 716 190 034 Worcester Part No. 7 716 190 104 Infill plate kit for high level horizontal flues Flat roof flashing kit (100mm & 125mm dia.) Pitched roof flashing kit (100mm & 125mm dia.) Stainless steel flue terminal guard Worcester Part No. 7 716 190 105 Worcester Part No. 7 716 191 090 Worcester Part No. 7 716 191 091 Worcester Part No. 7 716 190 050 Conventional flue 130mm adaptor Worcester Part No. 7 716 190 065 48 Greenstar Oilfit flexible flue kit accessories Greenstar Heatslave II Internal series Oilfit flexible flue kit (100mm dia.) Stainless steel 1,000mm extension kit (100mm dia.) Stainless steel 500mm extension kit (100mm dia.) Stainless steel telescopic extension (100mm dia.) Worcester Part No. 7 716 190 076 (8m) 7 716 190 077 (12m) Worcester Part No. 7 716 190 066 Worcester Part No. 7 716 190 067 Worcester Part No. 7 716 190 068 Stainless steel 45º bend (100mm dia.) Wall cover plate kit (100mm dia.) Worcester Part No. 7 716 190 069 Worcester Part No. 7 716 190 074 Greenstar Oilfit low level external flue system Greenstar Heatslave II External series Low level horizontal flue kit (125mm dia.) 90º bend* (125mm dia.) Stainless steel flue terminal guard Included in boiler Worcester Part No. 7 716 190 034 Worcester Part No. 7 716 190 050 Plume management accessories Greenstar Heatslave II Internal & Heatslave II External series Plume management kit (80mm dia.) 1,000mm extension (80mm dia.) 45º bend (80mm dia.) 90º bend (80mm dia.) Worcester Part No. 7 716 190 092 Worcester Part No. 7 716 190 093 Worcester Part No. 7 716 190 094 Worcester Part No. 7 716 190 095 *Used inside boiler when fluing to the side 49 Total training experience from Land’s End to John O’Groats Worcester has always been committed to setting the College-linked Learning industry standard for expert professional training and As well as offering training at our own centres, Worcester this is reflected in the scope and content of the courses, has established close partnerships with many colleges venues and options available. around the UK, equipping them with our latest products. We offer training on our entire range of domestic and Worcester has worked closely with leading colleges and commercial heating technologies as well as industry-led independent training centres for more than 20 years – a courses. All tuition is handled by expert heating specialists, successful enterprise which in 2007 was enhanced further combining classroom theory with, practical hands-on with the launch of the College Links Learning Scheme. experience. Keep up-to-date with legislation and experience hands-on-training with our new technologies. Mobile training We can also bring training to you. We have mobile vehicles To increase your skills, expertise and value in the fully equipped with operational Greenstar gas-fired boilers, market place, trust Worcester’s unique and proven dry strip-down models and even a Greensource air to air total training concept. heat pump. Our 7.5 tonne mobile oil vehicle is also available for hands-on oil product training and OFTEC assessments. Training centres throughout the UK Worcester Call now for more information 0330 123 0166. Worcester’s award-winning, state-of-the-art Training Academy is an innovative and spacious high tech training arena at our headquarters in Worcester. Facilities include open-plan domestic training areas with life-size single- Training centres T storey brick buildings. Here installers can get to grips with College links training centres Greenskies solar thermal systems working with Greenstar gas appliances, clearly demonstrating the importance of system design and operation. Elgin Wakefield Opened in Summer 2013, the Wakefield Training and Dundee Assessment Academy boasts a large gas laboratory which Fife features our entire range of Greenstar gas-fired appliances, Johnstone a flushing area, wet and dry boilers and a light commercial Borders Ayr area with a cascade of Worcester GB162 boilers. There is a Durham solar room with fully working components from our entire Greenskies solar range and a pitched roof for practical Workington Belfast training, as well as a large commercial training room. Burnley West Thurrock and Clay Cross Wakefield W Dublin Clay Cross Further academies are located at West Thurrock in Wrexham Essex and Clay Cross in Derbyshire, both of which offer Worcester a comprehensive choice of courses. Tredegar West Thurrock Wiltshire Camborne 50 Cambridge Paignton Oil-fired product courses Worcester’s oil manufacturing heritage stretches back to OFTEC establishes the standards for competence within the foundation of the company in 1962. Since then, we the domestic oil heating. OFTEC registered installers have built a strong reputation for not only manufacturing are able to self-certify their work under the building products at the highest levels of quality and reliability, regulations. Worcester offer OFTEC training with a but also for training installers, commissioning engineers variety of courses to choose from. and operatives. Oil-fired condensing boiler course Our oil-fired boiler training courses are extensive, Greenstar Danesmoor & Heatslave II high efficiency covering areas such as dismantling a jet burner, setting condensing oil-fired boilers. oil pump pressures, maintaining a condensate trap, Oil advanced fault finding. the relationship between air and oil supplies, as well as the detection of intermittent faults. Our oil advanced OFTEC training and assessment courses fault-finding course, running exclusively at Claycross, OFTEC 50. has been designed for installers and heating engineers OFTEC 101/105e, OFTEC 600a and OFTEC 101/105e/600a. who are already knowledgeable on our range of oil-fired products. Our expert trainers will further increase your experience, whilst also providing a strong understanding of fault-finding techniques. Oil-fired Course Oil Advanced Fault Finding OFTEC 50 OFTEC 101/105e OFTEC 600a OFTEC 101/ 105e/600a Duration 1 Day 1 Day 5 Days 4 Days 1 Day 4 Days Cost Free* Free* £200 £350 £175 £500 D D D D D U U A preparatory course for OFTEC assessment courses. (Price of course includes all necessary OFTEC text books). Domestic/light commercial pressure jet commissioning, servicing and boiler installation Oil tank installation and associated controls Combined OFTEC 101, 105e and 600a courses D D D D D D D D D D D D D D D D D D D D D D D D Training course covers Specification Installation Commissioning Servicing Maintenance D D D Course locations Worcester Clay Cross Wakefield West Thurrock College Links† Mobile† D D D D D D U D U U U U *A holding fee of £65 applies to free courses and is refunded on attendance of the course. If a booking is cancelled more than 10 working days before the course date, the fee will be fully refunded. The fee is non-refundable if a cancellation is made less than 10 working days before the course date. †Please contact Worcester Training for specific colleges and mobile dates. Any customers who book onto an OFTEC 50 course with Worcester are entitled to a £150 discount on their subsequent OFTEC 101/105e or 101/105e/600a course. To complement the above courses, Worcester also runs unvented, water treatment, Domestic ACS training and assessment, IDHEE domestic heating design, MCS Made Easy and Green Deal courses. Please note: to attend OFTEC courses you must have a minimum of 12 months’ experience installing/servicing oil boilers or have attended an OFTEC 50 course. For candidates with limited oil experience, our Greenstar one day oil-fired course offers pre-OFTEC training. Consult with the trainer at the end of the session to see if you are ready to undertake OFTEC assessment. For experienced oil technicians, training is not a pre-requisite for OFTEC assessment. 51 Additional product and industry training courses The diversity of products in today’s heating industry gives you the opportunity to expand your expertise, whilst offering more choice to your customers. Worcester provides comprehensive training from all its academies on its entire range of technologies. Call us on 0330 123 0166 to order a full course training brochure or to book yourself onto a training course, alternatively, you can visit www.worcester-bosch.co.uk/training Gas-fired condensing boiler courses Worcester commercial product courses • Greenstar CDi Classic gas-fired condensing • Greenspring CWi47 water heater. • GB162 overview. • GB162 domestic. • GB162 commercial. • Greenstar Heat Distribution Unit. • Commercial ACS training and assessment – CODNCO1. combi boilers. • Greenstar CDi Compact and Greenstar Si Compact gas-fired condensing combi boilers. • Greenstar i gas-fired condensing combi boilers. • Greenstar system & regular gas-fired condensing boilers. • Greenstar Highflow CDi & FS CDi Regular floor standing gas-fired condensing combi and regular boilers. • Greenstar Controls (covers MT10, MT10RF, Greenstar Comfort range, Wave internet connected room thermostat, NEW Greenstar Sense range and solar controls). Bosch commercial product courses • GB312 & GB402 overview. • Solar thermal product overview. • GWPL Gas Absorption Heat Pumps overview. • CHP overview. • Commercial controls overview. Renewable product courses • Renewables overview. • Greenskies solar. • Greenskies advanced solar. • Introduction to heat pumps. • Greenstore ground source heat pumps. • Greensource air to air heat pumps. Industry focused courses • Hot water systems & safety. • Chemical water treatment. • Construction skills F-Gas training/assessment certification. • IDHEE domestic heating design. • Domestic ACS training and assessment – reassessment. CCN1 + 3 appliances. • QCF Level 3 Award – Air source and ground source heat pumps. – Air to water and split air to water heat pumps. – Solar thermal. • MCS Made Easy. • LPG Changeover. • WRAS Water Regulations. 52 A complete after-sales service As part of the worldwide Bosch Group, Worcester strives to Spares maintain the highest possible standards of after-sales care. Genuine replacement parts for all supported Worcester products are readily available from stock, or on a next day Worcester Contact Centre delivery basis. Visit www.worcester-bosch.co.uk/spares Should you require support, our award winning Contact to find your local stockist. Centre team, based at our head office in Worcester, are ready to take your calls. Whatever your query our contact Customer Technical Support centre operators along with our nationwide team of The Worcester Technical Helpline is a dedicated phone engineers are ready to help you. line – committed to providing a comprehensive service to complement the brand name and quality of our products. Tel: 0330 123 9559 Our experienced team of technical experts provides answers to queries of a technical nature across the entire Opening times Worcester range. Monday – Friday: 7.00am – 8.00pm Saturday: 8.00am – 5.00pm Technical Support Sunday: 9.00am – 12 noon Tel: 0330 123 3366 Bank Holidays: 8.00am – 4.30pm Fax: 01905 752 741 Email: firstname.lastname@example.org Opening times Monday – Friday: 7.00am – 8.00pm Saturday: 8.30am – 4.00pm Bank Holidays: 8.00am – 4.30pm ErP Technical Helpline Tel: 0330 123 3641 Email: ErPemail@example.com 53 Notes 54 Notes 55 Useful numbers Customer Service Sales Service Enquiries Tel: 0330 123 9669 Email: firstname.lastname@example.org email@example.com or telephone 0330 123 9559 Spare Parts Guarantee Registration Tel: 0330 123 9779 To register your Worcester firstname.lastname@example.org guarantee, please visit our website worcester-bosch.co.uk/guarantee, Technical Helpline (Pre & Post Sales) download our guarantee Tel: 0330 123 3366 registration app or email@example.com Guarantee app telephone 0330 123 2552 ErP Technical Helpline Share Tel: 0330 123 3641 ErPfirstname.lastname@example.org We would love to see your installations. Training Tel: 0330 123 0166 Follow us on: email@example.com Tag your installations with: #WarmAtHeart Literature We are also on: @WorcesterBosch Email: firstname.lastname@example.org or download instantly from our website or telephone 0330 123 9119 Calls to and from Bosch Thermotechnology Ltd may be recorded for training and quality assurance purposes. worcester-bosch.co.uk In partnership with FD TE O OMEST I ITU D H E 1964 E S ER I TAL ENG INE MEN ON NG & EN EATI VIR CH INS T 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. Apple is a trademark of Apple Inc., registered in the U.S. and other countries. App Store is a service mark of Apple Inc. Google Play and Android are trademarks of Google Inc. 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