Bosch Worcester Greenstar Oilfit External User manual

EXTERNAL FLUE KIT INSTALLATION INSTRUCTIONS
LOW LEVEL HORIZONTAL BALANCED FLUE
GREENSTAR OILFIT FLUE EXTERNAL
6720807912
-00.2Wo
THIS MANUAL COVERS FLUE INSTALLATION FOR THE CAMRAY, DANESMOOR (2013) AND
BOTH VERSIONS OF HEATSLAVE BOILERS (HEATSLAVE AND HEATSLAVE II)
6 720 807 912 (2015/10)

CONTENTS
6 720 807 912 (2015/10)2
CONTENTS
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Balanced low level discharge flue components . . . . . . . . 4
3 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Balanced Low Level Discharge Flue options . . . . . . . . . . 4
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Balanced Low level Discharge Flue . . . . . . . . . . . . . . . . . 5
4.1.1 Flue Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Rear flue options - all models . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Side flue option:
Danesmoor (2013) and Heatslave II . . . . . . . . . . . . . . . . 6
4.4 Side flue option: Camray and Heatslave . . . . . . . . . . . . . 7
4.5 All flue options, final assembly . . . . . . . . . . . . . . . . . . . . . 8
4.6 Terminal guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heatslave and Heatslave II:
For Heatslave side flue option refer to
section 4.4 on page 7
For Heatslave II side flue option refer to
section 4.3 on page 6

KEY TO SYMBOLS AND SAFETY INSTRUCTIONS
6 720 807 912 (2015/10) 3
1 KEY TO SYMBOLS AND SAFETY
INSTRUCTIONS
1.1 KEY TO SYMBOLS
WARNINGS
Keywords indicate the seriousness of the hazard in terms of the
consequences of not following the safety instructions.
•NOTICE indicates that material damage may occur.
•CAUTION indicates that minor to medium injury may occur.
•WARNING indicates that serious injury may occur.
•DANGER indicates possible risk to life.
IMPORTANT INFORMATION
ADDITIONAL SYMBOLS
ABBREVIATIONS
1.2 SAFETY PRECAUTIONS
IN THE EVENT OF ANY OIL SMELLS, LEAKS OR FUMES FROM THE
APPLIANCE:
▶PUTOUTNAKEDFLAMES
▶ ISOLATE THE ELECTRICAL SUPPLY
▶ ISOLATE THE FUEL SUPPLY AT THE BOILER
▶ RECTIFY THE FAULT
BOILER OPERATION:
This boiler must only be operated by a responsible adult who has
been instructed in, understands, and is aware of the boiler‘s
operating conditions and effects.
HEALTH AND SAFETY
The appliance contains no asbestos and no substances have been used
in the construction process that contravene the COSHH Regulations
(Control of Substances Hazardous to Health Regulations 1988).
COMBUSTION AND CORROSIVE MATERIALS
Do not store or use any combustible materials (paper, thinners, paints
etc.) inside or within the vicinity of the appliance.
The combustion air must be free from chemically aggressive substances
which can corrode the appliance and invalidate any warranty.
FITTING AND MODIFICATIONS
Fitting the appliance and any controls to the appliance may only be
carried out by a competent engineer in accordance with these
instructions and the relevant Installation Regulations.
Flue systems must not be modified in any way other than as described in
the fitting instructions. Any misuse or unauthorised modifications to the
appliance, flue or associated components and systems could invalidate
the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
IMPORTANT
The service engineer must complete the Service Record at the back of
the Installation, Commissioning, and Serving instructions after each
service.
SERVICING:
Advise the user to have the system regularly serviced by a competent,
qualified engineer (such as OFTEC registered personnel) using
approved spares, to help maintain the economy, safety and reliability of
the appliance.
INSTALLATION REGULATIONS
Failure to install appliances correctly could lead to prosecution.
COMPLYING WITH THE BUILDING REGULATIONS:
The boiler and flue form part of the controlled services for the building.
It is law that all controlled services for buildings must comply with
building regulations. You must be able to satisfy your Local Authority
Building Control Body (LABC) that the work carried out concerning the
installation and commissioning of the heating appliances has been
carried out to a satisfactory standard.
OFTEC operate a competent persons scheme and registered installers
are able to certify that their work complies with building regulations.
Under the scheme:
• OFTEC must be informed about every installation.
• OFTEC will issue a building regulations compliance certificate to the
householder and will notify LABC.
OFTEC provide controlled document forms CD10 and CD11 for use
during installation and commissioning respectively.
Other organisations operate self-certification schemes e.g. NAPIT and
BESCA Ltd. and it may be possible for installers who are members of
these organisations to self certify their work.
Alternatively you must submit a building control notice to the LABC
before installing any boiler.
The LABC will then arrange regular inspection visits during the work to
ensure that the installation complies with the regulations.
The appliance must be installed by a competent person. The person
installing the appliance should be aware of the Healthand Safety at Work
Act and take appropriate action to ensure that the regulations are
adhered to. In order to give optimum efficiency and trouble free
operation the appliance must be commissioned by a qualified OFTEC
engineer.The compliance with a British Standard does not, in itself,
confer immunity from legal obligations. In particular the installation of
this appliance must be in accordance with the relevant requirements of
the following British Standards and regulations in respect of the safe
installation of equipment.
BS 5410: part 1: Code of practice for Oil Fired Boilers.The Building
Regulations Part J and L1 England and Wales; Part F and Part J Section
III Scotland;
Part L and Part F Northern Ireland.
Local water company bye-laws.The Control of Pollution (Oil)
Regulations.
OFTEC Standards.
Where no specific instruction is given, reference should be made to the
relevant codes of practice.
Warnings in this document are framed and identified by
a warning triangle which is printed on a grey
background.
Important information in cases where there is no risk of
personal injury or material losses is identified by the
symbol shown on the left. It is bordered by horizontal
lines above and below the text.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document or to other
related documents
•alistentry
–a list entry (second level)
ØDiameter
RS Room Sealed

PRODUCT INFORMATION
6 720 807 912 (2015/10)4
2 PRODUCT INFORMATION
2.1 BALANCED LOW LEVEL DISCHARGE FLUE
COMPONENTS
Fig. 1 Balanced flue components
[1] Air inlet clamp
[2] Telescopic air inlet section & acoustic insulation
[3] 80mm Ø flue pipe (including seal)
[4] Air box mounting bracket
[5] Air box gasket
[6] Air box
[7] Air box cover
[8] Flue terminal
[9] Accessory pack
ADDITIONAL COMPONENTS
Fig. 2 Additional components
[1] 80/125mm - 90° elbow kit (Swept) - (for side flue options)
and solvent free grease pack:
containing two no.8 screws and grease sachet
Part number: 7 716 190 034
[2] Terminal guard:
Part number: 7 716 190 050
3 PRE-INSTALLATION
3.1 BALANCED LOW LEVEL DISCHARGE FLUE OPTIONS
Fig. 3 Flue outlet options
[A] Left hand flue outlet, using items 1+2+3 from figure 4
[B] Rear flue outlet, using items 1+3 from figure 4
[C] Right hand flue outlet, using items 1+2+3 from figure 4
Fig. 4 Flue components
[1] External horizontal flue kit:
Part number 7 716 190 084
[2] 80/125mm - 90° elbow kit (Swept)
Part number 7 716 190 034
[3] Terminal guard:
Part number 7 716 190 050
6720807912
-01.3Wo
1 2 3 456
7 8
9
6720807912
-02.2Wo
2
1
NOTICE:
▶ It is recommended that the flue terminal faces away
from walls to minimise wetting
▶ Flue gases have a tendency to plume and in certain
weather conditions a white plume of condensate will
be produced. The flue terminal should be positioned
in such a way that the plume does not cause a
nuisance.
The balanced flue can be fitted to the rear or either side
of the cabinet. Refer to figure 3.
6720807912
-03.1Wo
A B C
FRONT
6720807912
-04.1Wo
1
2 3

INSTALLATION
6 720 807 912 (2015/10) 5
4 INSTALLATION
4.1 BALANCED LOW LEVEL DISCHARGE FLUE
4.1.1 FLUE COMPONENTS
Fig. 5 Flue components
[1] Air inlet clamp
[2] Telescopic air inlet section & acoustic insulation
[3] 80mm Ø flue pipe (including seal)
[4] Air box mounting bracket
[5] Air box gasket
[6] Air box
[7] Air box cover
[8] Flue terminal
[9] Air box cover screws x 6
[10] Mounting screws x 4 (Accessary pack)
4.2 REAR FLUE OPTIONS - ALL MODELS
▶ Fit the air inlet telescopic sections [2 & 3] to the boiler flue cowl and
secure the inner section with the clamp [1].
▶ Push the air inlet outer section [3] (see figure 11) through the rear
panel opening until the end of the tube is against the stops [4] on the
clamp assembly [5].
Fig. 6 Rear flue
[1] Flue clamp
[2] Telescopic inner section
[3] Telescopic outer section
[4] Clamp stops
[5] Clamp assembly
▶ Drill through the two sections of the flue inlet [2 & 3] with the 3.3mm
drill bit and secure the two sections with the self-tapping screw.
▶ Drill through the tab [6] with the 3.3mm drill bit, into the flue inlet
outer section [3] and secure with the self-tapping screw.
Fig. 7 Drilling detail
[2] Telescopic inner section
[3] Telescopic outer section
[6] Clamp tab
NOTICE:
▶ Ensure all seals are in good condition and seated
properly.
▶ To ease assembly of the flue components, lightly
grease the seals with the solvent free grease supplied.
▶ A terminal guard must be fitted if the terminal is 2 m or
less above a surface that is accessible by people.
80mmØ flue pipe length L in mm
Flue outlet
Boiler
Danesmoor
(2013)
Heatslave II Camray Heatslave
Rear 450 465 465 420
Table 1 Flue pipe lengths
12345
6720807912 -05.2Wo
67
8
9
10
6720807912
-09.1Wo
2&31
4
5
6720807912 -10.1Wo
2
6
3.3mmØ
3

INSTALLATION
6 720 807 912 (2015/10)6
4.3 SIDE FLUE OPTION:
DANESMOOR (2013) AND HEATSLAVE II
DANESMOOR (2013) AND HEATSLAVE II FLUE OPTIONS
[*] Danesmoor (2013) and Heatslave II righthand flue:
the 125mm air inlet outer section is not needed for these outlet
position and so there will be one screw spare.
[**] Heatslave II lefthand flue:
Use both inner and outer air inlet sections,
but cut the outer section down to 150mm.
▶ Cut the 80mm flue pipe as required, see table 2
▶ Fit the air inlet section [2] to the elbow [3].
▶ Fit the clamp [1] to the flue cowl.
Fig. 8
[1] Flue clamp
[2] Flue section
▶ Push the air inlet section through the side panel opening into the air
box until it meets the stops [4] on the clamp assembly
▶ Centralise the inner elbow pipe within the elbow.
▶ Fit the elbow [3] onto the flue cowl.
▶ Tighten the clamp [1] onto the flue elbow.
Fig. 9
[3] Elbow
[4] Clamp stops
[5] Clamp
▶ Drill through the tab [6] on the mounting bracket, with the 3.3mm
drill bit into the air inlet outer section and secure with a self-tapping
screw.
Fig. 10 Tab detail
To use the right hand or left hand flue options a 90°
swept flue elbow is required (part no. 7 716 190 034)
Lightly grease the 90° flue elbow seals with the solvent
free grease.
80mmØ flue pipe length L in mm
Flue outlet
Boiler
Danesmoor (2013) Heatslave II
Right hand 240* 230*
Left hand 255* 340**
Table 2 Flue pipe lengths
6720807912 -11.1Wo
12a
& 2b
6720807912 -12.1Wo
1
3
4
5
6720807912 -13.1Wo
3.3mmØ
6

INSTALLATION
6 720 807 912 (2015/10) 7
4.4 SIDE FLUE OPTION: CAMRAY AND HEATSLAVE
CAMRAY LEFT HAND OPTION & HEATSLAVE RIGHT HAND OPTION
[*] The air inlet outer section is not needed for this outlet position
and there will be one screw spare.
[**] Camray: for the right hand flue option reduce the air inlet outer
section by 130mm. Ensure that the cut is square and remove
burrs after cutting.
▶ Cut the flue as required, see table 3
▶ Fit the air inlet inner section [2] to the elbow.
▶ Fit the clamp [1] to the flue cowl.
Fig. 11
[1] Flue clamp
[2] Flue section
▶ Push the air inlet inner section through the side panel opening into the
air box until it meets the stops [4] on the clamp assembly
▶ Centralise the inner elbow pipe within the elbow.
▶ Fit the elbow [3] onto the flue cowl.
▶ Tighten the clamp [1] onto the flue elbow.
Fig. 12
[3] Elbow
[4] Clamp stops
[5] Clamp
▶ Drill through the clamp tab [6] on the mounting bracket, with the
3.3mm drill bit, into the air inlet outer section and secure with a self-
tapping screw.
Fig. 13
[6] Clamp tab
CAMRAY RIGHT HAND AND HEATSLAVE LEFT HAND OPTION
[*] The air inlet outer section is not needed for this outlet position
and there will be one screw spare.
[**] Camray: for the right hand flue option reduce the air inlet outer
section by 130mm. Ensure that the cut is square and remove
burrs after cutting.
▶ Cut the flue as required, see table 4
▶ Fit the air inlet inner section [2] to the elbow.
▶ Fit the clamp [1] to the flue cowl.
To use the right hand or left hand flue options a 90°
swept flue elbow is required (part no. 7 716 190 034)
Lightly grease the 90° flue elbow seals with the solvent
free grease supplied.
80mmØ flue pipe length L in mm
Flue outlet
Boiler
Camray Heatslave
Right hand 265** 230*
Left hand 230* 345
Table 3 Flue pipe lengths
6720807912 -11.1Wo
12a
& 2b
80mmØ flue pipe length L in mm
Flue outlet
Boiler
Camray Heatslave
Right hand 265** 230*
Left hand 230* 345
Table 4 Flue pipe lengths
6720807912 -12.1Wo
1
3
4
5
6720807912 -13.1Wo
3.3mmØ
6

INSTALLATION
6 720 807 912 (2015/10)8
▶ Push the air inlet inner section through the side panel opening into the
air box until it meets the stops [4] on the clamp assembly
▶ Centralise the inner elbow pipe within the elbow.
▶ Fit the elbow onto the flue cowl.
▶ Tighten the clamp [1] onto the flue elbow.
Fig. 14
[1] Clamp, flue elbow
[2] Air inlet inner section
[3] Air inlet outer section
[4] Clamp stops
[5] Clamp bracket
▶ Drill through the air inlet outer section [3], with the 3.3mm drill bit,
into the inner section [2] and secure the two sections with the self
tapping screw.
Fig. 15
▶ Drill through the clamp tab [6] on the mounting bracket, with the
3.3mm drill bit, into the air inlet outer section and secure with a self-
tapping screw.
Fig. 16 Tab detail
4.5 ALL FLUE OPTIONS, FINAL ASSEMBLY
▶ Lightly grease the flue pipe seal with the solvent free grease supplied.
▶ Remove the screw from the clamp bracket [1] and open the clamp.
▶ Insert the terminal [3] fully into the 80mmØ flue pipe.
▶ Pass the flue pipe [2] through the clamp bracket [1] and push into the
flue cowl or elbow.
Fig. 17 Final assembly
[1] Clamp bracket
[2] Flue pipe
[3] Terminal
▶ Drill two holes into the terminal [3] through the tabs [5], with the
3.3mm drill bit, one either side, and secure the terminal [3] to the
tabs [5] using the two self tapping screws.
▶ Fit the air box cover [4] over the lip on the top of the air box and
secure the bottom two screws removed earlier.
Fig. 18
[4] Air box cover
[5] Tab
6720807912 -14.1Wo
12&3
4
5
6720807912
-15.1Wo
3.3mmØ
6720807912
-16.1Wo
3.3mmØ
6
6720807912 -17.1Wo
3
1
2
6720807912
-18.1Wo
4
1
5
3

INSTALLATION
6 720 807 912 (2015/10) 9
4.6 TERMINAL GUARD
▶ To fit the terminal guard [1] not supplied:
Hold the terminal guard [1] in place and secure with the four screws
[2] removed from the air box earlier.
Fig. 19
[1] Terminal guard
[2] Screws
6720807912 -19.1Wo
1
2

6 720 807 912 (2015/10)10
NOTES

6 720 807 912 (2015/10) 11

Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. [phone]
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
6 720 807 912 (2015/10)
WORCESTER, BOSCH GROUP:
TECHNICAL SUPPORT: 0844 892 3366
APPOINTMENTS: 0844 892 3000
SPARES: 01905 752571
LITERATURE: 0844 892 9800
TRAINING: 01905 752526
SALES: 01905 752640