Worcester 12/18 User guide

UK
Installation, Commissioning and Servicing instruction manual
Floor Standing oil-fired Condensing Boiler using Room Sealed Flue
Greenstar Danesmoor External Regular ErP
& External System ErP 12/18, 18/25 & 25/32
6720809437-00.1Wo
For fully pumped open vent or sealed central heating systems and domestic hot water cylinders.
These appliances are for use with Kerosene (Class C2) only.
6 720 813 288 (2014/09)

Contents
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)2
Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Installation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Complying with the building regulations . . . . . . . . . . . . . 4
3 Appliance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Energy Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Layout and components - 18/25 Regular appliance shown
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Layout and components - 12/18 System appliance shown
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 10
4.1.1 Before cleaning the system: . . . . . . . . . . . . . . . . . . . . . 10
4.1.2 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1.3 Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1.4 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3.1 Single pipe gravity feed system: . . . . . . . . . . . . . . . . . . 11
4.3.2 Double pipe sub-gravity feed system: . . . . . . . . . . . . . 11
4.3.3 Single pipe suction lift with de-aerator: . . . . . . . . . . . . 12
4.3.4 Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3.5 Boiler isolation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Water systems and pipework . . . . . . . . . . . . . . . . . . . . 12
4.5 Condensate pipework . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.1 Condensate disposal connections . . . . . . . . . . . . . . . . 14
4.5.2 Soak away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Pressure relief pipework . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7 Boiler locations and clearances . . . . . . . . . . . . . . . . . . 16
4.8 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9.1 Cabinet mounted balanced horizontal flue options . . 18
4.9.2 Plume management . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Unpacking the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Pipework positions and flue opening . . . . . . . . . . . . . . 19
5.3 Boiler installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.5 Combustion chamber (18/25 Regular shown) . . . . . . 21
5.6 Pipework connections . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.7 Oil burner and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.8 Refitting components . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Pre-Commissioning checks - 18/25 Regular shown . . 27
6.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.1 Appliance drain points . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.2 Appliance vent points . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 32
6.5.1 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.5.2 Appliance guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7 Service and Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1 Inspection and service - 18/25 Regular shown . . . . . . . 33
7.2 Clean the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2.1 Accessing the flue manifold and secondary heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2.2 Cleaning the flue manifold . . . . . . . . . . . . . . . . . . . . . . . 34
7.2.3 Combustion chamber baffle check . . . . . . . . . . . . . . . . 34
7.2.4 Condensate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2.5 Clean the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3 Short parts list 12/18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4 Short parts list 18/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5 Short parts list 25/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.1 Burner functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2 Heating and hot water . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3 Boiler function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.4 Logic for the 535 SE/LD RDB control box . . . . . . . . . . . 43
8.5 Oil supply vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . 44

Key to symbols and safety instructions
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 3
1 Key to symbols and safety instructions
1.1 Key to symbols
Warnings
The following keywords are defined and can be used in this document:
•NOTICE indicates a situation that could result in damage to property
or equipment.
•CAUTION indicates a situation that could result in minor to medium
injury.
•WARNING indicates a situation that could result in severe injury or
death.
•DANGER indicates a situation that will result in severe injury or
death.
Important information
Additional symbols
Examples of additional symbols used
A numbered step in an action sequence
A sequence of numbered steps or actions carried out in a specific order
to complete a task.
1. First action
2. Second action
3. Third action
etc.
A step in an action sequence
A sequence of defined actions or steps carried out in order to complete
a task.
▶Action
▶Nextaction
▶etc
A reference to a related part in the document or to other related
documents.
To refer the reader to a specific figure/table/section within the manual.
e.g. figure 1.
A reference number to identify or refer to a part or item.
In a related figure, items or parts identified by a sequential number.
List entries, first and second levels
• A single component/item
• A component/list, made up of multiple parts/items.
– Sub component or sublist of main component/list.
–etc.
Abbreviations used in this manual
Read these instructions before starting any installation
These instructions are applicable to the Worcester appliance model(s)
stated on the front cove of this manual only and must not be used with
any other make or model of appliance.
The instructions apply in the UK and Eire only and must be followed
except for any statutory obligation.
This appliance must be installed by a competent person, failure to install
correctly could lead to prosecution.
1.2 General safety instructions
These installation instructions are intended for heating engineers,
plumbers, and electricians.
▶ Read any installation instructions (boiler, heating controls, etc.)
carefully before starting the installation.
▶ Observe the safety instructions and warnings.
▶ Observe national and regional regulations, technical rules and
guidelines.
▶ Record all work carried out.
Oil fumes or leaks from the appliance
If you smell oil fumes, observe the following rules.
▶ Extinguish any naked flames
▶ Isolate the electrical supply
▶ Isolate the fuel supply to the boiler
▶ Rectify the fault
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). Where
applicable, the CE mark indicates compliance with relative EU
Directives.
Combustible and corrosive materials
Do not store or use any combustible materials (paper, thinners, paints
etc.) inside or within the vicinity of the appliance.
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
This symbol indicates important information where
there is no risk to people or property.
Symbol Meaning
a numbered step in an action sequence
a step in an action sequence
a reference to a related part in the document or to other
related documents
a reference number to identify or refer to a part or item
a list entry
a list entry (second level)
Table 1 Symbols
1
ØDiameter
CH Central Heating
DHW Domestic Hot Water
DCW Domestic Cold water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional Flue
BF Balanced Flue
N/A Not Allowed
SEDBUK Seasonal Efficiency of Domestic Boilers in the UK
OFTEC Oil Firing Technical Association for the Petroleum Industry
IET Institute of Engineering and Technology
LABC Local Authority Building Control Body
DWTA Domestic Water Treatment Association

Installation regulations
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)4
The combustion air must be kept clear of chemically aggressive
substances which can corrode the appliance and invalidate any
warranty.
Handling instructions and guidelines
It is advised that more than one person is involved in the transfer of the
packaged appliance from the van to the point of installation.
It is advised that no attempt should be made to move the packaged
appliance without the use of a suitable truck.
At all times the correct method for handling heavy objects should be
strictly observed.
▶ Lift only a manageable weight, or ask for help.
▶ When lifting, bend the knees, and keep the back straight and feet
apart.
▶ Do not lift and twist at the same time.
▶ Lift and carry items close to the body.
▶ Wear protective clothing and gloves to protect fromany sharp edges.
Intended use
This boiler must only be used as a heat appliance in a heating system for
domestic purposes.
Any other use is considered inappropriate. Any damage that results from
such use is excluded from liability.
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.
Installation, commissioning and servicing
Installation, commissioning and servicing must only be carried out by a
competent registered engineer.
▶ Only use original spares.
▶ 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.
Fitting and Modification
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 thanas 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.
Electrical work
Electrical work must only be carried out by a qualified electrician.
▶ Before starting electrical work:
– Isolate the mains electrical supply and secure against
unintentional re-connection.
– Check for zero potential.
▶ Also observe connection diagrams of other system components.
Handover to the user
When handing over, instruct the user how to operate the heating system
and inform him about its operating conditions.
▶ Explain how to operate the heating system and draw the user's
attention to any safety-relevant action.
▶ Explain that modifications and repairs must only be carried out by an
authorised contractor.
▶ Advise the user to have the system serviced annually by a competent,
OFTEC registered engineer.
▶ Leave the installation instructions with the completed
commissioning form and the operating instructions with the user or
at the gas meter.
2 Installation regulations
2.1 Complying with the building regulations
This heating appliance forms part of the controlled services for the
building. It is law that all controlled services for buildings must comply
with building regulations. You must be able to satisfy your Local
Authority Building Control Body (LABC) that the work carried out
concerning the installation and commissioning of this heating appliance
has been carried out to a satisfactory standard.
OFTEC operate a competent persons scheme and registered installers
are able to certify that their work complies with building regulations.
Under the scheme;
• OFTEC must be informed about every installation.
• OFTEC will issue a building regulations compliance certificate to the
householder and will notify the LABC.
OFTEC provide controlled document forms CD10 and CD11 for use
during installation and commissioning respectively.
Other organisations operate self-certification schemes e.g. NAPIT and
BESCA Ltd. and it may be possible for installers who are members of
these organisations to self certify their work.
Alternatively you must submit a building control notice to the LABC
before installing any boiler. The LABC will then arrange regular
inspection visits duringthe work to ensure that the installation complies
with the regulations.
Installation
Failure to install appliances correctly could lead to prosecution.
The appliance should be installed by a competent person. The person
installing the appliance should be aware of the 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.
BS 799: part 5: Specification for Oil Storage Tanks.
BS 7593: Code of Practice for treatment of water in domestic
hot water central heating systems.
BS 5449: part 1: Specification for forced circulation hot water central
heating for domestic premises.
BS 5955: part 8: Specification for the installation of thermoplastic
pipes and associated fittings for use in domestic hot
and cold water services and heating systems.

Installation regulations
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 5
BS 7291: Thermoplastic pipes and associated fittings for hot
and cold water for domestic purposes and heating
installations in buildings.
BS 7074: part 1: Application, selection and installation of expansion
vessels and ancillary equipment for sealed water
systems.
BS 1254-2: Copper and copper alloys plumbing fittings part 2:
Fittings with compression ends for use with copper
tubes.
BS 7671: IET Wiring Regulations, current edition.
BS 1362: Specification for general purpose fuse links for
domestic and similar purposes.
The Building Regulations Part G, Part J and L1 England and Wales; Part
F, Part G 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.
Installations in Eire (Republic of Ireland)
The Installation must be performed by a competent and suitably trained
person in accordance with the following Eire regulations.
Current Building Regulations - Republic of Ireland
ETCI rules for electrical installation
For further guidance see:
OFTEC Technical book three - Regional requirements: Republic of
Ireland

Appliance information
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)6
3 Appliance information
3.1 General information
Standard package:
A - Floor standing oil fired condensing boiler
B - Literature pack:
• Greenstar Danesmoor external Installation, Commissioning and
Servicing instruction manual
• User Instructions
• Guarantee registration card
C - Condensate trap
D - BSP plug, one inch (Regular only)
E - ErP label
F - Cabinet key
G - 100mm Ø Services duct
H - Balanced flue kit
Fig. 1 Standard package
3.2 Technical data
6720813288-07.1Wo
A
B
C
D
F
E
G
H
Description Units 12/18 18/25 25/32
Central heating
Central heat output (max) kW 18 25 32
Primary water capacity (total) litres 20 21 22
Max.static head (Regular only) metres 30 30 30
Min. static head (Regular only) metres 111
Water side resistance (20°C
difference)
mbar 20 30 56
Maximum available pump head
(20°C difference) System only
mH2 O5.2 4.3 4.1
Maximum permissible sealed
system operating pressure in
accordance with WRAS
guidelines
bar 2.5 2.5 2.5
Flue
Exit flue gas mass flow kg/hr 29 40 51
Pipework connections
Fuel line (compression) mm 10 10 10
Flow Kitchen BSP 1” 1” 1”
Flow Kitchen System mm 22 22 28
Kitchen flow and optional vent/
air vent
BSP 1” 1” 1”
Return mm 22 22 28
Condensate (Polypropylene) mm 21.5 21.5 21.5
PRV outlet - System only mm 15 15 15
Electrical
Electrical power supply voltage ac ..V 230 230 230
Frequency Hz 50 50 50
Thermostats
Boiler flow temperature range
(cut in/cut out)
°C 55/81 55/81 55/81
Control thermostat differential °C 555
Boiler high limit thermostat set
point
°C 95 95 95
Boiler manual reset overheat
thermostat set point
°C 105 105 105
Flue manual reset overheat
thermostat set point
°C 110 110 110
General data
Maximum hearth temperature °C <100 <100 <100
SEDBUK 2009 % 91.1 90.9 90.7
SEDBUK 2005 % 93.2 93.0 92.8
Appliance protection rating IP 45 45 45
Weight (excluding packaging)
External Regular
kg 110 114 124
Weight (excluding packaging)
External System
kg 119 121 131

Appliance information
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 7
3.3 Energy Efficiency
The following product data satisfy the requirements of the EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.
Product data Symbol Unit 7731600059 7731600060 7731600061 7731600068 7731600069 7731600070
Product type – – Danesmoor
External
Regular ErP
12/18
Danesmoor
External
Regular ErP
18/25
Danesmoor
External
Regular ErP
25/32
Danesmoor
External
System ErP
12/18
Danesmoor
External
System ErP
18/25
Danesmoor
External
System ErP
25/32
Condensing boiler – – Yes Yes Yes Yes Yes Yes
Low temperature boiler – – No No No No No No
B1 boiler – – No No No No No No
Cogeneration space heater
(CHP)
– – No No No No No No
Combination heater – – No No No No No No
Rated heat output Prated kW 18 25 32 18 25 32
Seasonal space heating
energy efficiency
ηs% 919091919091
Energyefficiencyclass––AAAAAA
Useful heat output
At rated heat output and
high temperature regime 1)
1) High-temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.
P4kW 17.9 24.9 32.2 17.9 24.9 32.2
At 30 % of rated heat output
and low temperature regime
2)
2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).
P1kW 5.7 7.9 10.2 5.7 7.9 10.2
Useful efficiency
At rated heat output and
high temperature regime 1) η4% 91.1 90.9 91.4 91.1 90.9 91.4
At 30 % of rated heat output
and low temperature regime
2)
η1% 96.8 95.8 96 96.8 95.8 96
Auxiliary electricity consumption
At full load elmax kW 0.143 0.16 0.16 0.143 0.16 0.16
At part load elmin kW 0.043 0.048 0.048 0.043 0.048 0.048
In standby mode PSB kW000000
Other items
Standby heat loss Pstby kW 0.123 0.16 0.16 0.123 0.123 0.16
Ignition burner power
consumption
Pign kW------
Emissions of nitrogen
oxides
NOx mg/kWh 243 193 136 243 193 136
Annual energy consumption QHE kWh------
Sound power level, indoors LWA dB(A) N/A N/A N/A N/A N/A N/A
Table 2 Product data for energy consumption

Appliance information
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)8
3.4 Layout and components - 18/25 Regular appliance shown
Fig. 2 18/25 Appliance shown
Figure 2 does not include the top, front, and right hand side panel.
1 Control box assembly 18 Primary heat exchanger
2 Flue manifold access cover 19 Oil isolating valve
3Fluegassamplingpoint 20 Optional oil return position
4 Casing side panel 21 Burner mounting plate
5 Flue overheat thermostat phial 22 Base plate and oil drip tray
6 Control & manual reset overheat thermostat phial 23 Primary heat exchanger drain
7 Auto-reset high-limit thermostat phial 24 Burner air intake - connected by flexible duct (9) to air inlet casing (8)
8 Air inlet casing 25 Burner motor - behind plastic cover
9 Flexible air duct (connecting to air intake on burner) 26 Oil pump - behind plastic cover
10 Secondary heat exchanger bleed point (one on either side) 27 Lockout reset button (on front of burner control box)
11 Secondary heat exchanger 28 Combustion chamber access door (primary baffle inside)
12 Heat exchanger flow pipe 29 One piece baffle arrangement
13 Secondary heat exchanger drain 30 Combustion chamber
14 Condensate outlet 31 Mode switch
15 Condensate trap 32 Boiler overheat reset button
16 Condensate drain pipe 33 Flue overheat reset button
17 Flexible condensate drain pipe connection 34 Temperature control knob
Table 3 Appliance component details (Regular model)
6720809437-02.1Wo
67
29
28
30
24
26 2527
21
1
4
23
5
31
32
34
33
20
16
18
19
9
10
11
13
14
15
17
12
8
22
23

Appliance information
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 9
3.5 Layout and components - 12/18 System appliance shown
Fig. 3 Exploded system appliance view
1 Control box assembly 24 Primary heat exchanger drain
2 Demand indicator 25 Burner air intake - connected to air inlet casing by flexible duct
3Modeswitch 26 Oil pump (behind plastic cover)
4 Flue manifold access cover 27 Riello RDB burner
5 Flue gas sampling point 28 Burner motor (behind plastic cover)
6 Flue overheat thermostat phial 29 Plastic cover
7 Return connection 30 Lock out reset button (on the front of the burner control box)
8 Flow connection 31 Burner control box (behind plastic cover)
9 Pressure relief valve 32 Circulating three speed pump
10 Flexible air duct (connecting to air intake on burner) 33 Expansion vessel
11 Secondary heat exchanger 34 Combustion chamber access door (primary baffle inside)
12 Heat exchanger flow pipe 35 System pressure gauge
13 Secondary heat exchanger drain 36 Temperature control knob
14 Condensate outlet 37 Auto reset thermostat
15 Base plate and oil drip tray 38 Flue overheat reset button
16 Condensate drain pipe 39 Boiler overheat reset button
17 Condensate trap 40 Burner lead connector socket
18 Primary heat exchanger 41 Service socket
19 Optional oil return position 42 Control & manual reset overheat thermostat phial
20 Oil isolating valve 43 Auto-reset high-limit thermostat phial
21 Pump drain point 44 Secondary heat exchanger bleed point (one on either side)
22 Burner mounting plate 45 Secondary heat exchanger bleed point (one on either side)
23 Base plate and oil drip tray
Table 4 Appliance component details (System model)
6720813288-01.1Wo
1
23
4
5
6
7
8
9
10
36
37 38 39
40 41
43
44
42
45
3
2
35
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
2627
28
29
30
31 32
33
35
34
36

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)10
4 Pre-Installation
4.1 Cleaning primary systems
4.1.1 Before cleaning the system:
▶ Ensure that the system and pipe work is in good working order.
▶Where possible keep the existing appliance/circulating pump in
place when flushing the system.
Follow the guidance of BS7593:
Treatment of water in domestic hot water central heating and also the
flushing guidelines below.
4.1.2 Flushing the system
▶ Fill the system with cold water and check for leaks.
▶ Open vented systems only:
– Turn off the water to the system header tank.
▶ Open all drain cocks and drain the system.
▶ Close drain cocks and add a suitable flushing agent at the correct
strength for the system conditions in accordance with the
manufacturer‘s instructions.
▶ Circulate the flushing agent before the boiler is fired up.
▶ Run the boiler/system at normal operating temperature as directed
by the manufacturer of the flushing agent.
▶ Drain and thoroughly flush the system to remove the flushing agent
and debris.
▶ It may be necessary to use a power flushing machine to aid the
cleansing procedure in some circumstances.
▶ Close the drain cocks and manual air vents.
▶ Add a suitable inhibitor to the system in accordance with the
manufacturers instructions.
▶ Open vented systems only:
– Turn on the water to the system header tank and allow the system
to fill.
▶ Sealed systems only:
– Fill the system to between 1 and 1.5 bar via a WRAS approved
filling loop.
▶ Vent any air from the boiler and system.
4.1.3 Inhibitor
Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system
is exposed to freezing conditions, to the heating system in accordance
with the DWTA code of practice and manufacturer‘s guidelines.
Water treatment products
Suitable water treatment products can be obtain from the following
manufacturers:
4.1.4 Artificially softened water
It is possible to have an ion exchange water softener fitted to the cold
water system of the property. However, the boiler requires an untreated
cold water connection taken from the mains supply, before the water
softener, to the primary water filling point of the heating system.
Alternatively there are water softening/treatment devices that do not
adjust or alter the pH levels of the water. With these devices it may not
be necessary to provide an untreated water by-pass to the primary water
filling point of the heat system.
DANGER: Danger to life through electric shock!
▶ Before carrying out any work on electrical
components, isolate them from the power supply
(230 V AC) (fuse, circuit breaker) and secure against
unintentional reconnection.
NOTICE: Risk of damage to appliance or accessories!
▶ All the following pre-installation sections must be
read and requirements met before starting the
appliance or flue installations.
NOTICE: Risk of damage to system or appliance!
Debris from the system can damage the appliance and
reduce efficiency. Failure to comply with the guidelines
for the use of water treatment with the appliance will
invalidate the appliance guarantee and contravene the
Building Regulations.
▶ It is a requirement of the Building Services
Compliance Guide which is a second tier document
to the Building Regulations to flush and inhibit the
primary water system in accordance with BS 7593.
▶Itisrecommendedthatyou fit a primary water
cleanser to the system. Worcester recommends
fitting a filter that will help remove both magnetite
and non-magnetic debris.
The inhibitor or combined inhibitor/anti-freeze must not
cause damage to the materials within the boiler (mild
steel, stainless steel, copper and brass) and any other
materials/components within the system.
▶ The concentration level of inhibitor in the system
should be checked every 12 months or sooner if
system content is lost.
WARNING: Sealing agents
▶ In cases where all attempts to find a system micro
leak have failed, Worcester, Bosch Group supports
the use of Fernox F4 leak sealer.
FERNOX 0870 601 5000
www.fernox.com
SENTINEL 0800 389 4670
www.sentinel-solutions.net
NOTICE:
▶ Artificially softened water must not be used to fill the
central heating system.

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 11
4.2 Mains supply
4.2.1 Electrical supply
• Supply: 230V - 50 Hz
• Cable: PVC insulated 0.75 mm2 (24 x 0.2mm) temperature rated to
90°C.
• Circuit breaker incorporating earth leakage protection.
• External 5A fuse to BS1362.
• The appliance must be earthed.
• This appliance must not be connected to a three phase supply.
• Wiring must comply with the latest IET wiring regulations.
• It must be possible to isolate the appliance from the electrical supply
with at least a 3mm contact separation in both poles supplying the
appliance.
• Wiring between the appliance and the electrical supply must comply
with IET wiring regulations and any local regulations that may apply
for fixed wiring to a stationary appliance.
• Any system connected to the boiler must not have a separate
electrical supply.
4.3 Oil supply
•This appliance is suitable for Kerosene (Class C2) only, no other
fuel must be used.
• Plastic or steel tanks should be installed to BS 5410.
A steel tank should conform to BS 799: part 5 and have a slope of
1:24 away from the outlet with a sludge cock at the lower end.
•Do not use galvanised steel tanks or pipework for the oil system.
•Do not use soldered joints on the oil supply pipework.
4.3.1 Single pipe gravity feed system:
The oil storage tank [1] must be positioned so that the oil level does not
exceed 4 metres above the level of the burner oil pump [9] and in
addition the oil level must be at least 300mm above the oil pump [9].
Where the maximum oil level in the oil storage tank exceeds 4 metres, a
head breaking device must be installed between the tank [1] and the
burner oil pump [9].
Fig. 4 Single pipe feed
Maximum pipe run for single pipe gravity fed system
4.3.2 Double pipe sub-gravity feed system:
Maximum suction height 3.5 metres. Non-return valves must be fitted to
the inlet and return oil line between the oil pump [9] and oil storage tank
[1].
Fig. 5 Double pipe feed
Maximum pipe run for double pipe sub-gravity fed system
NOTICE: Contaminated oil supplies can damage the
appliance.
Failure to ensure that the oil supply is clear of
contaminants may invalidate the appliance warranty.
▶ Ensure the oil supply is free of contaminates and
measures are taken to prevent contamination of the
appliance.
Key to Oil supply illustrations, figures 4, 5 & 6
1OIlstoragetank
2 Full base (plastic tank)
3 Isolating valve
4 Oil strainer and water separator
5 Fire valve to BS 5410
6 External boiler casing
7 Oil filter (70μm max filtration size)
8 Fire valve sensor
9Oilpump
10 Oil burner
11 Non-return valve
12 De-aerator
Table 5 Key to oil supply feed system
All dimensions are in metres unless otherwise stated.
The maximum pipe run figures are based on using
copper pipe with an inside diameter of 2mm less than
the outside diameter.
Head (m) 10mmØ 12mmØ Head (m) 10mmØ 12mmØ
0.5 12 30 2.5 62 100
1.0 25 69 3.0 74 100
1.5 37 91 3.5 87 100
2.0 49 100 4.0 99 100
Head (m) 10mmØ 12mmØ Head (m) 10mmØ 12mmØ
050100 2.0 26 66
0.5 44 100 2.5 20 50
1.0 38 95 3.0 14 37
1.5 32 80 3.5 8 22
6720809437-41.2Wo
1
23 4
300mm Min.
4m Max.
68
53
109
13
7
1m Min.
150mm
26720809437-42.2Wo
13
3.5m Max.
1
3 4
73
6 8
5
11
109
1m Min.

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)12
4.3.3 Single pipe suction lift with de-aerator:
Maximum suction height 3.5 metres. The oil tank [1] must be positioned
below the oil pump [9]. Create an inlet and return loop between the de-
aerator [12] and oil pump [9].
A non-return valve must be incorporated within the de-aerator or fitted
to the oil line between the oil storage tank [1] and the de-aerator [12].
A top feed oil tank fitted with a de-aerator using an internal non-return
valve should have any non-return valves fitted in the base of the tank to
the suction line removed to assist purging air from the oil line.
Fig. 6 De-aerator feed
Maximum pipe run for single pipe suction lift with de-aerator
4.3.4 Pipework
▶ Refer to the oil supply sections Single pipe gravity feed
system: 4.3.1, Double pipe sub-gravity feed system: 4.3.2 & Single
pipe suction lift with de-aerator: 4.3.3 for oil supply pipework
configurations.
Oil supply pipework considerations:
• Lay the oil supply pipe as straight and level as possible to avoid air
pockets and unnecessary friction losses.
– Route away from the boiler access door or other hot surfaces.
• Install a manual isolating valve to the oil supply pipe, as close to the
oil storage tank as possible.
• Fit an oil strainer and water separator to the oil supply pipe, near the
oil storage tank.
– Fit an additional oil filter (70 μm max filtration size) close to the
boiler, but not inside the boiler casing.
• Fit a fire valve in accordance with BS 5410.
– The fire valve should be fitted externally to the building with the
fire valve sensor located within the appliance case.
– A fire valve with a shut off temperature of 85°C or higher must be
fitted to avoid the possibility of nuisance shut offs.
– A capillary type valve provides a neat and simple installation.
Alternatively, a fusible link or electrical system may be used.
• Under no circumstances should a combination isolating/fire valve be
used as the sole fire protection device.
4.3.5 Boiler isolation valve
▶ Use copper pipe of the correct diameter according to the information
shown in oil supply sections 4.3.1, 4.3.2 & 4.3.3.
– If using soft copper pipe (R220) with a compression fitting, an
insert must be used to prevent the pipe from collapsing or
distorting when the fitting is tightened.
▶ Slide nut [1] and olive [5] onto the oil supply pipe [4].
▶ Slide insert [3] into the pipe.
▶ Offer the pipe to the fitting [2] and tighten the nut [1].
Fig. 7 Isolation valve bracket removed for clarity
▶ Use flexible hoses to connect from the boiler isolation valve/s and the
oil pump.
4.4 Water systems and pipework
Primary system plastic pipework:
• Any plastic pipework used for the CH system must have a polymeric
barrier, complying with BS 7921 and installed to BS 5955 with
1000mm (minimum) length of copper or steel pipe connected to the
boiler.
• Plastic pipework used for underfloor heating must be correctly
controlled with a thermostatic blending valve limiting the
temperature of the circuits to approximately 50°C with 1000mm
(minimum) length of copper or steel pipe connected to the boiler,
and a 20K differential must be maintained at the appliance.
Primary system/connections/valves:
• Do not use galvanised pipes or radiators.
• All system connections, taps and mixing valves must be capable of
sustaining a pressure of 3 bar.
• Radiator valves should conform to BS 2767:10.
• All other valves should conform to BS 1010.
• An automatic bypass valve must be connected between the heating
flow and return where TRVs are used on all radiators, fitted to give at
least a 3 metre circuit when activated.
• Drain cocks are required at all the lowest points on the system.
• Air vents are required at all high points on the system.
FUEL FLOW RATE
2.5kg/h 5kg/h 10kg/h 10kg/h
Head (m) 8mmØ 8mmØ 8mmØ 10mmØ
010055 26 100
0.5 95 45 23 100
1.0 80 40 20 90
1.5 70 35 17 75
2.0 60 30 14 65
2.5 45 25 11 50
3.0 35 15 8 35
3.5 25 10 5 20
The table and illustration above is a guide only and does
not in any way override the de-aerator manufacturer’s
instructions.
6720809437-43.2Wo
13
24
3.5m Max.
1 6
12
5
33 7
109
8
1m Min.
NOTICE:
▶ The boiler should not be allowed to operate with a
return temperature of less than 30°C when the
system is up to operating temperature.
6720813288-03.1Wo
1
5
4
3
2

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 13
Open vent primary system (regular only)
• The open vent pipe [F] and feed and expansion pipe [H must rise
continuously from the appliance.
• The feed and expansion cistern [E] must be positioned to provide a
static head [S] of at least 1 metre above the highest point in the
heating system to the water level in the feed and expansion cistern
[E].
• Ensure adequate space is left in the expansion cistern for expansion
of the system water.
• No valve shall be fitted in the open vent pipe (H) or the feed and
expansion pipe [F].
• The open vent pipe [H] must be at least 22mmØ.
Fig. 8 Regular appliance system layout
[A] Regular appliance
[A1] System appliance
[B] Expansion vessel*
[C] Automatic bypass valve
[D] Drain cock
[E] Feed and expansion cistern
[F] Open vent 22mmØ min.
[G] Pressure gauge*
[H] Feed and expansion 15mmØ min.
[J] Circulating pump*
[K] Zone valves
[K1] Three port valve
[L] Lockshield valve
[M] Hot water cylinder
[N] Automatic air vent
[P] Pressure relief valve*
[P1] Pressure relief discharge
[R] Radiators
[T] Thermostatic radiator valve TRV
[U] To filling system
[NOTE] * Components included internally on the system boiler
Fully pumped sealed primary system:
• A pressure relief valve [P], spring loaded safety valve set to operate
at 3bar, must be fitted to the heating flow pipe as close as possible to
the boiler or onto one of the boiler top 1” BSP outlets.
• An expansion vessel [B] must be fitted to the heating return pipe as
close as possible to the boiler and pressurised for the system volume
according to the instructions supplied with the vessel.
• A pressure gauge [G], 3 bar minimum, must be fitted to the heating
flow pipe or one of the boiler 1” BSP outlets.
• An automatic air vent [N] must be fitted.
Fig. 9 Regular appliance system layout
Fig. 10 System appliance system layout
Sealed system considerations
6720808218-07.1Wo
The charge pressure of the built-in 12 litre expansion
vessel is 0.5 bar as dispatched, which is equivalent to a
static head of five metres.
Total system volume
(litres)
Initial system
pressure (bar)
Initial charge
pressure (bar)
180 0.5 0.5
107 1.0 0.5
138 1.0 1.0
If an extra expansion vessel is fitted to the central
heating return, adjust this to the same pressure as the
appliance internal expansion vessel, refer to separate
instructions supplied with the extra expansion vessel.
6720808218-08.1Wo
K1
6720808218-109.1Wo
K1
P1
A1

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)14
Filling primary sealed systems
• Where the system volume is more than 180 litres at 0.5 bar or
exceeds 2.65 bar at maximum heating temperature an extra
expansion vessel [B] figure 10 must be fitted as close as possible to
the appliance in the central heating return.
• Pressurise the extra expansion vessel [B] figure 10 to the same
figure as the expansion vessel built into the appliance (system
boilers).
• Filling the system must comply with one of the methods shown in the
figure 11.
• The filling point must be at low level and must never be a permanent
connection to the mains water supply.
• Filling loops must be WRAS approved.
Fig. 11 System fill and make up
4.5 Condensate pipework
Externally run condensate drainage pipe should terminate at a suitable
foul water discharge point, or purpose-designed soak away. If this
method is chosen then the following measures should be adopted:
▶ The external run be kept as short as possible and not exceed three
metres.
▶ The pipe diameter should be increased to 32mm and should be
insulated using suitable waterproof and weather resistant insulation.
▶ 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, with no 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 pipe work should be removed so that the
internal pipe section is as smooth as possible.
4.5.1 Condensate disposal connections
Fig. 12 Disposal to a soil vent stack
NOTICE: FILLING THE SYSTEM
▶ The system must not be filled with artificially
softened water.
SYSTEM FILL
CV = Check Valve
SV = Stop Valve
SV SV
Test point
Temporary hose
Hose union CV
CV
Heating
return
Mains
supply
SYSTEM MAKE UP
AA = Auto Air vent
CV = Check Valve
SV
CV
AA
Make up
vessel
Heating
return
1000 mm (39 in)
above the highest
point of the system.
Fill point
6720644743-08.1Wo
NOTICE:
▶ Where a new or replacement boiler is being installed,
access to an internal “gravity discharge” point should
be one of the factors considered in determining
boiler location.
▶ The condensate pipe must be nominally
21.5mm Ø Polypropylene pipe.
▶ The condensate pipe work must fall at least 52mm
per metre towards the outlet and should take the
shortest practicable route.
▶ Ensure there are no blockages in the pipe run.
Condensate drainage pipe can be run above or below
ground.
Key to condensate illustrations
1 Condensate discharge from boiler
2 Universal connector
3 Soil and vent stack
4 Minimum 450mm and up to three storeys
5 Pipe work transition
6 Insulate and increase pipe size
7 External rain water pipe into foul water
8Externalairbrake
9 43mm pipe (min 100mm upstand)
10 PVCu strap on fitting
11 43mm 90° male/female bend
* Condensate trap of 75mm already incorporated into the boiler
6720809437-03.1Wo
3
5
6
4
2
1
21.5mm Ø

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 15
Fitting an external air break
• Refer to figure 13 when a rain water down pipe is used to dispose of
condensate.
• An air break must be installed in the 43mm pipe work, between the
boiler condensate outlet and the drainpipe, outside the property, to
avoid flooding during adverse weather conditions.
Fig. 13 Disposal into a rainwater down pipe
Where the pipe terminates over an open drain or gully, the pipe should
terminate below the grating level, but above water level, in order to
minimise “wind chill” at the open end.
The use of a drain cover (such as those used to prevent blockage by
leaves) may offer further protection from wind chill.
Pipe drainage will be improved if the end is cut at 45° as opposed to a
straight cut.
Fig. 14 External drain
4.5.2 Soak away
• The condensate drainage pipe may be run above or below the ground
to the soak away. The examples shown on this page run above
ground.
• The soak away must use a 100mm Ø plastic tube with two rows of
three 12mm holes on 25mm centres and 50mm from the bottom of
the tube. The holes must face away from the house.
• The tube must be filled with and surrounded by at least 100mm of
limestone chippings to a depth of 400mm.
In situations where there are likely to be extremes of temperature or
exposure, the use of a proprietary trace-heating system for external pipe
work, incorporating an external frost thermostat, should be considered.
If such a system is used, the requirement to use 32mm pipe does not
apply. However, all other guidance above and the instructions for the
trace heating system, should be closely followed.
Fig. 15 Disposal to a soakaway
6720809437-04.1Wo
5
6
2
1
7
8
10
9
11
21.5mm Ø
25mm min.
6720809437-05.1Wo
5
2
1
6
21.5mm Ø
NOTICE: Condensate waste
▶ Care should be taken when siting a soak-away to
avoid obstructing existing services.
Minimum hole size for the condensate soak away must be
400mm deep by 300mmØ .
Key to condensate soakaway
1 Condensate discharge from boiler
2 Universal connector
3 Soil and vent stack
4 Minimum 450mm and up to three storeys
5 Pipe work transition
6 Insulate and increase pipe size
12 100mm Ø minimum plastic pipe
13 Drainage holes
14 Limestone chippings (25kg min.)
15 Bottom of sealed tube
* Condensate trap of 75mm already incorporated into the boiler
25mm min.
500mm min.
Unsuitable for clay soil types.
400mm min.
6720809437-06.2Wo
5
2
1
6
21.5mm Ø
15
13
14
12
12
13

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)16
4.6 Pressure relief pipework
• The pressure relief discharge pipe [2]should be at least 15 mm
diameter copper pipe and run downwards away from the boiler and
discharge away from any electrical or other hazard, preferably to an
external drain or soakaway.
• Pipe [2] should be finished with a partial bend, near the outlet to
prevent discharge onto entrances or other public access where it
could cause a hazard.
Fig. 16 Pressure relief pipe work
[1] External casing
[2] PRV discharge pipe
[3] Hardstanding
4.7 Boiler locations and clearances
Clearances:
▶ Minimum service and flue clearances.
– Above - 600mm
– Front - 600mm
– RH/LH clearance flue outlet on opposite side -10mm
– RH clearance flue outlet on rear - 45mm
– LH clearance flue outlet on rear - 85mm
– Rear clearance flue outlet on side - 50mm
– Rear clearance flue outlet on rear 2500mm
It is strongly recommended that the flue terminal faces away from
walls to reduce the possibility of wetting occurring.
Fig. 17 Above clearance
Fig. 18 Rear exit flue clearances
Fig. 19 Left exit flue clearances
Fig. 20 Right exit flue clearances
WARNING: This appliance should not be installed where
there is a potential for excessive ground water coverage.
This boiler is only suitable for installing externally at a
suitable location onto a fixed permanent rigid surface
capable of supporting the boiler weight.
There must be a sufficient hard standing around the
appliance to allow for servicing.
The boiler must be installed on a flat level surface to
ensure that condensate does not enter the primary heat
exchanger.
Tarmac and wood hardstandings are not recommended.
6720809437-07.1Wo
3
2
2
3
1
1
6720809437-08.1Wo
600mm
2500mm
600mm
BASE
FRONT
600mm min
6720809437-09.1Wo
FRONT
2500mm
45mm
85mm
600mm Plan
view
6720809437-10.1Wo
50mm
10mm
600mm
2500mm
FRONT
Plan
view
6720809437-11.1Wo
FRONT
2500mm
10mm
600mm
50mm
Plan
view

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 17
4.8 Flue terminal positions
Fig. 21 External boiler flue terminal positions
1. An opening means an openable element, such as an openable
window, or a permanent opening such as a permanently open air
vent.
Notwithstanding the dimensions above, a terminal should be at least
300mm from combustible material, e.g. a window frame.
Terminals should be positioned so as to avoid products of
combustion accumulating in stagnant pockets around the building or
entering into buildings.
2. A way of providing protection of combustible material would be to fit
a heat shield at least 750mm wide.
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.
• The following additional guidelines (from part L Exceptions Guidance
Document) are recommended when determining the flue outlet
position:
• Avoid discharging flue gases into car ports or narrow passageways.
• *Minimum distance of the flue terminal from above ground is
2100mm where directed to a public footpath, private access route
or a frequently used area and 2500mm from a car parking area.
• **Recommended minimum distance of the flue terminal to a facing
wall, fence, building or property boundary is 2500mm.
• Terminals should be positioned so as to avoid products of
combustion accumulating in stagnant pockets around the building or
entering into buildings.
• The flue must be fitted and terminated in accordance with the
recommendations of BS5410.
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a nuisance.
• Flue gases have a tendency to plume and in certain weather
conditions a white plume of condensation will be discharged from the
flue outlet which could be regarded as a nuisance, for example, near
security lighting.
• There should be no restriction preventing the clearance of
combustion products from the terminal.
• The air inlet/outlet duct and the terminal of the boiler must not be
closer than 25mm to any combustible material. Detailed
recommendations on protection of combustible materials are given
in BS 5410:1
• A protective stainless steel terminal guard, must be fitted if the
terminal is 2m or less above a surface where people have access.
– The guard must be spaced equally (minimum 50mm) around the
flue and fixed with plated screws.
– See 'Contact Information' on the back cover for flue guard
information.
6720809437-30.1Wo
boundary
F
I
H
B
A
G
E
C, D
F
F
J
K
boundary
Terminal position Balanced horizontal flue
A 1Directly below an opening, air brick, opening window etc. 600mm
B 1Horizontally to an opening, air brick, opening window, etc. 600mm
C Below a plastic/painted gutter, drainage pipe or eaves if combustible material is protected 75mm
D 2Below a plastic/painted gutter, drainage pipe or eaves without protection to combustible material 600mm
E From vertical sanitary pipework 300mm
F From an external or internal corner or from a surface or boundary alongside a terminal 300mm
G Above ground or balcony level 300mm*
H From a surface or boundary facing a terminal 600mm**
J From a terminal facing a terminal 1200mm**
K Vertically from terminal on the same wall 1500mm

Pre-Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)18
4.9 Flue options
4.9.1 Cabinet mounted balanced horizontal flue options
• The horizontal flue is fitted to the rear or either side of the cabinet.
Fig. 22 Flue options
4.9.2 Plume management
Fitting the terminal plume management kit
1. Remove and retain the screws that secure the terminal end into the
flue.
2. Discard the terminal end.
3. Fit the terminal elbow into the flue but do not secure with the screws
until the plume management system has been assembled.
Fig. 23 Fitting the terminal bend
1. Connect the sections of the plume management for desired length.
– Screw the clamp into the wall.
– Push the extension/s tube fully into the 90° bend, then withdraw
the tube by approximately 10mm to allow for expansion.
2. Once the plume management system is in place and secured to the
wall, secure the terminal bend with the screws remove earlier.
▶ The terminal end can be positioned up to 45° either side of the
central position, for plume re-direction.
▶ Adjust the plume management terminal end into the desired position
and secure with the screws provided.
Fig. 24 Plume management detail
It is strongly recommended that the flue terminal faces
away from walls to minimise the occurrence of wetting.
NOTICE: Flue length:
▶ The flue length of all the external boilers using this
plume management application will be in the range
of 160 to 2000mm.
Effective lengths of elbows
Bend Flue Plume
90° 1000mm 1000mm
45° 500mm 500mm
Table 6 Effective lengths of bends
6720809437-12.1Wo
FRONT
Plan
View
FRONT
Plan
View
FRONT
Plan
View
REAR FLUE OUTLET
LEFT HAND FLUE OUTLET
RIGHT HAND FLUE OUTLET
2.
3.
6720645523-50.1Wo
1.
1.
6720645523-51.1Wo
1.
2.
±45°
Min. 150mm
M

Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09) 19
5 Installation
5.1 Unpacking the boiler
Unpacking
It is advised that at least two or more persons are involved in the transfer
of the packaged boiler from the van to the point of delivery.
1. Once the packaged boiler has been delivered, the outer carton is
removed first.
Care should be taken when releasing the straps. If a sharp implement
is used make sure the outer carton is not pierced and that the
implement is used in such a way so that it may not cause personal
injury. All sharp objects must be covered or the blade retracted after
use and put away in a safe place.
2. Lift carton up and away from the boiler.
▶ Remove the plastic bag and upper front protection cover from the
boiler and place safely aside.
▶ Two or more persons are required to move the boiler taking care not
to damage the boiler, panels or the floor.
Fig. 25 Unpacking
5.2 Pipework positions and flue opening
Fig. 26 Pipework and flue positions (all measurements in mm)
[A] Flue
[B] Services
[C] Condensate
[D] Fire valve & drain access
[E] PRV (Pressure Relief Valve)
[F] Oil
CAUTION: Lifting and carrying
▶ Lift only a manageable weight, or ask for help.
▶ When lifting or putting things down, bend your
knees, keep your back straight, and feet apart.
▶ Do not lift and twist at the same time.
▶ Lift and carry object close to your body.
▶ Wear protective clothing and gloves to protect
against sharp edges.
NOTICE: Before installation
▶ All the previous Pre-Installation sections must be
read and requirements met before starting boiler or
flue installation.
NOTICE: Heavy objects
▶ At all times the correct method for handling heavy
objects should be strictly observed.
6720809437-13.1Wo
CAUTION: Drilling
▶ Ensure there are no pipes, electrical cables, damp
proof courses or other hazards before drilling.
6720809437-14.1Wo
93
A
REAR
RIGHT HAND SIDE
LEFT HAND SIDE
B
C
D
E
91
269 152
171
559
715
704
55
94
105
105
330
784 794
784
659
669
659
679
699
625
624.5
492
437
327
224
794
784 794
A
A
B
B
C
E
D
F
C
E
F
55
90
715
124
491.5

Installation
Greenstar Danesmoor External ErP and External System ErP - 6 720 813 288 (2014/09)20
Safety
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety goggles must be worn as
appropriate.
Pipework connections - Regular
• Flow connections (optional combined feed and vent) 1” BSP
• Return connections 22mmØ copper on 12/18, 18/25 models and
28mmØ copper on 25/32 models
• Condensate outlet 21.5mm Ø
Pipework connections - System
• Flow connections 12/18 & 18/25 - 22mm Ø , 25/32 - 28mm Ø .
• Return connections 22mmØ copper on 12/18, 18/25 models and
28mmØ copper on 25/32 models
• Condensate outlet 21.5mm Ø
• PRV - 15mm
5.3 Boiler installation
▶ Mark position of the 100mm services duct on the exterior wall and
make a hole through.
▶ Remove the screws [1] securing the base panel to the transit pallet
and lift the boiler off the pallet and into its installation position taking
care not to scrape the base panel across the hard standing.
– Do not attempt to lift and position the boiler on your own.
– Do not use the copper pipes to move the boiler.
▶ Fasten the base to the hard standing using the holes provided. Care
should be taken to ensure that the base is level.
▶ Remove the key for the door fasteners from the literature pack.
– Undo the screws at the bottom of the front panel (using the key
provided) and remove the screws from the rear panel pulling both
panels down and out to remove. Store safely away from the
installation point.
▶ Remove the screws from the top panel and lift up to remove, store
safely away from the installation point. Remove the screw tool from
the installation pack.
Fig. 27 Access to boiler
▶ Unplug burner lead [1]from control box.
▶ Unscrew to loosen the retaining ring [4] that secures the flexible air
supply tube [3] to the burner and remove from the burner.
▶ Undo and remove the retaining nut [2] on the top of the burner.The
burner can now be removed from the heat exchanger. Store the
burner and retainer nut safely away from the boiler.
▶ Measure the 100mm Ø services duct to give at least 10mm inside the
casing and to finish flush with the interior wall surface, cut to size and
fit the duct. Fit the 100mm sealing ring where the duct enters the
casing and seal the joint to the exterior wall and inside the cabinet
with a suitable sealant.
Fig. 28 Disconnecting burner
▶ Measure the 100mm Ø services duct to give at least 10mm inside the
casing and to finish flush with the interior wall surface, cut to size and
fit the duct. Fit the 100mm sealing ring where the duct enters the
casing and seal the joint to the exterior wall and inside the cabinet
with a suitable sealant.
5.4 Flue installation
Installation notes
▶ Ensure all the seals are in good condition and seated properly.
▶ To ease assembly of flue components, grease seals lightly with the
solvent free grease supplied.
▶ A terminal guard must be fitted if the terminal is 2m or less above a
surface where people have access.
▶ Lightly grease the flue cowl seal with the solvent free grease
supplied.
▶ Carefully remove the blanking plate from the appropriate flue
aperture (if necessary) and refit the blanking plate in the unused
aperture.
▶ Carefully remove the insulation from the flue aperture in the cabinet
that the flue is to pass through, and fit to the unused aperture (if
necessary).
▶ Refer to the flue manual supplied with the flue kit for flue installation.
For servicing purposes, keep condensate discharge pipe
away from components and pipework connections.
6720809437-15.1Wo
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6720809437-16.1Wo
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3
1