Worcester GREENSTAR 24i junior User guide

UK/IE
INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR 24i Junior/28i Junior
6720643895-00.1Wo
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
6 720 802 047 (2013/05)
The appliance is for use with Natural Gas or
L.P.G. (Cat II 2H3P type C13, C33 & C53)
Model GC Number
Natural Gas 24i Junior 47-406-54
28i Junior 47-406-56
Liquid Petroleum Gas 24i Junior 47-406-55
28i Junior 47-406-57

CONTENTS
6 720 802 047 (2013/05)2
CONTENTS
1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 APPLIANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Electricity supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.3 Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 10
3.4 Condensate pipe work . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.2 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Pressure relief pipe work . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Boiler location and clearances . . . . . . . . . . . . . . . . . . . 14
3.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.2 Servicing clearances - Ventilated compartments . . . . 14
3.6.3 Compartments: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.4 Boiler clearances - unventilated compartments: . . . . . 14
3.6.5 Installation clearances - Unventilated compartments . 14
3.6.6 Bathrooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.9 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.10 Plume management terminal positions . . . . . . . . . . . . 19
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Unpacking wall frame & ancillary items . . . . . . . . . . . . 20
4.2 Wall mounting template & flue openings . . . . . . . . . . . 20
4.3 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Boiler connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.1 Measuring the flue (Standard flue): . . . . . . . . . . . . . . . 24
4.5.2 Reducing the telescopic flue length . . . . . . . . . . . . . . . 24
4.5.3 Installing the telescopic flue . . . . . . . . . . . . . . . . . . . . . 25
4.5.4 Flue terminal plume re-direction . . . . . . . . . . . . . . . . . 25
4.6 Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7.1 Mounting optional plug-in controls . . . . . . . . . . . . . . . . 28
4.7.2 Domestic installations . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . 30
5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5.1 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 32
5.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5.3 Domestic hot water: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6.1 Replace outer casing: . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6.2 Fitting fascia flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6.3 Installing bottom panel . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.6.4 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 SERVICE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2 Check the gas inlet pressure . . . . . . . . . . . . . . . . . . . . . 35
6.3 Checking flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.5 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6.1 Setting the CO/CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.7 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 38
6.8 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.8.1 Removing outer case . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.8.2 Primary sensor (CH NTC) . . . . . . . . . . . . . . . . . . . . . . . . 41
6.8.3 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.8.4 Flue overheat thermostat (with grommet) . . . . . . . . . . 41
6.8.5 Moving controls to service position . . . . . . . . . . . . . . . . 41
6.8.6 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.8.7 Air/gas manifold and fan assembly . . . . . . . . . . . . . . . . 42
6.8.8 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.8.9 Electrode assembly and burner . . . . . . . . . . . . . . . . . . . 43
6.8.10 Re-assembly of the burner clamping plate . . . . . . . . . . 43
6.8.11 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.8.12 Access to boiler control components . . . . . . . . . . . . . . 45
6.8.13 PCB fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.8.14 Access to PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.8.15 Replacing controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.8.16 Syphon removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.8.17 Diverter valve motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.8.18 Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.8.19 Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.8.20 DHW Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . 48
6.8.21 Pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.8.22 Flow sensor, flow restrictor housing and filter . . . . . . . 48
6.8.23 Flow regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.8.24 Drain tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8.25 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8.26 Hydraulic block removal . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8.27 CH Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.28 DHW Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.29 DHW plate heat exchanger . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.30 Bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.31 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.9 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 FAULT FINDING AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 53
7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1.1 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2 Central heating function . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.3 Preheat and DHW function . . . . . . . . . . . . . . . . . . . . . . . 57
7.4 Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

KEY TO SYMBOLS AND SAFETY PRECAUTIONS
6 720 802 047 (2013/05) 3
1 KEY TO SYMBOLS AND SAFETY
PRECAUTIONS
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
SYMBOLS USED IN THIS MANUAL
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
STARTING INSTALLATION.
1.2 SAFETY PRECAUTIONS
IF YOU SMELL GAS
A gas leak could potentially cause an explosion. If you smell gas, observe
the following rules.
▶ Prevent flames or sparks:
– Do not smoke, use a lighter or strike matches.
– Do not operate any electrical switches or unplug any equipment.
– Do not use the telephone or ring doorbells.
▶ Turn off the gas at the meter or regulator.
▶ Open windows and doors.
▶ Warn your neighbours and leave the building.
▶ Prevent anyone from entering the building.
▶ Well awayfrom the building: call the National Gas Emergency Service
on 0800 111 999.
▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank.
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.
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 Explanation
▶ Step in an action sequence
Cross-reference to another part of the document
• List entry
– List entry (second level)
Table 1
Domestic Hot Water
Central Heating
Hot Water Storage Cylinder
Domestic Cold Water Supply
Electrical Supply
Gas Supply
Table 2 Commonly used symbols
These instructions are applicable to the Worcester appliance model(s)
stated on the front cover of this manual only and must not be used with
any other make or model of appliance.
These instructions apply in the UK and Ireland only and must be
followed except for any statutory obligations.
This appliance must be installed by a GAS SAFE registered,
competent person. Failure to install correctly could lead to
prosecution.
If you are in any doubt, contact the Worcester Technical helpline
(0844 892 3366).
Please leave these instructions with the completed BENCHMARK
CHECKLIST, (or a certificate confirming compliance with IS 813, Eire
only) and the user manual with the owner or at the gas meter after
installation or servicing.
Distance learning and training courses are available from Worcester.
The BENCHMARK CHECKLIST can be found in the back of this
Installation manual.
ØDiameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
DCW Domestic Cold Water
PRV Pressure Relief Valve
NTC Negative Temperature Coefficient (sensor)
IP Ingress Protection
RCD Residual Current Device
TRV Thermostatic Radiator Valve
ECV Emergency Control Valve
WRAS Water Regulations Advisory Scheme
SEDBUK Seasonal Efficiency of Domestic Boilers in the United
Kingdom
Table 3 Abbreviations use in this manual

KEY TO SYMBOLS AND SAFETY PRECAUTIONS
6 720 802 047 (2013/05)4
Benchmark places
responsibilities on both
manufacturers and
installers.
The purpose is to ensure
that customers are provided with the correct equipment for their needs,
that it is installed, commissioned and serviced in accordance with the
manufacturer's instructions by competent persons and that it meets the
requirements of the appropriate Building Regulations. The Benchmark
Checklist can be used to demonstrate compliance with Building
Regulations and should be provided to the customer for future
reference.
Installers are required to carry out installation, commissioning and
servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hotwater Industry Council who
manage and promote the scheme.
Visit centralheating.co.uk for more information.
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.
Chemically aggressive substances 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 the current Gas
Safety (Installation and Use) Regulations.
Flue systems must not be modified in any way other than asdescribed in
the fitting instructions. Any misuse or unauthorised modifications to the
appliance, flue or associated components and systems could invalidate
the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING
Advise the user to have the system serviced annually by a competent,
qualified Gas Safe registered engineer. Approved spares must be used
to help maintain the economy, safety and reliability of the appliance.
IMPORTANT
The service engineer must complete the Service Record on the
Benchmark Checklist after each service.
INSTALLATION REGULATIONS
Current Gas Safety (Installation & Use) Regulations:
All gas appliances must be installed by a competent person in
accordance with the above regulations.
Failure to install appliances correctly could lead to prosecution.
The appliance must be installed in accordance with, and comply to, the
current: Gas Safety Regulations, IEE Regulations, Building Regulations,
Building Standards (Scotland) (Consolidation), Building Regulations
(Northern Ireland), local water by-laws, Health & Safety Document 635
(The Electricity at Work Regulations 1989) and any other local
requirements.
British Standards:
Where no specific instruction is given, reference should be made to the
relevant British Standard codes of Practice.
BS7074:1 Code of practice for domestic and hot water supply
BS6891 Installation of low pressure gas pipe work up to 28mm (R1)
BS5546 Installation of gas hot water supplies for domestic purposes
EN12828 Central heating for domestic premises
BS5440:1 Flues and ventilation for gas appliances of rated heating not
exceeding 70kW (net): Flues
BS5440:2 Flues and ventilation for gas appliances of rated heating not
exceeding 70kW (net.: Air Supply
BS7593 Treatment of water in domestic hot water central heating
systems
BS6798 Installation of gas fired boilers of rated input up to 70kW (net)
Irish Standards
The relevant Irish standards should be followed, including:
• ECTI National rules for electrical installations
• IS 813:2002 for Domestic Gas Installations.
LPG Installations
An appliance using L.P.G. must not be installed in a room or internal
space below ground level unless one side of the building is open to the
ground.
Timber framed building:
Where the boiler is to be fitted to a timber framed building the guidelines
laid down in BS5440: Part 1 and IGE "Gas Installations in Timber Frame
Buildings” should be adhered to.
Potable water:
All seals, joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
be approved by WRAS.
CH Water:
Artificially softened water must not be used to fill the central heating
system.
BOILER FEATURES AND CHECKLIST
• Pre-wired and pre-plumbed
• Galvanised steel inner frame
• Digital control system
• Automatic ignition
• Direct burner ignition electrodes
• Built-in frost protection
• Built-in fault finding diagnostics
• Modulating automatic gas valve
• Combustion air fan with speed regulator
• CH temperature sensor & control
• Low NOx option
•FXIntelligentcontrols
• Pump anti-seizure protection
• Flue gas temperature sensor
• Condensate siphonic trap
• DHW flow sensor and temperature control
• Plate type DHW heat exchanger
CHECK LIST - HARDWARE LITERATURE PACK: Qty.
Greenstar 24i/28i Junior Installation, Commissioning and
Servicing Instructions
1
Users Instructions 1
Consumer Guarantee Card 1
Sealing Pack: 1
- Compression Nut 22mm 3
- Compression Ring 22mm 3
- Compression Nut 15mm 3
- Compression Ring 15mm 3
- Fibre Washer 18.6 x 13.5 x 1.5 2
- Fibre Washer 23.9 x 17.2 x 1.5 2
- Bonded Washer 3/4 1
Syphon assembly 1
- Installation instructions 1

APPLIANCE INFORMATION
6 720 802 047 (2013/05) 5
2 APPLIANCE INFORMATION
2.1 APPLIANCE
2
43
5
* 710mm to top of case front
1
700mm*
400mm
330mm Depth to wall
(When fitted to wall frame)
6
6720643895-01.3Wo
STANDARD PACKAGE:
1 Wall hung gas fired condensing combi boiler for central heating
and domestic hot water
2 Wall mounting frame
3 Hardware literature pack (see checklist)
4 Bottom Panel
5Fasciapanel
6Syphonassembly

APPLIANCE INFORMATION
6 720 802 047 (2013/05)6
2.2 TECHNICAL DATA
DESCRIPTION NATURAL GAS LPG
UNIT
24i
junior
Low NOx1)
24i & 28i
junior
1) The low NOx code plugs for the 24i and 28i Junior are available as an optional accessory.
24i Junior code plug kit number -7 716 192 356- 28i Junior code plug kit number - 7 716 192 357
28i
junior
24i
junior
28i
junior
Domestic Hot Water
Low NOx
only applies
to Central
Heating
Minimum heat input kW 7.00 7.00 9.64 9.64
Maximum rated heat output kW 24 28 24 28
Maximum rated heat input (net) kW 24.49 28.57 24.49 28.57
Minimum DHW flow rate to activate the boiler l/min 3333
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m³/h 2.59 3.02 - -
Propane Gas (LPG) kg/h --1.92.22
Maximum mains inlet pressure bar 10 10 10 10
Minimum mains inlet pressure (working) for max. flow bar 1.3 1.3 1.3 1.3
Minimum mains inlet pressure (working) for operation bar 0.2 0.2 0.2 0.2
Domestic Hot Water temperature range °C 40 - 60 40 - 60 40 - 60 40 - 60
2)Max. Domestic Hot Water flow rate - 40 °C rise ±15%
2) Greenstar i Junior combi boilers are fitted with a flow regulator set to achieve a 40°C temperature rise. This ensures comfortable bathing during the colder winter months.
l/min. 8.6 10 8.6 10
Central Heating
Maximum rated heat input (net) kW 24.62 13.4 24.62 24.62 24.62
Maximum rated heat output 40/30 °C kW 25.67 13.97 25.67 25.67 25.67
Maximum rated heat output 50/30 °C kW 25.45 13.85 25.45 25.45 25.45
Maximum rated heat output 80/60 °C kW 24 13 24 24 24
Maximum flow temperature °C 82 82 82 82 82
Maximum permissible operating pressure bar 2.5 2.5 2.5 2.5 2.5
Available pump head at 21 °C system temperature rise m 2.0 2.0 2.0 2.0 2.0
Flue
Flue gas temperature 80/60 °C, rated/min. load °C 78/63 66/57 78/64 79/64 79/65
Flue gas temperature 40/30 °C, rated/min. load °C 54/35 43/35 54/36 55/38 55/39
CO2level at max. rated heat output (after 30 minutes) % 9.8 9.8 9.8 11.0 11.0
CO2level at min. rated heat output (after 30 minutes) % 8.8 8.8 8.8 10.5 10.5
NOx class 55 555
NOx rating mg/kWh 66 38 66 69 69
Condensate
Maximum condensate rate l/h 2.0 1.02 2.0 2.0 2.0
pH value, approx. 4.8 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage a.c. V 230 230 230 230
Frequency Hz 50 50 50 50
Maximum power consumption W 140 140 140 140
Power consumption in standby mode. W 3.5 3.5 3.5 3.5
General data
Appliance protection rating IP X4D X4D X4D X4D
Appliance protection rating with mechanical or RF mechanical timer or
FW100 module fitted
IP 20 20 20 20
Permissible ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50
Nominal capacity of appliance litre 3.9 3.9 3.9 3.9
Noise output level (Max central heating) dBA 42 42 42 42
Total boiler weight kg 37.5 37.5 37.5 37.5
Lift weight kg 26.2 26.2 26.2 26.2
SEDBUK 2005 band AAAA
SEDBUK 2005 % 90.1 90.1 91.8 91.8
SEDBUK 2009 % 89.1 89.1 90.1 90.1

APPLIANCE INFORMATION
6 720 802 047 (2013/05) 7
2.3 LAYOUT
Fig. 1 Main boiler components
6720804530-10.1Wo
12
33
32
31
30
29
10
12
11
13
14
16
17
18
15
28
27
25
26
24
23
22 21 20 19
34
5
6
7
8
9

APPLIANCE INFORMATION
6 720 802 047 (2013/05)8
Fig. 2 Hydraulic block components
1ExpansionVessel 26 Left side hand-hold for lifting boiler
2 Flow temperature sensor (NTC) 27 Plate to Plate heat exchanger
3 Removable panel - for servicing 28 Gas valve
4Electrodeassembly 29 Flue air pressure switch connection (not used)
5 Overheat thermostat 30 Fan
6 Securing nut - Air/Gas manifold clamp 31 Manual vent point
7 Silicon tube - heat exchanger air vent 32 Fan pressure test point
8 Heat exchanger 33 Air/Gas manifold
9 Flue over heat thermostat 34 Compact hydraulic - left mounting point
10 Access panel - Heat exchanger/sump cleaning 35 Flow connector from heat exchanger
11 Right side hand-hold for lifting boiler 36 Expansion vessel hose connection point
12 Pump 37 Auto air vent
13 Diverter valve assembly (body) 38 Return connection to heat exchanger
14 Diverter valve actuator (stepper motor) 39 Flow turbine
15 Diverter valve protective cover 40 Unused port
16 Drain point 41 Compact hydraulic - right mounting point
17 Central Heating (CH) return isolator 42 Pressure relief valve
18 Domestic Cold Water mains (DCW) isolator 43 CH return connection to service valve
19 System pressure gauge 44 DCW in connection to service valve
20 Control panel (in service position) 45 Internal by-pass
21 Cover - external wiring connections 46 DHW out connection
22 Cover - PCB 47 CH flow connection to service valve
23 Gas inlet connection 22mm 48 Pressure gauge connection point
24 Domestic Hot Water (DHW) connection 49 DHW temperature sensor (NTC)
25 Central Heating (CH) flow isolator
Table 4 Boiler components
34 35 27 3736 38 39
40
41
42
49
48
47
46
12 45 44 16 43
14 13
6720804530-17.1Wo

PRE-INSTALLATION
6 720 802 047 (2013/05) 9
Fig. 3 Additional components
3 PRE-INSTALLATION
3.1 CLEANING PRIMARY SYSTEMS
BEFORE CLEANING THE SYSTEM:
▶ Ensure that the system and pipe work is in good working order.
▶Where possible keep the existing boiler/circulating pumpin 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.
FLUSHING THE SYSTEM
▶ Fill the system with cold water and check for leaks.
▶ Open all drain cocks and drain the system.
▶ Close drain cocks and add a suitable flushing agent compatible with
aluminium at the correct strength for the system conditions in
accordance with the manufacturer‘s instructions.
The pH value of the system water must be less than 8 or the
appliance guarantee will be invalidated.
▶ Circulate the flushing agent before the boiler is fired up.
▶ Run the boiler/system at normal operatingtemperature asdirected 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 refill with fresh water and a suitable
inhibitor.
▶ Vent any air from the boiler and system.
1 Burner ON indicator light (green) 10 CH return isolator
2 Power ON/OFF indicator/fault diagnostic light (blue) 11 DCW mains in isolator
3 Position for optional programmer 12 Gas inlet connection 22mm & isolator
4 Reset button 13 DHW connection
5 System pressure gauge 14 CH flow isolator
6ECObutton 15 Condensate connection
7 DHW temperature control 16 CH temperature control
8 Boiler identification label 17 Service mode button
9 PRV pipe connection point
Table 5 Additional boiler components
123 45
6
7
17
16
910111213
15 14
6720643895-15.1Wo
8
NOTICE:
▶ Allthe following Pre-Installation sections mustbe read
and requirements met before starting boiler or flue
installations.
CAUTION:
▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING
ANY WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
NOTICE:
Debris from the system can damage the boiler and
reduce efficiency.
Failure to comply with the guidelines for the use of water
treatment with the appliance will invalidate the
appliance warranty.
NOTICE: ARTIFICIALLY SOFTENED WATER MUST NOT
BE USED TO FILL THE CENTRAL HEATING SYSTEM.

PRE-INSTALLATION
6 720 802 047 (2013/05)10
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:
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
benecessary to provide an untreated water by-passto the primary water
filling point of the heat system.
3.2 MAINS SUPPLY
3.2.1 ELECTRICITY SUPPLY
• Supply: 230V - 50 Hz, 140 Watts
• Cable: PVC insulated 0.75mm2(24 x 0.2mm) rated to 90 °C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• This appliance must not be connected to a three phase supply.
• IPX4D.
• Wiring must comply with the latest edition of BS7671 (IEE wiring
regulations).
3.2.2 GAS SUPPLY
• Boilers using Natural Gas (NG) must be connected to a governed
meter.
• Liquid Petroleum Gas (LPG) must be connected to a regulator.
• Installation and connection of the gas supply to the boiler must be in
accordance with BS6891.
• Under no circumstance should be size of the gas supply pipe be less
than 22mm.
• The meter or regulator and pipe work to the meter must be checked,
preferably by the gas supplier.
This is to ensure that the equipment is in good working order and can
meet the gas flow and pressure requirements, in addition to the
demand from any other appliance being served.
3.2.3 WATER SUPPLY
WATER MAINS PRESSURE:
• Minimum mains water pressure: 1.3 bar for 24 and 28i Junior, for
maximum performance.
• Maximum mains fed water pressure 10 bar.
If necessary fit a pressure reducing valve.
• Where the mains water supply has a non-return, flow back prevention
valve fitted, a mini expansion vessel (1) should be connected to the
mains water inlet pipe (2) between the non-return valve (3) and the
boiler (4) as shown below.
USE IN HARD WATER AREAS:
Normally there is no need for watertreatmentto prevent scale formation
as the maximum temperature of the HW heat exchanger is limited by the
electronic control.
In areas where temporary water hardness exceeds 200 ppm,
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.
3.3 WATER SYSTEMS AND PIPE WORK
PLASTIC PIPE WORK:
• Any plastic pipe work must have a polymeric barrier with 600mm
(minimum) length of copper pipe connected to the boiler.
• Plastic pipe work used for underfloor heating must be correctly
controlled withathermostatic blending valve limitingthetemperature
of the circuits to approximately 50 °C.
PRIMARY SYSTEMS CONNECTIONS/VALVES:
• All system connections, taps and mixing valves must be capable of
sustaining a pressure up to 3 bar.
• Radiator valves should conform to BS2767:10.
• All other valves should conform to BS1010.
• Thermostatic radiator valves (TRV’s) must be used on all radiators
within the sleeping accommodation but not the radiator where the
room thermostat is sited. This must be fitted with lock-shield valves
and left open.
• A drain cock is required at the lowest point in the system.
• An air vent is required at all the high points in the system.
WARNING: Sealing agents
▶ Normally the addition of sealing agents to the system
water is not permitted as this can cause problems
with deposits left in the heat exchanger.
▶ In cases where all attempts to find a micro leak have
failed, Worcester, Bosch Group supports the use of
Fernox F4 leak sealer.
FERNOX 0870 601 5000 or www.fernox.com
SENTINEL 0800 389 4670 or www.sentinel-solutions.net
NOTICE: This is reduced to IP20 if the following
mechanical timers are fitted;
7 716 192 036 or 7 716 192 037 or FW100 controller
7 716 192 067.
NOTICE: Non-return, flow back prevention devices
(including those associated with water meters) fitted to
the mains water supply can cause a pressure build up
which could damage the boiler and other household
appliances.
1 Mini expansion vessel - part no. 7 716 102 105
2 Mains water inlet pipe
3 Non return valve
4Boiler
1
4
32
6720643895-04.1Wo

PRE-INSTALLATION
6 720 802 047 (2013/05) 11
SHOWERS/BIDETS:
• Ensure that the shower is suitable for use with mains water pressure.
• If a shower head can be immersed in water or comes closer than
25mm from the top edge of a bath or shower tray spill over level then
an anti-syphon device must be fitted to the shower hose.
• Bidets with direct hot and cold mains water can be used (with the
approval of the local water authority) and must be the over rim
flushing type with shrouded outlets to prevent the fitting of hand held
sprays.
SEALED PRIMARY SYSTEM:
• The CH sealed system must be filled using a WRAS approved filling
loop or comply with figure 4 for system fill.
• Where the system volume is more than 100 litres or exceeds 2.65 bar
at maximum heating temperature, an extra expansion vessel (2) must
be fitted as close as possible to the appliance in the central heating
return.
• Pressurise the extra expansion vessel (2) to the same figure as the
expansion vessel built into the appliance.
•Do not use galvanised pipes or radiators.
SYSTEM FILL
Fig. 4 System fill
TYPICAL SEALED SYSTEM
Fig. 5 Existing build - Sealed system
NEW BUILD - SEALED SYSTEM WITH ZONE VALVES
Thelatest Part L1a regulationfor new installationsrequire separatezone
controls for the central heating.
Fig. 6 New build - Sealed system
3.4 CONDENSATE PIPE WORK
3.4.1 INTERNAL CONNECTIONS
In order to minimise risk of freezing during prolonged cold spells, the
following methods of installing condensate drainage pipe should be
adopted, in order of priority.
Wherever possible, the condensate drainage pipe should be routed and
terminated so that the condensate drains away from the boiler under
gravity to a suitable internal foul water discharge point such as an
internal soil and vent stack. A suitable permanent connection to the foul
waste pipe should be used.
The boiler is equipped with an internal by-pass.
The internal bypass is not intended to be a substitute for
an external system bypass.
An external automatic bypass should be used if the
system flow can be significantly adjusted or stopped by
zone valves and thermostatic radiator valves (TRV).
NOTICE: Artificially softened water must not be used to
fill the central heating system.
CV = Check Valve
SV = Stop Valve
SV SV
Test point
Temporary hose
Hose union CV
CV
Heating
return
Mains
supply
6720643895-05.1Wo
44
1
2
3
5 5
55
6720643895-06.1Wo
1 Appliance expansion vessel - CH
2 Extra expansion vessel - CH return
3 Pressure relief discharge
4 Drain cock
5Radiators
6 Zone valves
Table 6 Key to fig. 5 & 6
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
22mm Ø plastic 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.
Key to condensate illustrations
1 Condensate discharge from boiler
2 Soil and vent stack
3 Minimum 450mm and up to three storeys
4 Visible air break at plug hole
5 Sink or basin with integrated overflow
6 75mm sink waste trap
7 Condensate pump
* Condensate trap of 75mm already incorporated into the boiler
4
6
4
2
3
5 5
55
M
M
6720646608-04.1Wo
1

PRE-INSTALLATION
6 720 802 047 (2013/05)12
Fig. 7 Disposal to soil vent stack
Alternatively if the first option is not possible an internal kitchen or
bathroom waste pipe, washing machine waste pipe etc. can be used.
Ensure that the condensate drain pipe is connected “down stream” of
the waste trap.
Fig. 8 Disposal to a waste pipe
CONDENSATE PUMP
Where “gravity discharge” to an internal termination is not physically
possible, or where very long internal runs would be required to reach a
suitable discharge point, condensate should be removed using a
proprietary condensate pump, of a specification recommended by the
boiler or condensate pump manufacturer.
The pump outlet pipe should discharge to a suitable internal foul water
discharge point such as an internal soil and vent stack, internal kitchen
or bathroom waste pipe, washing machine waste pipe etc. A suitable
permanent connection to the foul waste pipe should be used.
Fig. 9 Condensate pump disposal
3.4.2 EXTERNAL CONNECTIONS
If no other discharge method is possible then the use of an externally run
condensate drainage pipe terminating at a suitable foul water discharge
point, or purpose-designed soak away, may be considered. If this
method is chosen then the following measures should be adopted:
▶ Use a CondenseSure siphon to help prevent the condensate freezing.
▶ The external run be kept as short as possible and not exceed 3 metres.
▶ The pipe should be run internally as far as possible before going
externallyand the pipe diametershouldbe increasedto32mm before
it passes through the wall to the exterior. The pipe should be insulated
using suitable waterproof and weather resistant insulation, if not
using a CondenseSure siphon.
▶ 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.
2
22mm Ø
1
3
6720644744-06.2Wo
*
100mm
75mm
min.
4
5
6
1
22mm Ø
6720644744-07.2Wo
*
NOTICE: Freezing conditions
▶ When the position of the boiler prevents internal
routing, we recommend installing a CondenseSure
siphon to significantly reduce the risk of freezing.
▶ Pipework length should be kept to aminimumandthe
route as vertical as possible.
▶ Weather proof insulation must be used, if not using a
CondenseSure siphon.
NOTICE: Condensate waste
▶ Careshould betaken whensiting a soak-away to avoid
obstructing existing services.
Continued - Key to condensate illustrations
8 PVCu strap on fitting
9 100mm Ø minimum plastic pipe
10 Drainage holes
11 Limestone chippings
12 Bottom of sealed tube
13 Insulate and increase pipe size
14 Pipe work transition
15 External air break
16 Air gap
17 External rain water pipe into foul water
18 43mm 90° male/female bend
* Condensate trap of 75mm already incorporated into the boiler
75mm
min.
4
7
5
6
1
22mm Ø
6720644744-08.2Wo
*

PRE-INSTALLATION
6 720 802 047 (2013/05) 13
▶ 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.
FITTING AN EXTERNAL AIR BREAK
• Refer to figure 10 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. 10 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. 11 External disposal
CONDENSATE 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 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. 12 Condensate pump to external disposal
Fig. 13 Soak away
Condensate drainage pipe can be run above or below
ground.
18 8
13
14
17
15
16
1
6720644744-09.2Wo
*
25mm min.
14
13
1
6720644744-10.2Wo
*
Minimumholesizeforthe condensatesoak away must be
400mm deep by 300mmØ .
NOTICE: Unheated internal areas.
▶ Internal pipe runs in unheated areas such as lofts,
basements and garages should be treated as external
runs and consideration should be given to using a
CondenseSure siphon.
25mm min.
14 13
1
7
6720644744-12.2Wo
*
13
14
10
500mm min.
25mm min.
400mm
min.
1
12
11
9
6720644744-11.2Wo
9
10
*

PRE-INSTALLATION
6 720 802 047 (2013/05)14
3.5 PRESSURE RELIEF PIPE WORK
• The pressure relief drain pipe (1) from the boiler should be at least
15mm diameter copper pipe and run downwards, away from any
electrical equipment or other hazard, preferably to an external drain
or soak away.
• Pipe (1) should be finished with a partial bend, near the outlet to face
the external wall (as shown) to help prevent freezing.
Fig. 14 Pressure relief pipe work
3.6 BOILER LOCATION AND CLEARANCES
3.6.1 INSTALLATION
This boiler is only suitable for installing internally within a property at a
suitable location onto a fixed, rigid surface at least the same size as the
boiler and capable of supporting the boiler weight.
3.6.2 SERVICING CLEARANCES -
VENTILATED COMPARTMENTS
Figure 15 shows the minimum space required to install and service the
boiler in a ventilated compartment.
• If a boiler is installed in a compartment with clearances less than
shown in the tables 9, 10, or 11 ventilation is required. Refer to
table 8 for ventilation requirements.
Fig. 15 Ventilated compartment
3.6.3 COMPARTMENTS:
Follow the requirements of BS6798 and BS5440 Part 2 and note:
• Minimum clearances must be maintained.
• An access door is required to install, service and maintain the boiler
and any ancillary equipment.
• If the boiler is installed in an unventilated airing/storage cupboard,
thereis norequirement to make a partitionbetween theboiler and the
storage space as long as the minimum clearances around the boiler
are maintained.
• Ideally, storage should be below the boiler, where the boiler is
mounted in the upper part of the cupboard, whilst maintaining the
clearances given in tables 9, 10, or 11.
3.6.4 BOILER CLEARANCES - UNVENTILATED COMPARTMENTS:
3.6.5 INSTALLATION CLEARANCES - UNVENTILATED
COMPARTMENTS
NOTICE:
▶ The pressure relief valve is a safety device for the
boiler and if activated may discharge boiling water or
steam through the relief valve drain pipe.
▶ Care should be taken when siting the outlet pipe so
that it does not cause an obstruction or discharge
above a window, entrance or other public access
where it could cause a hazard.
2Outsidewall
1,3 Drain pipe
4Externaldrain
Table 7 Key to fig 14
NOTICE:
No surface protection is required against heat transfer
from the boiler
1
2
3
4
2
3
4
1
2
6720646608-123.1Wo
Vent position To room or internal space Direct to outside
High level Minimum free area 122cm2Min. free area 61cm2
Low level Minimum free area 122cm2Min. free area 61cm2
Table 8 Compartment ventilation
* Minimum clearance to removable door
** Minimum clearance required for servicing
The tables below show the options for the minimum space required to
install and service the boiler inside an unventilated compartment.
CAUTION: CLEARANCES
▶ Top and bottom clearances must not be reduced
below the values shown in table 9 as they are the
minimum clearances required for servicing.
Unventilated Compartment Installation Clearances (millimetres)
Suggested total unventilated compartment minimum clearances are:
Side Above Below Front (to removable door)
400 170 approx.
(30 above the elbow)
200 100
Table 9 Minimum unventilated compartment clearances
6720643895-121.2Wo
+ 30 mm
above elbow
930 mm 410 mm
20 mm*
600 mm**
5 mm
Using 100 mm
ue kit
1080 mm
Using 125 mm
ue kit
1100 mm
200 mm
5 mm

PRE-INSTALLATION
6 720 802 047 (2013/05) 15
3.6.6 BATHROOMS
A boiler fitted with a mechanical timer or RF mechanical timer (receiver)
or FW100 controller may only be installed outside the shaded area.
A boiler with any other timer fitted (or blanking panel for an optional
programmer) can be installed in zone 2.
Additional RCD (Residual Current Device) protection may be required.
Refer to the latest IEE wiring regulations.
Fig. 16 Bathroom installations
3.7 PLUMBING MANIFOLD
3.7.1 CONNECTIONS
Use the fittings supplied in the Hardware literature pack.
• If the boiler pipes are to be run behind the appliance ensure that the
pipes pass through the slot in the white cardboard guide. Thisis fitted
to the boiler frame.
• For further ease of fitting, an optional Vertical Pre-piping Assembly kit
is available, comprising five
pre-formed copper pipes and an earth bonding strip.
Part number: 7 716 192 570.
• To cover the pipe work under the boiler, down to the counter top, an
optional “Below boiler pipe cover” can be used.
Part number: 7 716 192 608
Fig. 17 Pipe dimensions
If Side Clearances are Reduced (millimetres)
If total side clearance is
reduced to:
(Combined left & right
clearances excluding
appliance)
Increase height
clearances to (approx):
(Combined top &
bottom clearances
excluding appliance)
or Frontclearance
(to removable
door) must be
increased to:
350 441 129
300 523 161
250 617 200
200 717 243
150 856 295
100 1012 358
50 1202 434
Table 10 Reduced side clearances
If Front Clearance is Reduced (millimetres)
If front clearance
(to removable
door) is reduced
to:
Increase overall height
clearances to (approx):
(Combined top and
bottom clearances
excluding the appliance)
or Increase total side
clearance to:
(Combined left & right
clearances excluding
the appliance)
50 511 505
25 596 569
Table 11 Reduced front clearances
2* Without the end wall, zone 2 must extend 600mm from the bath
6720646608-124.3Wo
2*
Radius 600mm
1
212
2
1
600mm
600mm 600mm
2250mm
2250mm
2*
Heating System 22mm compression fittings
DHW 15mm compression fittings
Gas 22mm compression fitting
Further guidance on pipe routing can be found printed
on the boiler template (supplied with the boiler).
123 4 567
6720643895-107.1Wo

PRE-INSTALLATION
6 720 802 047 (2013/05)16
Fig. 18 Plumbing manifold
3.8 FLUE OPTIONS
FLUE LENGTHS
The flue systems have different maximum flue lengths
The Greenstar series has the option of two horizontal 60/100 RSF
(telescopic and longer telescopic) and one horizontal 80/125 RSF
(telescopic) flue system and two vertical RSF (60/100 or 80/125) flue
systems:
The next page shows various fluing options.
Refer to the Flue options in table 13 for the straight flue lengths required
to achieve the maximum flue length.
#Function
From left
case edge
Diameter of
pipe
1CHFlow 70mm 22mm
2 DHW Outlet 135mm 15mm
3Gas 200mm 22mm
4DomesticColdMainsIn 267mm 15mm
5CHReturn 330mm 22mm
6Condensate 35mm 22mm
7 Pressure Relief Valve 367mm 15mm
Table 12 Key to figures 17 & 18
6720643895-11.3Wo
12345
123
45
CAUTION: Non accessible flue systems:
▶ Where a flue system is not going to be accessible,
provision must be made for service and inspection.
▶ Voids containing concealed flues must have at least
one inspection hatch no less than 300mm square.
▶ Flue joints within the void must not be more than 1.5
metres from the edge of the inspection hatch.
▶ Inspection hatches should be located at changes of
direction.
▶ If this is not possible, bends should be viewable from
both directions.
NOTICE: Effective flue lengths:
▶ each 90° bend used is equivalent to
2 metres of straight flue
▶ each 45° bend used is equivalent to
1 metre of straight flue
Plume management kits are available for the 60/100
horizontal flue system.
Refer to the manual supplied with the plume
management kits for complete installation instructions
24i and 28i junior boilers
Maximum total
flue length (mm)
FLUE TYPE 60/100 80/125
1 Telescopic horizontal flue assembly 570 1,070
Longer telescopic horizontal flue assembly 790 N/A
2 Horizontal flue extension 4,600 13,000
3 Horizontal flue with 1 x 90° bend 2,600 11,000
4 Horizontal flue with 2 x 90° bends N/A 9,000
5 High level horizontal flue 4,600 13,000
6 High level horizontal flue with 2 x 90° bends 2,600 11,000
7 High level horizontal flue with 3 x 90° bends N/A 9,000
8 Vertical balanced flue assembly 6,400 15,000
9 Vertical balanced flue with 2 x 90° bends 2,400 11,000
10 Vertical balanced flue with 2 x 45° bends 4,400 13,000
Table 13 Flue options
Part number Flue Description
7 716 191 082 60/100 Telescopic horizontal flue assembly
7 716 191 171 60/100 Longer telescopic horizontal flue
assembly
7 719 003 702 80/125 Telescopic horizontal flue assembly
7 719 002 430 60/100 Vertical flue assembly
7 719 002 431 80/125 Vertical flue assembly
Table 14 Flue option part numbers

PRE-INSTALLATION
6 720 802 047 (2013/05) 17
350 mm - 570 mm
130 mm Min
Flat roof
300 mm
500 mm
Pitched
roof
2
3
4
5
6
10
9
8
7
1
6720643895-12.1Wo

PRE-INSTALLATION
6 720 802 047 (2013/05)18
3.9 FLUE TERMINAL POSITIONS
Fig. 19 Flue terminal positions
Key to illustration
1.300mm adjacent to a boundary line.
2. The dimension below eaves, gutters, pipes and drains can be reduced
to 25mm, as long as the flue terminal is extended to clear any
overhang. External flue joints must be sealed with suitable silicon
sealant.
3.1,500mm between a vertical flue terminal and a window or dormer
window.
4.1,200mm between terminals facing each other.
5.Vertical flue clearance, 300mm adjacent to a boundary line unless it
will cause a nuisance. BS 5440:Part 1 recommends that care is
taken when siting terminal in relation to boundary lines
6.600mm distance to a boundary line, unless it will cause a nuisance.
BS 5440:Part 1 recommends that care is taken when siting terminal
in relation to boundary lines.
7.600mm minimum clearance from a skylight to a vertical flue.
8. Vertical flue clearance,500mm to non-combustible building material,
and 1,500mm clearance to combustible building material.
9.300mm above, below and either side of an opening door, air vent or
opening window.
10.600mm diagonally to an opening door, air vent or opening window.
11.300mm to an internal or external corner.
12.2,000mm below a Velux window, 600mm above or to either side of
the Velux window.
13.400mm from a pitched roof or 500mm in regions with heavy snow
fall.
14.500mm clearance to any vertical structure on a roof, 600mm to
room sealed flue or 1,500 to an open flue.
15.200mm below eaves and 75mm below gutters, pipe and drains.
16.The dimension below eaves, balconies and car ports can be reduced
to 25mm, as long as the flue terminal is extended to clear any
overhang. External flue joints must be sealed with suitable silicon
sealant.
17.Flue clearance must be at least 300mm from the ground. Terminal
guards must be fitted if the flue is less than 2 metres from the ground
or if a person could come into contact with the flue terminal.
18.600mm distance to a surface facing a terminal, unless it will cause a
nuisance. BS 5440: Part 1 recommends that care is taken when siting
terminals in relation to surfaces facing a terminal.
16
600
300
200
300
1,200
Boundary Line
1,500
1,500
All measurements in millimetres
2
1
12
11
10
9
5
18
7
6
13
15
4
3
17
14
300 300
300 300
300
300 300
500
600
300
600
600
400
300
25
8
300
500
600
6720643895-13.3Wo
300
25
225 16
2m
1m
52mm 104mm
NOTICE:
▶ All measurements are the minimum clearances required.
▶ Terminals must be positioned so to avoid combustion products entering the building.
▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.
(flue bracket 100mm part number: 7 716 191 177,
flue brackets 100mm x 6 part number: 7 716 191 178,
flue bracket 125mm part number: 7 716 191 179).
Note:
▶ Installations in car ports are not recommended.
▶ The flue cannot be lower than 1,000mm from the top
of a light well due to the build up of combustion
products.
▶ Dimensions froma flue terminal to a fanned air inlet to
be determined by the ventilation equipment
manufacturer.

PRE-INSTALLATION
6 720 802 047 (2013/05) 19
3.10 PLUME MANAGEMENT TERMINAL POSITIONS
Fig. 20 Plume terminal positions
Key to illustration
1.This feature allows some basic plume re-direction options on a
standard telescopic horizontal flue terminal.
300mm minimum clearances to a opening e.g. window.
However the minimum clearances to an opening in the direction that
the plume management is facing, must be increased to 1,500mm.
Where the flue is less than 150mm to a drainpipe and plume re-
direction is used the deflector should not be directed towards the
drainpipe.
2.300mm adjacent to a boundary line.
3. Plume Management kit air intake can be reduced to 150mm providing
the flue exhaust outlet is no less than 300mm adjacent to a boundary
line.
4.1,200mm between terminals facing each other.
5.600mm distance to a boundary line, unless it will cause a nuisance.
BS 5440:Part 1 recommends that care is taken when siting terminal
in relation to boundary lines.
6.Using a Plume Management kit the air intake measurement can be
reduced to 150mm providing the flue exhaust outlet has a 300mm
clearance.
Plume kits running horizontally must have a 10° fall back to the boiler
for proper disposal of condensate.
For details on specific lengths see relevant boiler Technical &
Specification information.
7.Internal/external corners. The air intake clearance can be reduced to
150mm providing the flue exhaust outlet has a 300mm clearance.
8. Clearances no less than 200mm from the lowest point of the balcony
or overhang.
9. 1,200mm from an opening in a car port on the same wall e.g. door or
window leading into the dwelling.
10.600mm distance to a surface facing a terminal, unless it will cause a
nuisance. BS 5440: Part 1 recommends that care is taken when siting
terminals in relation to surfaces facing a terminal.
200
300
150
200
8
4
5
3
2
9
200
600
All measurements in millimetres
300
300
150
150
300
300
25
25
150
1,200
300
200
10
100
600
Plume re-direction:
180°
±80°
1
7
±45°
Flue Exhaust
Outlet
Air Intake
6
10
Boundary Line
6720643895-14.2Wo
150
300
300
Flue terminal guard 7 716 191 176
600
1,500
Maximum and minimum plume management lengths:
▶ A minimum distance of 500mm must be maintained between the plume management outlet and the flue air intake.
▶ The maximum plume management length is 4.5 metres for the appliances detailed on the front of this manual.
▶ The 45° bend is equivalent to 0.75 metres of straight plume management and the 90° bend is equivalent to 1.5 metres.
NOTICE:
▶ All measurements are the minimum clearances required.
▶ Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume
terminal positions”.
▶ Terminals must be positioned so to avoid combustion products entering the building.
▶ Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings.
Note:
▶ Installations in car ports are not recommended.
▶ The flue cannot be lower than 1,000mm from the top
of a light well due to the build up of combustion
products.
▶ Dimensions froma flue terminal to a fanned air inlet to
be determined by the ventilation equipment
manufacturer.

INSTALLATION
6 720 802 047 (2013/05)20
4 INSTALLATION
4.1 UNPACKING WALL FRAME & ANCILLARY ITEMS
1.Wall mounting frame
2.Wall mounting template
3.Inner packaging
4.Installer pack
5.Bottom panel
6.Front fascia
7.Syphon assembly
Fig. 21 Unpacking
IMPORTANT HANDLING INSTRUCTIONS:
• It is advised that two people are used to carry the carton from the van
to the point of delivery.
• Once the carton 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.
Care should be taken when lifting the boiler from the base and the
proper technique for safe lifting of any heavy object should be strictly
observed.
Additional requirements for roof space installation:
• The boiler should be first unpacked before ascending ladder to loft
space.
• Two sets of steps should be used.
• Two people should share the lifting of the boiler up to the loft hatch,
wherethe boileris entered into the loft spacetilted andslid onits back
into the loft.
• Once the appliance is removed from its packaging check the contents
against the packing list.
1. Remove straps and open the top of the boiler packaging.
2. Remove the wall mounting frame (1) and wall mounting template (2)
and from the packaging.
3. Remove the boiler bottom panel (5), front fascia (6), hardware
literature pack (4) and syphon assembly (7) from the carton.
4.2 WALL MOUNTING TEMPLATE & FLUE OPENINGS
SAFETY:
All relevant safety precautions must be undertaken. Protective clothing,
footwear, gloves and safety goggles must be worn as appropriate.
FIXING THE WALL MOUNTING FRAME:
▶ The boiler wall mounting template shows the relative positions of the
flue and the top and bottom fixing of the wall mounting frame.
1. Fix the wall mounting template to the wall in the desired position.
2. Drill 4 holes for the wall mounting frame through the template.
REAR FLUE OUTLET
▶ The figure 22 shows the boiler wall mounting template with the flue
centre lines of both the 100mm and 125mm flue systems.
3. Mark centre line of flue to be used (3); the external diameter of the
hole can also be marked if required.
▶ If a 100mm diameter flue is to be used, a 125mm diameter hole is
required. However, if using the weather sealing collar by pushing it
through from inside the property, then a 150mm diameter hole is
required to accommodate this.
▶ The flue turret of the 100mm flue has an in-built 3° angle.
▶ If extensions are to be added then the complete flue must rise at an
angle of 3°.
▶ Drill hole using a core drill or similar.
SIDE OUTLET:
4. Mark from the centre line of the wall mounting template to the wall
which the flue will pass through (4).
▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle.
▶ Clear any debris from the site.
WARNING: All the previous “Pre-Installation” sections
must be read and the requirements met before starting
boiler or flue installation.
CAUTION: LIFTING AND CARRYING
▶ Only lift a manageable weight, or ask for help.
▶ Bend the knees and keep the back straight with feet
apart, when lifting or putting down heavy objects.
▶ DO NOT lift and twist at the same time.
▶ Lift and carry object close to the body.
1
3
2
4
5
6
7
6720643895-16.1Wo
NOTICE:
▶Before installing the appliance, ensure that the
system has been cleaned as explained on page 9.
WARNING: BEFORE DRILLING:
Ensure that there are no pipes, electrical cables,
damp proof courses or other hazards.
The wall mounting template has been sized to allow for
minimum clearances of 5mm sides, 200mm base and
30mm above a 100mm diameter flue elbow.
An optional filling loop: 7 716 192 281 is available to fill
the system (not supplied with the boiler).