Worcester Greenstar 8000 Life Series User manual

6720883865 (2021/11) UK/IE
Installation and Maintenance Instructions
Gas fired condensing combi boiler
Greenstar 8000 Life
GR8300iW 30 C | GR8300iW 35 C | GR8300iW 40 C | GR8300iW 45 C | GR8300iW 50 C

Table of contents
Greenstar 8000 Life – 6720883865 (2021/11)
2
Table of contents
1 Explanation of symbols and safety instructions . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4
2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 About the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Appliance type overview . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Pipework positions and flue outlet . . . . . . . . . . . . . . . . . 9
3.7 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Product data for energy consumption . . . . . . . . . . . . . 11
4 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 System preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.1 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.2 Water systems and pipework . . . . . . . . . . . . . . . . . . . . 12
4.1.3 System layouts examples. . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.4 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.3 Water supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Appliance location and clearances . . . . . . . . . . . . . . . . 15
4.3.1 Appliance location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.2 Rooms containing a bath or shower . . . . . . . . . . . . . . . 16
4.3.3 Appliance clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Flue systems considerations . . . . . . . . . . . . . . . . . . . . . 17
4.4.1 Flue length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.2 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.3 Plume management system. . . . . . . . . . . . . . . . . . . . . . 20
4.4.4 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.5 Plume re-direct and plume management terminal
positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.1 Condensate pipework . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.2 Appliance siphonic condensate trap. . . . . . . . . . . . . . . 28
4.5.3 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.4 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.6 Pressure relief discharge . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6.1 Pressure relief pipework . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6.2 Alternative PRV connections - Combined PRV/
condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 33
4.7.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1.1 Mounting frame fixing . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Appliance connections . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Hanging the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Flue turret/adaptor installation. . . . . . . . . . . . . . . . . . . 40
5.5 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5.1 Installer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5.2 Cable preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.5.3 External controls - domestic installations . . . . . . . . . . 44
6 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.1 Pre-Commissioning checks. . . . . . . . . . . . . . . . . . . . . . 44
6.2 Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.2.1 Filling the appliance and adding Inhibitor . . . . . . . . . . 45
6.2.2 Adjusting the operating pressure of the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3.2 Turn on the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3.3 Siphon filling mode, manual activation/de-
activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4 Chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5 Combustion casing removal . . . . . . . . . . . . . . . . . . . . . 47
6.6 Checking gas inlet pressure . . . . . . . . . . . . . . . . . . . . . 47
6.6.1 Checking the gas supply pressure . . . . . . . . . . . . . . . . 47
6.7 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8 Checking for gas leaks during operation . . . . . . . . . . . 49
6.9 CO and combustion check . . . . . . . . . . . . . . . . . . . . . . 49
6.10 Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.11 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.12 Range rating the appliance . . . . . . . . . . . . . . . . . . . . . . 51
6.13 Finishing commissioning. . . . . . . . . . . . . . . . . . . . . . . . 52
6.13.1 Fitting the appliance casing . . . . . . . . . . . . . . . . . . . . . 52
6.13.2 Appliance/product guarantee. . . . . . . . . . . . . . . . . . . . 53
7 Settings in the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1 Operating the service menu . . . . . . . . . . . . . . . . . . . . . 53
7.2 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2.1 Service functions overview . . . . . . . . . . . . . . . . . . . . . . 54

Table of contents
3
Greenstar 8000 Life – 6720883865 (2021/11)
8 Inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .60
8.1 Inspection and maintenance considerations . . . . . . . .60
8.2 Resources for inspection and maintenance . . . . . . . . .60
8.3 Inspection and maintenance steps . . . . . . . . . . . . . . . .60
8.4 Component access. . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.5 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
8.6 Check working gas inlet pressure . . . . . . . . . . . . . . . . .62
8.7 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
8.8 Checking the flue integrity . . . . . . . . . . . . . . . . . . . . . . .63
8.9 Cleaning the siphon and heat exchanger . . . . . . . . . . .63
8.9.1 Checking the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . .63
8.9.2 Checking the non-return valve in the air-gas
manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
8.9.3 Fan removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
8.9.4 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . .65
8.9.5 Checking electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . .67
8.9.6 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
8.10 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . .68
8.10.1 Checking and, if required, adjusting the gas/air
ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
9 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
9.1 Draining the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .71
9.2 Overheat thermostat removal . . . . . . . . . . . . . . . . . . . .71
9.3 Pressure sensor removal . . . . . . . . . . . . . . . . . . . . . . . .71
9.4 Pressure relief valve removal . . . . . . . . . . . . . . . . . . . . .72
9.5 Replacing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . .72
9.6 Checking the strainer in the cold water pipe and
the flow turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
9.7 Checking/replacing the motor of the 3-way valve. . . . .73
9.8 Replacing the 3-way valve . . . . . . . . . . . . . . . . . . . . . . .73
9.9 Replacing the plate heat exchanger. . . . . . . . . . . . . . . .74
9.10 Following inspection/maintenance . . . . . . . . . . . . . . . .74
10 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10.1 Operating and fault displays . . . . . . . . . . . . . . . . . . . . .74
10.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10.1.2 Fault code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
10.1.3 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . .81
11 Environmental protection and disposal . . . . . . . . . . . . . . . . .83
12 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.1.1 Specifications Combi. . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.2 Ionisation current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
12.3 Component resistance characteristics . . . . . . . . . . . . . 88
12.3.1 Sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12.4 Code plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12.5 Pump characteristic map of the heating pump. . . . . . . 88
12.6 Limiting nominal heat output (range rating)
(Service function 3-b1) . . . . . . . . . . . . . . . . . . . . . . . . . 88
12.7 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
12.8 Gas Boiler System Commissioning Checklist and
Warranty Validation Record. . . . . . . . . . . . . . . . . . . . . . 92
12.9 Inspection and maintenance checklist . . . . . . . . . . . . . 93
12.10 Service and Interim Boiler Work Record. . . . . . . . . . . . 94

Explanation of symbols and safety instructions
Greenstar 8000 Life – 6720883865 (2021/11)
4
1 Explanation of symbols and safety instructions
1.1 Explanation of symbols
Warnings
In warnings, signal words at the beginning of a warning are used to
indicate the type and seriousness of the ensuing risk if measures for
minimizing danger are not taken.
The following signal words aredefined and can be used in this document:
DANGER
DANGER indicates that severe or life-threatening personal injury will
occur.
WARNING
WARNING indicates that severe to life-threatening personal injury may
occur.
CAUTION
CAUTION indicates that minor to medium personal injury may occur.
NOTICE
NOTICE indicates that material damage may occur.
Important information
The info symbol indicates important information where there is no risk to
people or property.
Additional symbols
Table 1
1.2 General safety instructions
HPlease read these instructions carefully before
starting installation.
• These instructions are applicable to the Worcester
appliance model(s) stated on the front cover of this
manual only and must not be used with any other
make or model of appliance.
• 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 competent
registered gas engineer, such as a Gas Safe
registered engineer including a British Gas
engineer. Failure to install correctly could lead to
prosecution.
• If you are in any doubt, contact the Worcester,
Bosch Group help line
(0330 123 3366).
• Distance learning and training courses are available
from Worcester.
• The BENCHMARK Commissioning Checklist can be
found on page 92 of this Installation manual.
HNotices for the target group
These installation instructions are intended for gas,
plumbing, heating and electrical contractors. All
instructions must be observed. Failure to comply with
instructions may result in material damage and
personal injury, including danger to life.
▶ Read the installation, service and commissioning
instructions (heat source, heating controller,
pumps, etc.) before installation.
▶ Observe the safety instructions and warnings.
▶ Follow national and regional regulations, technical
regulations and guidelines.
▶ Record all work carried out.
HIntended use
The appliance may only be used for heating water or
domestic hot water in domestic properties.
▶ Observe the details on the data plate and the
specifications (installation manual) to ensure
correct use of this appliance.
▶ Worcester Bosch offer flue gas systems which are
suitable for use with the appliance. It is the
responsibility of the installer of the flue to ensure
this flue gas system operates correctly and in a safe
manner.
HIf 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.
▶ Move well away from 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.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document
• a list entry
–a list entry (second level)

Explanation of symbols and safety instructions
5
Greenstar 8000 Life – 6720883865 (2021/11)
HRisk to life from carbon monoxide poisoning.
There is a risk to life from escaping flue gases
▶ Do not modify the flue gas system.
▶ Ensure that flue pipes and gaskets are undamaged.
If flue pipes are damaged or leaking:
▶ Turn off and isolate the appliance.
▶ Open windows and doors.
▶ If necessary, leave the building and warn your
neighbours.
▶ Prevent anyone from entering the building.
▶ Rectify any damage to the flue system immediately.
HInstallation and maintenance
Installation and maintenance must only be carried out
by a competent registered gas engineer, such as a Gas
Safe registered engineer or British Gas engineer.
▶ Carry out a gas tightness test after completing work
on gas-carrying components.
▶ Only use original spares.
HElectrical work
Electrical work must only be carried out by a qualified
electrician:
▶ Before starting electrical work;
– Ensure that the electricity supply is safely
Isolated and secured to prevent inadvertent re-
connection.
Information on safe isolation can be found in the
Health and Safety Executive guidance HSG85.
– Using test equipment approved to GS38 to
confirm that the electricity supply is
disconnected.
▶ Refer to the manufacturer’s information when
installing non Worcester components and systems
to the Worcester appliance.
HHandover to the user
When handing over, instruct the user how to operate
the heating system and inform the user about its
operating conditions.
▶ Explain how to operate the heating system and draw
the user's attention to any safety relevant action.
▶ In particular:
– Advise that alterations, servicing and repairs
must only be carried out by a competent,
registered gas engineer, such as a Gas Safe
registered engineer or British Gas engineer.
– Advise the user to have the appliance and system
serviced annually to help ensure economy, safety
and reliability.
▶ Point out the possible consequences (including
personal injury, danger to life and material damage)
of improper or inadequate inspection, cleaning and
maintenance.
▶ Point out the dangers of carbon monoxide (CO) and
recommend the use of CO detectors.
▶ Leave the installation instructions with the
completed Benchmark Checklist (or a certificate
confirming compliance with IS 813, Eire only) and
the operating instructions with the user or at the gas
meter.
HServicing
Advise the user to have the appliance and heating
system thoroughly serviced annually by a competent,
registered gas engineer, such as a Gas Safe registered
engineer or British Gas engineer.
In the Republic of Ireland servicing work must be
carried out by a Registered Gas Installer (RGII).
Approved spares must be used to help maintain the
efficiency, safety and reliability of the appliance.
HBenchmark Service Record
The service engineer must complete the Benchmark
Service Record at the back of this manual after each
service.
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 Hot water Industry Council who
manage and promote the scheme.
Visit hhic.org.uk for more information.
HHealth 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).

Regulations
Greenstar 8000 Life – 6720883865 (2021/11)
6
HCombustion 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.
HFitting and modification
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 as described in the fitting instructions. Any
misuse or unauthorised modifications to the
appliance, flue or associated components and
systems could invalidate the warranty. The
manufactureracceptsnoliability arising from any such
actions, excluding statutory rights.
HGeneral manual handling guidelines
▶ Only remove packaging at the time of the final
installation.
▶ Always use Health and Safety guidance for manual
handling of an appliance.
– Never lift or carry more than the safe guidance
limit on your own.
– Always use appropriate methods and equipment
when lifting/carrying an appliance.
▶ Never lift or carry packages by the shipping straps.
▶ During handling and unpacking, wear safety gloves.
▶ Dispose of packing materials appropriately.
HImportant handling instructions
Care should be taken when transporting, lifting and
carrying the appliance.
▶ Use a means of transport suitable for handling
appliances (e.g. sack truck with strap, stair
climbing or step trolley).
▶ When handling appliances, secure them against a
fall.
▶ Let only trained personnel undertake the handling.
▶ The correct method for handling heavy objects
should be strictly observed, at all times.
2Regulations
Installation regulations
Current Gas Safety (Installation and Use) Regulations:
All gas appliances must be installed by a competent, registered gas
engineer, such as a Gas Safe registered engineer or British Gas engineer
in accordance with the current 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
▶IETRegulations
▶ Building Regulations (England)
▶ Building Regulations (Wales)
▶BuildingStandards(Scotland) (Consolidation)
▶ S.I. No. 183 and 292 - Energy Performance of Buildings Regulations
(Ireland; current version)
▶ Health and Safety Document 635 (The Electricity at Work
Regulations 1989) and any other local requirements
▶ EU Regulations No. 2017/1369 - Energy Labelling (as retained in UK
law and amended)
▶ EU Regulations No. 811/2013 - Energy Labelling (as retained in UK
law and amended)
Building Regulations Part L1A (Current version) - new dwellings
If the installation is in a new build property or it is a first time installation
in an existing property, the heating systems must conform to current
building regulations Part L1A.
The exception to this are single storey, open plan dwellings where the
living area is more than 70% of the total usable floor area. Then this type
of dwelling can be controlled as one zone.
An alternative would be individual electronically controlled TRVs.
For dwellings with a floor area over 150m2, separate time and
temperature control for each zone is required. It is best practice to fit
Thermostatic Radiator Valves (TRV's) to all radiators except the area
where the room thermostat is sited.
Building Regulations Part L1B (Current version) - existing dwellings
For appliance replacements on an existing system, it is not necessary to
zone the upstairs and downstairs separately, compliance with the zone
requirements can be achieved by a single room thermostat or
programmable room thermostat.
While the system is drained down, it is best practice to fit Thermostatic
Radiator Valves (TRV's) to all radiators except the area where the room
thermostat is sited.

Product Information
7
Greenstar 8000 Life – 6720883865 (2021/11)
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 pipework 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)
•BS7671
– IET Wiring Regulations
Irish Standards
The current relevant Irish standards should be followed, including:
•ECTI
– National rules for electrical installations
• IS 813
– Domestic Gas Installations
LPG Installations
An appliance using LPG 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 buildings
Where the appliance 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.
Water supply:
All seals joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
meet the requirements of the WRC and hold approval by a notified body,
e.g. WRAS. The installation must also comply with the requirements of
Part G of the Building Regulations.
CH Water
Salt based artificially softened water must not be used to fill the central
heating system.
3ProductInformation
3.1 About the appliance
The boiler has the following features:
• 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
•Automaticgasvalve
• Modulating combustion air fan with speed regulator
• CH temperature sensor & control
• Pump anti-seizure protection
• Flue gas temperature sensor
• Condensate siphonic trap
• Plate type DHW heat exchanger
• Low Energy Modulating pump
• Range rated (the ability to change the maximum power output to suit
the heat demand of the building)
HMisuse
Appliance must be used as per the intended use
statement. Operation outside the parameters of the
intended use is considered misuse and could cause
harm to people and damage to property.
Accessories should be as per accessories list.
Minimum operational parameters are included in this
document.
Using the appliance outside of its intended use may
also invalidate the manufacturer's guarantee.

Product Information
Greenstar 8000 Life – 6720883865 (2021/11)
8
3.2 Scope of delivery
Fig. 1 Scope of delivery
[1] Wall mounted gas condensing boiler
[2] Mounting bracket
[3] Mounting plate with Keyless Filling Link pre-installed
[4] PRV discharge pipe
[5] Mounting bracket
[6] Guarantee card
[7] Set of printed documents for product documentation
[8] Fixing materials
[9] Lower cover
3.3 Declaration of Conformity
The design and operation of this product comply with European
Directives and the supplementary national requirements. Conformity
has been demonstrated by the CE marking.
You can ask for a copy of the declaration of conformity for this product.
For this see the contact address on the back cover of these instructions.
3.4 Appliance type overview
This appliance are for use with:
• Natural Gas or LPG (Cat.II 2H3P type C13, C33 & C53)
This document refers to the following appliance types:
Table 2 Type overview
The name of the appliance consists of the following parts:
• GR8300iW: Type name
• 30, 35, 40, 45 or 50: Hot water output in kW
• C: Combi appliance
• NG: Gas type (Natural Gas)
• LPG: Gas type (Liquid Petroleum Gas)
3.5 Product identification
Data plate
The data plate includes the product performance information, approval
data and serial number. The data plate location can be found in the
product overview.
Additional type plate
The product name and the most important product data are shown on
the additional data plate. The additional type plate can be found on the
outside of the product in an easily accessible location.
21
3
4
5
7
6
8
9
0010031218-002
Appliance type Part number Gas Council number
GR8300iW 30 C NG 7 738 100 800 47-800-18
GR8300iW 35 C NG 7 738 100 801 47-800-17
GR8300iW 40 C NG 7 738 100 802 47-800-16
GR8300iW 45 C NG 7 738 100 803 47-800-15
GR8300iW 50 C NG 7 738 100 804 47-800-14
GR8300iW 30 C LPG 7 738 100 849 47-800-23
GR8300iW 35 C LPG 7 738 100 850 47-800-22
GR8300iW 40 C LPG 7 738 100 851 47-800-21
GR8300iW 45 C LPG 7 738 100 852 47-800-20
GR8300iW 50 C LPG 7 738 100 853 47-800-19

Product Information
9
Greenstar 8000 Life – 6720883865 (2021/11)
3.6 Pipework positions and flue outlet
Fig. 2 Pipe and flue outlet dimensions
Table 3 Appliance and flue outlet dimensions
Table 4 Pipe dimensions
For servicing purposes, keep condensate and pressure release valve
discharge pipes away from other hydraulic components.
Description Dimensions [mm]
X Appliance width 440
Y Appliance height 780
Z Appliance depth 365
WFlue centre from appliance left side 220
D Flue centre from rear of appliance 87
#Function From left
case edge
Diameter of pipe
1 Condensate outlet 58mm 22mm
• Rubber push fit connection
2CH flow 90mm 22mm
• Compression fitting
3 DHW outlet 155mm 15mm
• Compression fitting
4Gas inlet 220mm 22mm
• Compression fitting
5 DCW inlet 285mm 15mm
• Compression fitting
6PRV discharge 314mm 15mm
• Compression fitting
7 CH return 350mm 22mm
• Compression fitting
0010023464-001
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Product Information
Greenstar 8000 Life – 6720883865 (2021/11)
10
3.7 Product overview
Fig. 3 Product overview Combi boilers, combustion cover removed
0010035843-002
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15
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14
12
11
9
10
8
1
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23
5
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26
27
29
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Product Information
11
Greenstar 8000 Life – 6720883865 (2021/11)
[1] Plate heat exchanger
[2] Key accessory housing slot (wireless Gateway)
[3] Condensate trap
[4] Data plate 1
[5] Hot water temperature sensor
[6] Pressure sensor
[7] Pressure gauge
[8] Venturi (sealed)
[9] Schrader Valve
[10] Fan
[11] Expansion vessel
[12] Heating flow
[13] Air-gas manifold with non-return valve
[14] Ignition transformer
[15] Flue
[16] Ignition electrodes
[17] Flame sensing electrode
[18] Heating block temperature limiter
[19] Flow temperature sensor at heating block
[20] Inspection cover
[21] Condensate sump
[22] Gas valve
[23] Automatic air vent valve
[24] Flow turbine
[25] Data plate 2
[26] Diverter valve
[27] Heating pump
[28] Drain point
[29] Pressure relief valve (heating circuit)
[30] Filling Link
[31] Control unit
3.8 Product data for energy consumption
The product data on energy consumption can be found in the operating
instructions for the user.

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Greenstar 8000 Life – 6720883865 (2021/11)
12
4Pre-Installation
NOTICE
Risk of damage to system or appliance!
Before installation
▶ All the following Pre-Installation sections must be read and
requirements met before starting appliance or flue installations.
4.1 System preparation
4.1.1 Artificially softened water
The heating system must not be filled with water which has been treated
using an ion exchange (salt based) water softener. Where these water
softeners are installed, a permanent untreated water supply should be
provided to maintain pressure in the heating system.
A bypass must be provided at the water softener to comply with
BS:14743. Where a permanent untreated supply cannot be provided,
the system must be initially filled using the bypass provided at the water
softener. Occasional topping up of the system with artificially softened
water is acceptable. Inhibitor must be added to the system. The pH levels
must be between 6.5 and 8.0 at the time of commissioning. When a
permanent untreated supply is not provided to the heating system filling
point, the pH levels must be checked annually and recorded in the
service record.
NOTICE
Risk of damage to appliance!
▶ The heating system must not be filled with water which has been
treated using an ion exchange water softener.
▶ If the system is partially drained for maintenance or repair work, the
system must be refilled by utilising the bypass valve at the water
softener. The pH and inhibitor levels should be checked.
4.1.2 Water systems and pipework
Primary system plastic pipework:
• Any plastic pipework must have a polymeric barrier, complying with
BS 7921 and installed to BS5955 with 600mm (minimum) length of
copper connected to the appliance.
• Plastic pipework used for under-floor 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
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.
• It is best practice to fit Thermostatic Radiator Valves (TRV's) to all
radiators, except the area where the room thermostat is sited which
must be fitted with lockshield valves that are left open.
• If the circulating pump speed is fixed and system circulation can be
significantly adjusted or stopped by TRV's or zone valves, a system
bypass should be installed to give at least a 3 metre circuit when
activated. However; any appliance fitted with a modulating pump
may not require a system bypass.
• Drain cocks are required at all the lowest points on the system.
• Air vents are required at all high points on the system.
Showers/Bidets:
• If a shower head can be immersed in water or comes closer than
25mm from the top edge of a bath or shower tray spill-over level then
an anti-siphon device must be fitted to the shower hose.
• 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 ofhand held
sprays.
Hot water:
• Taps and mixing valves must be capable of sustaining a pressure up to
10 bar.
• Hot water temperature and flow rate are affected by the size and
insulation of pipework making up the distribution system and are
controlled by the hot water tap and the water main inlet pressure. A
mixing valve can be fitted if a more permanent temperature setting is
required.
• If using more than one outlet at once causes water flow starvation, fit
flow balancing valves or Ball-O-Fix valves to the appropriate outlets.
• Thermostatic mixing valves (TMVs) must be fitted at the point of use
as specified in G3 of the building regulations and if specific, accurate
temperature control is required by the user.
Primary system considerations - Combi & System appliances
Sealed system
• The CH sealed system must be filled using a WRAS approved filling
loop or comply with examples in section 4.1.4 "System fill".
• Where the system volume is more than 100 litres or exceeds 2.5 bar
at maximum heating temperature an additional 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 value as the
built-in expansion vessel [1] (default pre-charge pressure is 0.75
bar).
Fig. 4 Additional expansion vessel
[1] Appliance expansion vessel
[2] Additional expansion vessel
[3] Pressure relief discharge
[4] Heating return
[5] Heating flow
0010021117-001
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Pre-Installation
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Greenstar 8000 Life – 6720883865 (2021/11)
Checking the size of the expansion vessel
To determine whether an additional expansion vessel is required: Follow
the steps below:
▶ Calculate the total system volume (litres). Plotting a line vertically on
the chart (Fig. 5).
▶ Determine the central heating maximum operating flow temprature
(73 °C for condensing). Plot a line horizontally on the chart
(Fig. 5).
▶ Determine the precharge in the expansion vessel based on static
head, 1 metre = 0.1 bar (default = 10 metres).
▶ Select a curve from the key below (1-5).
If the dissected lines are in area A then no additional expansion is
required.
If the dissected line is in are B then an additional expansion vessel must
be installed (Fig. 4).
Fig. 5 Curves for the expansion vessel
1 Pre-charge pressure 0.5 bar (minimum)
2 Pre-charge pressure 0.75 bar (default setting)
3 Pre-charge pressure 1.0 bar
4 Pre-charge pressure 1.2 bar
5 Pre-charge pressure 1.3 bar
T Maximum operating temperature [ °C]
V Total System Volume [l]
4.1.3 System layouts examples
Sealed primary system - Single central heating circuit:
Typical primary system example
Fig. 6 Single central heating circuit example
[1] Appliance
Sealed primary system - 2 x central heating zones:
• Requirement for new builds if the floor area of a property is over
150m2.
Fig. 7 Separated heating zones
[1] Appliance
[2] Zone valves
4.1.4 System fill
Filling primary sealed systems
NOTICE
Filling the primary sealed system
The system must not be filled with salt based softened water.
▶ Ensure the primary water filling point uses an untreated cold water
connection from the mains supply, before a water softener.
• Filling the system must comply with one of the following methods
shown.
• 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.
• If the external filling link is sited away from the appliance, then a
pressure gauge should be installed at the filling point.
The pressure shown on the gauge may differ from that shown on the
digital display. Final system pressure adjustments must be made whilst
referencing the digital display.
Integral filling link
• An optional filling link accessory is available to fill the system
(section "Integral keyless filling link", page 45).
0010016558-002
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60
70
80
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0 100 200 300 400 500 600 700
T[°C]
V[l]
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0010021228-002

Pre-Installation
Greenstar 8000 Life – 6720883865 (2021/11)
14
External filling loop
Fig. 8 External filling loop system fill example
[1] Cold mains inlet pipe
[2] Stop valve
[3] Check valve
[4] Test point
[5] Hose union
[6] Central heating flow pipe
4.2 Mains supply
4.2.1 Electrical supply
• Supply: 230V AC - 50 Hz
• This appliance must not be connected to a three phase supply.
• The wiring between the appliance and the electrical supply must
comply with the latest IET wiring regulations that apply to wiring a
fixed appliance for Class 1 equipment.
• The correct type of RCD must be employed where additional
protection is required that is suitable for a low energy DC modulating
pump according to IET wiring regulations.
• External 3A A fuse to BS1362.
• The appliance must be earthed.
• Cable: PVC insulated 0.75mm2(24 x 0.2mm) temperature rated to
90 °C, to BS EN50525.
• Any additional components that are connected to the appliance with
mains electrical supply must not have a separate supply.
• Additional equipment wired to the appliance must comply with the
latest IET wiring regulations.
• Appliance IP rating - IPX4D
4.2.2 Gas supply
• Appliances using Natural Gas (NG) must be connected to a governed
meter.
• Appliances using Liquid Petroleum Gas (LPG) must be connected to
a regulator.
• Installation and connection of the gas supply to the appliance must
be in accordance with the latest version of BS6891.
• Gas pipe sizing should be calculated to ensure no more than the
permitted mbar drop between the meter/governor to the appliance
inlet (chapter 12.8).
• The meter or regulator and its pipework 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.
Pipe sizing (NG & LPG)
Gas pipework:
▶ Gas installation pipework must be designed to ensure the pressure
loss between the meter outlet (NG) or storage and regulator (LPG)
and the inlet to each appliance does not exceed 1mbar (NG) 2.5mbar
(LPG) (table 16 ”Allowed mbar pressure drop”).
Basic pipe sizing calculation
Basic pipe sizing calculation.
▶This method is only an estimate - for more complex design please
refer to latest version of BS6891 and training given in ACS.
Natural Gas (NG):
Discharge rates for copper tube with 1mbar differential pressure
between the ends for Natural Gas.
Table 5 Natural Gas (NG)
Natural Gas:
▶ When using this table to estimate the gas flow rate in pipework of a
known length, the effective length will be increased by 0.5m for each
90° elbow and tee fitted and by 0.3m for each 45° bend.
Liquid Petroleum Gas (LPG):
Discharge rates for copper tube with 2.5mbar differential pressure
between the ends for LPG.
Table 6 Liquid Petroleum Gas (LPG)
Liquid Petroleum Gas (LPG):
▶ When using this table to estimate the Gas flow rate in pipework of a
known length, the effective length will be increased by 0.6m for each
90° elbow or tee and by 0.3m for each 45° bend or straight coupler.
0010012942-001
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Discharge rates for Natural Gas (m3/hr)
with straight horizontal copper tube
Pipe Pipe size (mm)
length (m) 15 22 28 35
32.9 8.7 18 32
61.9 5.8 12 22
91.5 4.6 9.4 17
12 Discharge 1.3 3.9 8 15
15 m3/hr 1.1 3.4 7 13
20 0.95 2.9 5.9 11
25 0.92 2.5 5.2 9.5
30 0.88 2.3 4.7 8.5
Discharge rates for LPG (m3/hr & kW)
with straight horizontal copper tube
Tubing Outside diameter
length (m) 15mm 22mm 28mm
kW m3/hr kW m3/hr kW m3/hr
3 38.4 1.49 207 8.01 412 15.92
626.1 1.01 135 5.21 230 8.86
9 20.5 0.79 108 4.19 215 8.33
12 17.9 0.70 94 3.62 187 7.25
15 15.5 0.60 82 3.20 168 6.51
18 13.5 0.53 74 2.86 145 5.61
21 12.9 0.50 67 2.58 135 5.24
24 12.0 0.47 61 2.58 126 4.87

Pre-Installation
15
Greenstar 8000 Life – 6720883865 (2021/11)
4.2.3 Water supply
Water supply:
All seals joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
meet the requirements of the WRC and hold approval by a notified body,
e.g. WRAS. The installation must also comply with the requirements of
Part G of the Building Regulations.
Use in hard water areas:
Normally there is no need for water treatment to prevent scale formation
as the maximum temperature of the DHW heat exchanger is limited by
the electronic control.
In areas where temporary water hardness exceeds 200ppm,
consideration may need to be given to the fitting of a scale prevention
device. In such circumstances, the advice of the local water authority
should be sought.
Water mains pressure:
• Minimum mains water pressure, for maximum performance refer to
section 12 "Technical Specifications/Logs".
• Maximum mains fed water static pressure is 10 bar.
If necessary fit a pressure reducing valve.
NOTICE
Non-return, back flow prevention devices (including those
associated with water meters) fitted to the mains water supply can
cause a pressure build up which could damage the boiler and other
household appliances.
NOTICE
Non-return valves in the cold water feed system.
If a non-return valve is fitted on the mains inlet, then pressure can
increase significantly over normal standing pressure when the appliance
carries out a DHW preheat or due to fast acting valves closing on other
appliances/outlets.
▶ To ensure water pressure stays at a level that will not damage the
boiler or other household appliances, we would recommend on
installations where standing pressure exceeds 3bar, that a 3 bar
pressure reducing valve and mini expansion vessel are fitted.
• Where the mains water supply has a non-return, back flow prevention
valve fitted, a mini expansion vessel [3] should be connected to the
mains water inlet pipe [1] between the non-return valve [2] and the
appliance[4] as shown below.
Fig. 9 Mini expansion vessel location
[1] Mains water inlet pipe
[2] Non-return valve
[3] Mini expansion vessel - part no. 7 716 192 105
[4] Appliance
4.3 Appliance location and clearances
4.3.1 Appliance location
• Follow local regulations for the location within the property that the
appliance is to be installed.
• This appliance is only suitable for installing internally within a
property at a suitable location onto a flat, fixed rigid surface capable
of supporting the appliance weight.
• The appliance is not suitable for external installation.
• Protect installation area against dust and moisture.
No surface protection is required against heat transfer from the
appliance.
DANGER
Danger to life from explosion!
An increased and permanent ammonia concentration may lead to stress
corrosion cracking on brass (e.g.gas valves, union nuts). As a result,
there is a risk of explosion from gas escaping.
▶Donotusewallmountedgasboilers in rooms where there is an
increased or permanent ammoniac concentration (e.g. livestock
stables or storage room for fertilisers).
▶ If contact with ammonia is unavoidable, make sure that there are no
brass parts installed in the system.
DANGER
Danger from explosive and flammable materials:
Storage of explosive and flammable materials.
▶ Do not store flammable materials (paper, curtains, clothing, primer,
paint, …) in proximity to the appliance.
NOTICE
Damage to appliance:
Contaminated combustion air.
▶ Do not use any cleaners containing chlorine or hydrogen halide (i.e.
spray cans, primers, cleaners, paint and glue).
▶ Do not store or use these substances in the appliance or room.
▶ Avoid the build-up of dust.
NOTICE
Damage to appliance:
Extreme temperatures may cause damage to the heating system.
▶ Ensure the ambient temperature is above 0 °C and below 35 °C.
NOTICE
Damage to system:
The heating system pipework can be damaged by frost if installed in an
internal unheated area, such as a loft, basement or garage.
The appliance internal frost protection only monitors the system water
temperature within the appliance to provide protection for the
appliance.
▶ Install a frost thermostat and pipe thermostat connected in series, to
protect the system pipework.
We recommend that the frost thermostat is sited in the coldest
unheated area in which pipework is located and that it is set to call for
heat at 5 °C. The Pipe stat should be located on whichever pipe is
0010015563-001
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Pre-Installation
Greenstar 8000 Life – 6720883865 (2021/11)
16
furthest from the heated area where warmer water will be drawn from
considering the direction of flow, and set to end the demand at 15 °C.
▶ The system pipework in the internal unheated area should be
insulated.
▶ If the appliance is to be shut down for an extended period, drain the
central heating system.
The appliance must be installed where:
▶ The area is well lit, allowing users to clearly see the appliance to carry
out any work or checks.
▶ An engineer can gain clear and safe access to work on the product or
component, including making adequate provision for visual
inspection of flues in voids.
▶ The homeowner can gain clear and safe access to the controls or to
check, top up or reset the appliance.
▶ Roof space installations must fully conform to BS 5410 part 1: roof
space installations.
▶ Products in roof spaces must have permanent fixed lighting, a
permanent fixed retractable ladder and a fixed floor area sufficient to
allow access for normal use and servicing around the product and
between the product and the access hatch.
We would also recommend that a remote pressure gauge and filling
loop are sited where the customer can gain easy access to assist with
checking and topping up.
4.3.2 Rooms containing a bath or shower
CAUTION
Risk of electric shock
▶ Any switch or appliance control using mains electricity must not be
within reach of a person using the bath or shower.
• In all cases the installation must be in accordance with the latest
amendments to the latest edition of the IET Wiring Regulations
(BS7671).
• Check the IP rating of any control units to be used on this appliance.
• Circuit breaking appliances should be used in accordance with the
regulations.
• Figure 10 is for guidance only.
Fig. 10 Bathroom installations
[1] Zone 1
[2] Zone 2
[2*] Without the end wall, zone 2 must extend 600mm from the bath
[A] 600mm radius from the bath or shower
4.3.3 Appliance clearances
• The following details cover the installation, service and maintenance
clearances for the appliance.
CAUTION
Risk of damage to appliance or property
The appliance will overheat if the clearance space around the appliance
is restricted by objects.
▶ Do not restrict this space with the addition of cupboards, shelves etc.
next to or around the appliance.
▶ Do not store any combustible materials on or next to the appliance,
such as clothes, towels, paper or plastic bags.
Fig. 11 Appliance minimum clearances
Table 7
[*] Height for either 60/100 flue or 80/125 flue
Reduced front maintenance minimum clearances
The front servicing clearance for this appliance can be reduced to
450mm.
For installations with a front servicing clearance less than 600mm
(minimum of 450mm), the following additional criteria must be
achieved.
• The bottom of the appliance case must be between 1000mm and
1500mm from the floor.
0010017086-001
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600mm 600mm
2250mm
2250mm
2*
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Minimum clearances
Description Dimensions [mm]
X Appliance width 440
YAppliance height 780
Z Appliance depth 365
Installation/Maintenance
1 Overall clearance height 1,150/1,190*
2Overall clearance depth 965
3In front of appliance 450
4Overall clearance width 450
5 Above the appliance 170/210*
6Either side of appliance 5
7 Below the appliance 200
8Compartment depth 385
9 Appliance to removable door 20
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Greenstar 8000 Life – 6720883865 (2021/11)
• There must be at least 450mm clearance in front of the appliance to
floor level. Anything sited below the appliance must not protrude into
this clear space.
• There must be at least 200mm clearance to any structure which is
sited below the appliance.
• There must be at least 300mm clear space to either the left hand or
right hand side of the appliance. This clear space must be from the
required clear height above the appliance to floor level.
– This clearance will not apply if the appliance is sited within
300mm of a door way and the door frame is the only obstruction.
Minimum clearances must be observed to any obstruction/ surface,
(dark shaded areas, figures 12 and 13).
Fig. 12 Reduced front maintenance clearances - Side view
[A] Appliance.
[1] Above appliance - Same clearance required as for standard
clearances of 60/100 flue or 80/125mm flue.
[2] In front of appliance - Minimum 450mm.
[3] Bottom of appliance to the floor - 1,000 - 1,500mm.
[4] Below appliance - 200mm
Fig. 13 Reduced front maintenance clearances - Front view
[A] Appliance.
[1] Above appliance - Same clearance required as for standard
clearances of 60/100 flue or 80/125mm flue.
[3] Bottom of appliance to the floor - 1,000 - 1,500mm.
[4] Below appliance - 200mm
[5] One side of appliance - Minimum 300mm.
[6] One side of appliance - Minimum 5mm.
Appliances in compartments
Follow the latest requirements of BS6798 and BS5440 and note:
• Minimum clearances must be maintained.
• An access door is required to install, service and maintain the
appliance and any ancillary equipment.
• If the appliance is installed in an unventilated airing/storage
cupboard, there is no requirement to make a partition between the
appliance and the storage space as long as the minimum clearances
around the appliance are maintained.
4.4 Flue systems considerations
WARNING
Flue systems
Possible flue gas escape
▶ Use Worcester, Bosch Group approved Condensfit II flue systems
only, no other manufacturer’s flue have been tested or approved for
use with Worcester, Bosch Group appliances.
0010031674-001
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Greenstar 8000 Life – 6720883865 (2021/11)
18
CAUTION
Concealed flue systems:
▶ Where a flue system is going to be concealed, 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.
Refer to the manual supplied with the Worcester, Bosch Group flue kit for
complete installation instructions.
Flue kit part numbers
Table 8 Flue kit assembly part numbers
4.4.1 Flue length
The maximum flue length will depend on the following factors:
• 60/100mm flue system
– Vertical/horizontal flue type
– Appliance output
– Plume management length
• 80/125mm flue system
– Vertical/horizontal flue type
– Appliance output
Horizontal maximum flue lengths
Table 9 Maximum flue lengths - Horizontal flues
Vertical maximum flue lengths
Table 10 Maximum flue lengths - Vertical flues
Flue system bends
NOTICE
Effective flue lengths of bends:
Each bend used has an equivalent straight flue length.
▶ Refer to table 11.
Table 11 Effective length of bends
4.4.2 Flue options
The systems have different maximum flue lengths, refer to the following
example flue options for those maximum flue lengths.
Horizontal high level flue assembly
Fig. 14 Horizontal flue option
• Flue length [L] (initial bend included in length calculation)
– 60/100 = 202 - 603mm
– 80/125 = N/A
Telescopic horizontal flue assembly
Fig. 15 Horizontal flue option
Telescopic horizontal flue assembly [A]
• Flue length [L] (adaptor bend included in length calculation)
– 60/100 = 180 - 570mm
– 80/125 = 405 - 600mm
Extended telescopic horizontal flue assembly [B]
• Flue length [L] (adaptor bend included in length calculation)
– 60/100 = 570 - 790mm
– 80/125 = N/A
Part number Flue Ø Description
7 738 112 869 60/100 Telescopic horizontal flue kit (Silver)
7 716 191 082 60/100 Telescopic horizontal flue kit
7 716 191 171 60/100 Extended telescopic horizontal flue kit
7 733 600 048 60/100 Horizontal high level telescopic flue kit
7 719 003 702 80/125 Telescopic horizontal flue kit
7 719 002 430 60/100 Vertical balanced flue kit
7 719 002 431 80/125 Vertical balance flue kit
Flue length [L]
60/100
Fluelength[L]
80/125
Output No plume
management
+ 500mm
of plume
management
+ 4500mm of
plume
management
No plume
management
available
50 kW 9,000mm 9,000mm 6,200mm 40,000mm
45 kW 8,000mm 8,000mm 5,200mm 35,000mm
40 kW 11,000mm 11,000mm 8,200mm 35,000mm
35 kW 10,000mm 10,000mm 7,200mm 29,000mm
30 kW 17,000mm 17,000mm 14,200mm 25,000mm
Flue length [L] Flue length [L]
Output 60/100 80/125
50 kW 12,000mm 40,000mm
45 kW 12,000mm 35,000mm
40 kW 15,000mm 35,000mm
35 kW 14,000mm 29,000mm
30 kW 21,000mm 25,000mm
Effective flue length
Bend 60/100 80/125
45° 0.5m 0.5m
90° 1.5m 1.5m
0010015190-001
383 mm - 603 mm
60/100 mm
130 mm Min
0010015191-001
[A] 350 mm - 570 mm
[B] 570 mm - 790 mm
60/100 mm
130 mm Min

Pre-Installation
19
Greenstar 8000 Life – 6720883865 (2021/11)
Horizontal fixed length flue assembly
Fig. 16 Horizontal flue option
• Flue length [L] (adaptor bend included in length calculation)
– 60/100 = 330 - 1,050mm
– 80/125 = N/A
Extended horizontal flue
Fig. 17 Horizontal flue option
• Flue length [L] (adaptor bend included in length calculation)
– Maximum flue length as stated in "Horizontal maximum flue
lengths".
Horizontal flue with additional 90° elbow
Fig. 18 Horizontal flue option
• Flue length [L] (adaptor bend included in length calculation)
– Maximum flue length as stated in "Horizontal maximum flue
lengths" minus the 90° bend equivalent straight flue length as
stated in Table 11 "Effective length of bends".
Horizontal flue with additional 90° elbows
Fig. 19 Horizontal flue option
• Flue length [L] (adaptor bend included in length calculation)
– Maximum flue length as stated in "Horizontal maximum flue
lengths" minus 2 x 90° bends equivalent straight flue length as
stated in Table 11 "Effective length of bends".
High level horizontal flue
Fig. 20 Horizontal flue option
• Flue length [L] (initial bend included in length calculation)
– Maximum flue length as stated in "Horizontal maximum flue
lengths".
High level horizontal flue with additional 90° elbow
Fig. 21 Horizontal flue option
• Flue length [L] (initial bend included in length calculation)
– Maximum flue length as stated in "Horizontal maximum flue
lengths" minus the 90° bend equivalent straight flue length as
stated in Table 11 "Effective length of bends".
High level horizontal flue with additional 90° elbows
Fig. 22 Horizontal flue option
• Flue length [L] (initial bend included in length calculation)
– Maximum flue length as stated in "Horizontal maximum flue
lengths" minus 2 x 90° bends equivalent straight flue length as
stated in Table 11 "Effective length of bends".
0010015192-001
330 mm Min
1050 mm
0010015193-001
0010015194-001
0010015195-001
0010015196-001
0010015197-001
0010015198-001

Pre-Installation
Greenstar 8000 Life – 6720883865 (2021/11)
20
Vertical balanced flue assembly
Fig. 23 Vertical flue option
• Flue length [L]
– Maximum flue length as stated in "Vertical maximum flue
lengths".
Vertical balanced flue with 90° elbow offset
Fig. 24 Vertical flue option
• Flue length [L]
– Maximum flue length as stated in "Vertical maximum flue lengths"
minus 2 x 90° bends equivalent straight flue length as stated in
Table 11 "Effective length of bends".
Vertical balanced flue with 45° elbow offset
Fig. 25 Vertical flue option
• Flue length [L]
– Maximum flue length as stated in "Vertical maximum flue lengths"
minus 2 x 45° bends equivalent straight flue length as stated in
Table 11 "Effective length of bends".
4.4.3 Plume management system
For every extra 1,000mm of plume management after the first 500mm,
the internal 60/100 flue length must be reduced by 700mm, up to a
maximum of 4,500mm of plume management.
Fig. 26 Reduction to flue length as plume length increases graph
[1] Reduction to flue length [mm] (maximum reduction 2,800mm)
[2] Plume length [mm] (maximum plume length 4,500mm)
NOTICE
Plume management length:
▶ The plume management length must be a minimum of 500mm and
must not exceed the maximum straight length for a horizontal Ø 60/
100mm flue with a 60mm plume management system as stated
previously.
Horizontal plume management runs
▶ The initial horizontal run from the terminal elbow must have a
minimum 10° fall back, (stop tabs in the elbow prevent less than 10°)
to the appliance for proper disposal of condensate.
▶ Any further horizontal runs after an elbow can be 3°.
WARNING
Minimum plume management length:
The minimum distance of 500mm must be maintained between air inlet
and exhaust.
▶ Do not terminate the plume management inside the terminal
exclusion zone (shaded area) shown in figure 27.
0010015199-001
A
= 300 mm
B = 500 mm
0010015200-001
A = 300 mm
B = 500 mm
0010015201-001
A = 300 mm
B = 500 mm
0010023114-001
0
700
1,400
2,100
2,800
500 1,500 2,500 3,500 4,500
[mm]
[mm]
2
1