Worcester Greenstar Heatslave II External 12/18 User manual

INSTRUCTION MANUAL
INSTALLATION, COMMISSIONING & SERVICING
FLOOR STANDING OIL FIRED CONDENSING COMBINATION BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
GREENSTAR HEATSLAVE II
EXTERNAL 12/18, 18/25 & 25/32
FOR SEALED CENTRAL HEATING SYSTEMS WITH MAINS FED DOMESTIC
HOT WATER
UK
THE APPLIANCE IS FOR USE WITH KEROSENE
(28 SECOND OIL) ONLY

INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
2
SYMBOLS USED IN THIS MANUAL:
INSTALLATION & SERVICING INSTRUCTIONS
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that more than one person is
involved in the transfer of the packaged appli-
ance from the van to the point of installation.
It is advised that no attempt should be made to
move the packaged appliance without the use of
a suitable truck.
At all times the correct method for handling
heavy objects should be strictly observed.
GENERAL HANDLING GUIDELINES:
• Lift only a manageable weight, or ask for
help.
• When lifting, bend the knees, and keep the
back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry items close to the body.
• Wear protective clothing and gloves to
protect from any sharp edges.
PLEASE 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.
THE INSTRUCTIONS APPLY IN THE UK AND EIRE ONLY AND MUST BE FOLLOWED
EXCEPT FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.
COMPLYING WITH THE BUILDING REGULATIONS:
This heating appliance forms part of the controlled services for the building. It is law that all controlled
services for buildings must comply with building regulations. You must be able to satisfy your Local
Authority Building Control Body (LABC) that the work carried out concerning the installation and
commissioning of this heating appliance has been carried out to a satisfactory standard.
OFTEC operate a competent persons scheme and registered installers are able to certify that their
work complies with building regulations. Under the scheme;
lOFTEC must be informed about every installation.
lOFTEC will issue a building regulations compliance certificate to the householder and will
notify the LABC.
OFTEC provide controlled document forms CD10 and CD11 for use during installation and
commissioning respectively.
Other organisations operate self-certification schemes e.g. NAPIT and BESCA Ltd. and it may be
possible for installers who are members of these organisations to self certify their work.
Alternatively you must submit a building control notice to the LABC before installing any boiler. The
LABC will then arrange regular inspection visits during the work to ensure that the installation
complies with the regulations.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE ON:
0844 892 3366.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM
AND THE USER MANUAL WITH THE OWNER OR WITH THE APPLIANCE AFTER
INSTALLATION OR SERVICING. THE SERVICE INTERVAL RECORD CAN BE FOUND ON
THE BACK PAGE OF THIS MANUAL.
ABBREVIATIONS USED IN THIS MANUAL:
Ø Diameter
CH Central Heating
DHW Domestic Hot Water
DCW Domestic Cold Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional flue
BF Balanced flue
N/A Not allowed
SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
OFTEC Oil Firing Technical Association for the Petroleum Industry
IEE Institute of Electrical Engineers
LABC Local Authority Building Control Body
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
WATER TREATMENT:
FERNOX 01799 550811
fernox.com
SENTINEL 0800 389 4670
sentinel-solutions.net
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply

SAFETY & REGULATIONS
IMPORTANT INFORMATION AND SYMBOLS 2
SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS 4
APPLIANCE INFORMATION
GENERAL INFORMATION 5
TECHNICAL DATA 6
LAYOUT & COMPONENTS 7
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 8
MAINS SUPPLY 9
OIL SUPPLY 10
WATER SYSTEMS & PIPEWORK 12
CONDENSATE PIPEWORK 14
CONDENSATE PIPEWORK TO SOAK AWAY 15
PRESSURE RELIEF PIPEWORK 16
BOILER LOCATION & CLEARANCES 17
FLUE TERMINAL POSITIONS 18
PLUME MANAGEMENT 20
CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS 21
INSTALLATION
UNPACKING THE BOILER 22
PIPEWORK POSITIONS / FLUE OPENING 23
BOILER INSTALLATION 24
FLUE INSTALLATION 25
COMBUSTION CHAMBER 26
PIPEWORK CONNECTIONS 27
OIL BURNER AND PUMP 28
REFITTING COMPONENTS 29
ELECTRICS 30
WEATHER COMPENSATION 34
COMMISSIONING
PRE-COMMISSIONING CHECKS - APPLIANCE 35
FILLING THE SYSTEM 36
STARTING THE APPLIANCE 37
WATER TREATMENT 43
FINISHING COMMISSIONING - APPLIANCE 44
SERVICING & SPARES
INSPECTION AND SERVICE 45
SHORT PARTS LIST 12/18 50
SHORT PARTS LIST 18/25 51
SHORT PARTS LIST 25/32 52
FAULT FINDING & DIAGNOSIS
MENUS 53
RESET & ERRORS 55
FUNCTION CHARTS 57
SOLAR COMPATABILITY 60
BURNER DIAGNOSTICS MODE 61
FAULT FINDING LOGIC FOR RIELLO DIGITAL CONTROL BOX 62
COMMISSIONING CHECKLIST 64
SERVICE INTERVAL RECORD 65
CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
3
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
FAULT FINDING
& DIAGNOSIS

SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
4
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
OIL FUMES OR LEAKS FROM THE APPLIANCE:
✔ Extinguish any naked flames.
✔ Isolate the electrical supply.
✔ Isolate the fuel supply to the boiler.
✔ Rectify fault.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the construction
process that contravene the COSHH Regulations (Control of Substances Hazardous to Health
Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the
vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances which can corrode
the appliance and invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer in accordance with these instructions and the relevant Installation Regulations.
Flue systems must not be modified in any way other than as described in the fitting instructions.
Any misuse or unauthorised modifications to the appliance, flue or associated components and
systems could invalidate the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified engineer (such
as OFTEC registered personnel) using approved spares, to help maintain the economy, safety
and reliability of the appliance.
IMPORTANT:
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.
Failure to install appliances correctly could lead to
prosecution.
The appliance must be installed by a competent
person. The person installing the appliance should
be aware of the Health and Safety at Work Act and
take appropriate action to ensure that the
regulations are adhered to. In order to give
optimum efficiency and trouble free operation the
appliance must be commissioned by a qualified
OFTEC engineer.
The compliance with a British Standard does not,
in itself, confer immunity from legal obligations. In
particular the installation of this appliance must be
in accordance with the relevant requirements of the
following British Standards and regulations in
respect of the safe installation of equipment:
BS 5410: part 1: Code of practice for Oil Fired
Boilers.
BS 799: part 5: Specification for Oil Storage
Tanks .
BS 7593: Code of Practice for treatment of water
in domestic hot water central heating systems.
BS 5449: part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 5955: part 8: Specification for the installation
of thermoplastic pipes and associated fittings for
use in domestic hot and cold water services and
heating systems.
BS 7291: Thermoplastic pipes and associated
fittings for hot and cold water for domestic
purposes and heating installations in buildings.
BS 7074: part 1: Application, selection and
installation of expansion vessels and ancillary
equipment for sealed water systems.
BS 1254-2: Copper and copper alloys plumbing
fittings part 2: Fittings with compression ends for
use with copper tubes.
BS 7671: IEE Wiring Regulations, current edition.
BS 1362: Specification for general purpose fuse
links for domestic and similar purposes.
The Building Regulations Part G, Part J and L1
England and Wales; Part F, Part G and Part J
Section III Scotland; Part L and Part F Northern
Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
Where no specific instruction is given, reference
should be made to the relevant codes of practice.
Installations in Eire (Republic of Ireland)
The Installation must be performed by a
competent and suitably trained person in
accordance with the following Eire regulations.
Current Building Regulations -
Republic of Ireland
ETCI rules for electrical installation
For further guidance see:
OFTEC Technical book three -
Regional requirements: Republic of Ireland

GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
5
APPLIANCE
INFORMATION
A
B
E
770mm
950mm
640mm
D
C
F
C
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing oil fired condensing
combination boiler for sealed central heating
and mains fed domestic hot water.
B - Literature pack.
C -100mmØ services duct.
D - Balanced flue kit
E - Cabinet key
F - Mains supply socket
Check List
Item Qty
Greenstar Heatslave II External Installation/Servicing
Instructions.......................................................................................................1
Users Instructions ..........................................................................................1
Hardware Pack.................................................................................................1
100mm Ø Services Duct...............................................................................1
Balanced Flue Kit............................................................................................1
Cabinet Key.......................................................................................................1
Mains supply socket........................................................................................1

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
6
APPLIANCE
INFORMATION
TECHNICAL DATA
Central Heating
Primary water capacity (total) litres
Available pump head (20°C difference) at max. output metres water
Max. permissible system operating pressure bar
in accordance with WRAS guidelines
Flow restrictor colour
Domestic Hot Water
Maximum flow rate (±15%) litres/min
Minimum inlet pressure (dynamic) for maximum flow rate bar
Maximum hot water temperature rise for 90 litres draw off (@max flow rate) °C
Flue
Exit flue gas mass flow kg/hr
Pipework connections
Fuel line (compression) mm
CH flow mm
CH return mm
Water main inlet mm
DHW outlet mm
CH drain hose connection
Condensate (polypropylene) mm
Electrical
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption (running) W
Sensors & Thermostats
CH control range °C
Slave tank control range °C
Boiler manual reset overheat set point °C
Flue manual reset overheat thermostat set point °C
Tank manual reset overheat thermostat set point °C
General Data
Maximum hearth temperature °C
SEDBUK 2009 %
Appliance protection rating IP
Weight (excluding packaging) kg
DESCRIPTION UNITS 12/18 18/25 25/32
62
4.7
2.5
Lime
15
1.5
40
29
10
22
22
15
22
21.5
230
50
230
50/82
55/84
105
110
95
<100
89.4
44
151
63
4.0
2.5
Beige
18
1.2
40
40
10
22
22
15
22
21.5
230
50
230
50/82
55/86
105
110
95
<100
89.2
44
154
64
4.2
2.5
Grey
22
1.6
40
51
10
28
28
15
22
21.5
230
50
260
50/82
55/88
105
110
95
<100
89.0
44
158

LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
7
APPLIANCE
INFORMATION
10 11
12 13
14
15
19
16
17
20
21
22
23
24
25
26
27
28
30
29
a
37
38
39
41
42
43 4544 46 47 48
40
789
5
32
33 34
35
36
1
2
3
4
6
31
18
LAYOUT & COMPONENTS
The diagram opposite excludes the top, front
and RH side casing panels.
A
1 CONTROL BOX ASSEMBLY
2 SERVICE MODE BUTTON
3 CH TEMPERATURE CONTROL KNOB
4 LCD DISPLAY
5 CASING SIDE PANEL
6 FLUE “KNOCK-OUT” SECTION
7 TANK TEMPERATURE CONTROL KNOB
8 DIAGNOSIS PORT - WORCESTER ENGINEER
9 SYSTEM PRESSURE GUAGE
10 FLUE GAS SAMPLING POINT
11 FLUE MANIFOLD COVER
12 FLUE OVERHEAT THERMOSTAT PHIAL
13 AIR INLET CASING FLEXIBLE AIR DUCT
(CONNECTING TO AIR INTAKE ON BURNER)
14 CASING SUPPORT BRACKET
15 SECONDARY HEAT EXCHANGER DRAIN
16 HEAT EXCHANGER FLOW PIPE
17 CONDENSATE OUTLET
18 CONDENSATE TRAP
19 CONDENSATE DRAIN PIPE
20 FLEXIBLE CONDENSATE DRAIN PIPE
CONNECTION
21 PRIMARY HEAT EXCHANGER
22 OIL ISOLATING VALVE
23 BASE PLATE AND OIL DRIP TRAY
24 COMBUSTION CHAMBER ACCESS DOOR
AND ONE PIECE BAFFLE SET LOCATION
25 PRIMARY HEAT EXCHANGER DRAIN
26 EXPANSION VESSEL
27 EXPANSION VESSEL BRACKET/DATA LABEL
28 RIELLO RDB 2.2 BURNER (ALL OUTPUTS)
2 9 H E ATS LAV E TA N K
3 0 H E ATS LAV E TA N K DR A I N
31 CASING BRACE AND CONTROL BOX
SUPPORT
a OPTIONAL FASCIA MOUNTED PROGRAMMERS
AVAILABLE (not supplied with the appliance)
B
32 CIRCULATING PUMP
33 MANUAL RESET TANK OVERHEAT
THERMOSTAT
34 DRAIN POINT
35 DIVERTER VALVE ASSEMBLY
36 AUTOMATIC AIR VENT
C
37 DHW FLOW TURBINE
38 TANK TEMPERATURE SENSOR (NTC)
39 DHW HEAT EXCHANGER
40 DHW TEMPERATURE SENSOR (NTC)
41 DHW PRESSURE RELIEF VALVE
42 MAINS INLET TEMPERATURE SENSOR (NTC)
43 PRIMARY MANUAL AIR VENT
44 FLOW TEMPERATURE SENSOR (NTC)
45 PRIMARY HEAT EXCHANGER SAFETY
SENSOR (NTC)
46 SECONDARY HEAT EXCHANGER MANUAL
AIR VENT
47 SECONDARY HEAT EXCHANGER
48 PRESSURE RELIEF VALVE
18/25 APPLIANCE SHOWN
A
B
C

CLEANING PRIMARY SYSTEMS INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
8
PRE -
INSTALLATION
CLEANING PRIMARY SYSTEMS
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER.
FLUSH THE EXISTING SYSTEM WITH A
POWER FLUSHING MACHINE OR WITH A
CHEMICAL CLEANER BEFORE
INSTALLING NEW COMPONENTS.
WE RECOMEND THE USE OF A MAGNETIC
SYSTEM FILTER SUCH AS THE
WORCESTER GREENSTAR SYSTEM FILTER
OR FILTERS FROM FERNOX AND
SENTINEL.
CLEANING THE PRIMARY SYSTEM:
4Cleanse the system in accordance with
BS 7593.
4Fill the system with cold mains water to the
recommended pressure and check for leaks.
4Open all drain cocks and drain the system.
4Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
4Circulate the flushing agent before the boiler
is fired up.
4Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
4Drain and thoroughly flush the system to
remove the flushing agent and any debris.
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: 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.

MAINS SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
9
PRE -
INSTALLATION
MAINS SUPPLY
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2(24 x
0.2mm) temperature rated to 90°C.
• Protection IP44.
• External 5A fuse to BS1362.
• The appliance must be earthed.
• Refer to IEE regulations for cross bonding
requirements.
• It must be possible to isolate the appliance
from the electrical supply with at least a 3mm
contact separation in both poles supplying
the appliance.
• Wiring between the appliance and the
electrical supply must comply with IEE wiring
regulations and any local regulations which
may apply for fixed wiring to a stationary
appliance.
• Any system connected to the boiler must not
have a separate electrical supply.
WATER SUPPLY:
The following are general requirements and if
necessary the advice of the local water company
should be sought before fitting the appliance.
• The appliance cold water supply should be
the first connection off the water main where
possible.
• The appliance will accept pre-heated hot
water to a maximum of 60°C
• Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
IMPORTANT: 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.
• Where the water main supply has a non-
return, back flow prevention valve fitted, a
mini expansion vessel (A) must be connected
to the mains water inlet pipe (B) between the
non-return valve (C) and the boiler (D) as
shown opposite.
Use in hard water areas:
Normally there is no need for water treatment to
prevent scale formation as the maximum
temperature of the heat exchanger is limited by
the electronic control circuit.
In areas where the temporary water hardness
exceeds 200ppm, consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances, the advice of
the local water authority should be sought.
12/18kW
Water Mains Pressure:
Minimum dynamic mains water pressure for
maximum performance.
1.5 bar 1.2 bar 1.6 bar
18/25kW 25/32kW
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 192 105
B - Mains water inlet
C - Non-return valve
D - Boiler
A
BC
D
IMPORTANT: The appliance provides a permanent external electrical supply
for servicing and must therefore be fed via a circuit breaker incorporating
earth leakage protection.

OIL SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
10
PRE -
INSTALLATION
OIL SUPPLY
OIL SUPPLY :
•This appliance is suitable for kerosene (28
second oil) only, no other fuel must be used.
• Plastic or steel tanks should be installed to
BS 5410. A steel tank should conform to
BS 799: part 5 and have a slope of 1 in 24
away from the outlet valve with a sludge cock
at its lower end.
• Do not use galvanised steel tanks or
pipework for the oil supply system.
• Do not use soldered joints on the oil
supply pipework.
a) Single pipe gravity feed system:
The oil storage tank (A) must be positioned so
that the oil level does not exceed 4 metres above
the level of the burner oil pump (J) and in addi-
tion the oil level must be at least 300mm above
the oil pump (J). Where the maximum oil level in
the oil storage tank exceeds 4 metres, a head
breaking device must be installed between the
tank (A) and the burner oil pump (J).
b) Double pipe sub-gravity feed system:
Maximum suction height 3.5 metres. Non-return
valves must be fitted to the inlet and return oil line
between the oil pump (J) and oil storage tank (A).
A - Oil storage tank.
B - Isolating valve.
C - Oil strainer & water separator.
D - Fire valve to BS 5410.
E - External wall.
F - Fire valve sensor.
G - Oil burner.
H - Oil supply pipe.
J - Oil pump.
K - Full base (plastic tanks).
L - Non-return valve.
M - De-aerator.
N - Oil filter (70μmmax filtration size)
NOTE: All dimensions are in metres unless stated otherwise.
The maximum pipe run figures are based on using copper pipe with an inside diameter of
2mm less than the Ø.
HEAD 10mmØ 12mmØ
0.5 12 30
1.0 25 69
1.5 37 91
2.0 49 100
HEAD 10mmØ 12mmØ
2.5 62 100
3.0 74 100
3.5 87 100
4.0 99 100
HEAD 10mmØ 12mmØ
050 100
0.5 44 100
1.0 38 95
1.5 32 80
HEAD 10mmØ 12mmØ
2.0 26 66
2.5 20 50
3.0 14 37
3.5 8 22

OIL SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
11
PRE -
INSTALLATION
OIL SUPPLY
c) Single pipe suction lift with de-aerator
Maximum suction height 3.5 metres. The oil
tank (A) must be positioned below the oil pump
(J). Create an inlet and return loop between the
de-aerator (M) and oil pump (J).
A non-return valve must be incorporated within
the de-aerator or fitted to the oil line between
the oil storage tank (A) and the de-aerator (M).
A top feed oil tank fitted with a de-aerator
using an internal non-return valve should have
any non-return valves fitted in the base of the
tank to the suction line removed to assist
purging air from the oil line.
Pipework
4Use copper pipe of the correct diameter
according to the information shown opposite.
• If using soft copper pipe (R220) with a
compression fitting, an insert must be used
to prevent the pipe from collapsing or
distorting when the fitting is tightened.
4Slide nut (P) and olive (R) onto the oil
supply pipe (H).
4Slide insert (S) into the pipe.
4Offer the pipe to the fitting (T) and tighten the
nut (P).
4Use flexible hoses to connect to the oil pump (J).
4Lay the oil supply pipe (H) as straight and
level as possible to avoid air pockets and
unnecessary friction losses. Route away
from the boiler access door or other hot
surfaces.
4Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage
tank (A) as possible.
4Fit an oil strainer and water separator (C) to
the oil supply pipe, near the oil storage tank.
Fit an additional oil filter (N, 70μmmax
filtration size with the filter element to be of
the disposable media (paper) type) close to
the boiler, but not inside the boiler casing.
4Fit a fire valve in accordance with BS 5410.
The fire valve (D) should be fitted externally
to the building with the fire valve sensor (F)
located within the appliance case using the
clip located under the right hand side of the
cross brace at the top of the boiler.
A fire valve with a shut off temperature of
85°C or higher must be fitted to avoid
the possibility of nuisance shut offs.
A capillary type valve provides a neat and
simple installation. Alternatively, a fusible
link or electrical system may be used.
Under no circumstances should a
combination isolating/fire valve be used
as the sole fire protection device.
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
0 100 55 26 100
0.5 95 45 23 100
1.0 80 40 20 90
1.5 70 35 17 75
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
2.0 60 30 14 65
2.5 45 25 11 50
3.0 35 15 8 35
3.5 25 10 5 20
The table and illustration above is a guide only and does not in any way override the
de-aerator manufacturers instructions.

D
R R
R R
B
P
D
C
TLTL
TL LL
A
U
E
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework used for the CH system
must have a polymeric barrier, complying with
BS 7921 and installed to BS 5955 with
1000mm (minimum) length of copper or steel
pipe connected to the boiler.
• Plastic pipework used for underfloor heating
must be correctly controlled with a
thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C
with 1000mm (minimum) length of copper or
steel pipe connected to the boiler, and a 20k
differential must be maintained at the
appliance.
PRIMARY SYSTEM/CONNECTIONS/VALVES:
• Do not use galvanised pipes or radiators.
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
• Radiator valves should conform to
BS 2767:10.
• All other valves should conform to BS 1010.
• An automatic bypass valve must be connected
between the heating flow and return pipes
if TRVs are used on radiators or motorised
zone valves are present that cut off CH
circulation. This must be fitted to give at least
a 3m circuit when activated.
• Drain cocks are required at all the lowest
points on the system.
• Air vents are required at all high points on the
system.
SEALED PRIMARY SYSTEM:
• Where the system volume is more than 180
litres at 0.5 bar or exceeds 2.65 bar at
maximum heating temperature an extra
expansion vessel (B) must be fitted as close
as possible to the appliance in the central
heating return.
• Pressurise the extra expansion vessel (B) to
the same figure as the expansion vessel (A)
built into the appliance.
A - Appliance expansion vessel
B - Extra expansion vessel
C - Automatic bypass valve
D - Drain cock
E - Appliance
L - Lockshield valve
P - Pressure relief discharge
R - Radiators
T - TRV
TYPICAL SEALED SYSTEM
IMPORTANT: The boiler should not be
allowed to operate with a return
temperature of less than 30°C when the
system is up to operating temperature.
WATER SYSTEMS & PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
12
PRE -
INSTALLATION

Heating return
Hose
return
Non return
valve
Non return
valve
Test cock
Stop
cock
Water main
supply
Stop
cock
Temporary hose
Greenstar Heatslave II External
oil fired combination boiler
Hot water supply
to property
Mini expansion
vessel
(0.75ltr capacity)
Balanced cold water
supply to property
3 bar pressure
reducing
valve
MCW
Check valve/
non return valve
Incoming mains
stop valve
Blending valve
set to 60°C
WATER SYSTEMS & PIPEWORK
FILLING PRIMARY SEALED SYSTEMS:
• Filling the system must comply with one of the
methods shown opposite.
• The filling point must be at low level and must
never be a permanent direct fixing to the
mains water supply.
• Filling links must be WRAS approved.
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.
Only thermostatically controlled showers are
suitable for use with this appliance.
• Bidets with direct hot & 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.
DOMESTIC HOT WATER:
Plastic pipework
• Any plastic pipework used for the DHW
system must have a polymeric barrier,
complying with BS 7921 and installed to
BS 5955 with 1000mm (minimum) length
of copper or stainless steel pipe connected to
the boiler.
• Before installing plastic pipework, the pipe
manufacturer’s literature should be consulted.
• To prevent the temperature & pressure
exceeding the limits advised by the pipe
manufacturer, a pressure reducing valve must
be used to prevent the incoming water
pressure exceeding 3 bar (maximum). Also a
mini expansion vessel must be fitted to
absorb the expanding water and a blending
valve set to 60°C must be fitted before the
DHW plastic pipework.
• When selecting plastic pipework for use with
domestic water supply, it should be ensured that
it is compliant with all current local & national
legislation & regulations, including building
regulations part G, BS 7291 - 1,2 & 3: 2006,
BS 8000 - 15-15: 1990 and information.
GENERAL:
• Taps and mixing valves must be capable of
sustaining a pressure up to 10 bar in
accordance with the Water Regulations as
they will be operating at mains water pressure.
• Hot water temperature and flow rate are
affected by the size and insulation of pipework
making up the distribution system and are
controlled by the hot water tap and the water
main inlet pressure. A mixing valve can be fitted
if a more permanent setting is required.
• If using more than one outlet at once causes
water flow starvation, fit flow balancing valves
or Ball-O-Fix valves to the appropriate outlets.
WATER SYSTEMS & PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
13
PRE -
INSTALLATION

CONDENSATE PIPEWORK
INTERNAL CONNECTION
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
14
PRE -
INSTALLATION
CONDENSATE PIPEWORK
Key to diagrams:
1. Condensate discharge from boiler
2. Universal connector
3. Soil and vent stack
4. Minimum 450mm and up to three storeys
5. Pipe work transition
6. Insulate and increase pipe size
7. External rain water pipe into foul water
8. External air brake
9. Air gap
10. PVCu starp on fitting
11. 43mm 90° male/female bend
CONDENSATE PIPEWORK:
• The condensate pipe must be a minimum of
21.5mm 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.
CONDENSATE PIPEWORK RUN
EXTERNALLY:
• Pipe work length should be kept to a
minimum and the route as vertical as possible.
• Weather proof insulation must be used.
• Care should be taken when siting a
soakaway to avoid obstructing existing
services.
• 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.
4The external run be kept as short as possible
and not exceed three metres.
4The pipe diameter should be increased to
32mm.
4The pipe should be insulated using suitable
waterproof and weather resistant insulation.
4The 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.
4The 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.
21.5mm Ø
21.5mm Ø

CONDENSATE PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
15
PRE -
INSTALLATION
21.5mm Ø
CONDENSATE PIPEWORK
Fitting an external air brake:
• 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.
NOTE: Condensate drainage pipe can be run
above or below ground.
• 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.
CONDENSATE SOAK AWAY:
Key to diagrams:
12. 100mm Ø minimum plastic pipe
13. Drainage holes
14. Limestone chippings
15. Bottom of sealed tube
• All national and, where appropriate, local
regulations for the discharge and neutralisation
of condensate should be followed.
• 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.
NOTE: Minimum hole size for the condensate
soak away must be 400mm deep by 300mmØ.
• 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.
Making it safe:
• Condensate pipework must not leak, freeze
or block up.
• Condensate traps must be filled before starting
up the boiler to prevent potentially harmful flue
products escaping via the condensate route.
• Do not dispose of condensate into water
recovery systems.
UNSUITABLE FOR CLAY SOIL TYPES

PRESSURE RELIEF PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
16
PRE -
INSTALLATION
PRESSURE RELIEF PIPEWORK:
• The pressure relief drain pipe (2) should be
at least 15mm diameter copper pipe and run
downwards away from the boiler and discharge
away from any electrics or other hazard,
preferably to an external drain or soakaway.
• Pipe (2) should be finished with a partial
bend, near the outlet to face the external wall
(as shown) to help prevent freezing.
IMPORTANT: 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 into a public area
where it could cause a hazard.
PRESSURE RELIEF PIPEWORK
1 - Boiler casing.
2 - Drain pipe.

BOILER LOCATION &
CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
17
PRE -
INSTALLATION
BOILER LOCATION &
CLEARANCES
WARNING:
This appliance should not be installed where
there is a potential for excessive ground
water coverage.
This boiler is only suitable for installing
externally at a suitable location onto a fixed
permanent rigid surface capable of
supporting the boiler weight.
There must be a sufficient hard standing
around the appliance to allow for servicing.
The boiler must be installed on a flat level
surface to ensure that condensate does not
enter the primary heat exchanger.
Tarmac and wood hardstandings are not
recommended.
CLEARANCES: Min service & flue clearances
Above 600mm
Front 600mm
RH/LH clearance flue outlet on opposite side: 10mm
RH clearance flue outlet on rear: 45mm
LH clearance flue outlet on rear: 85mm
Rear clearance flue outlet on side: 50mm
Rear clearance flue outlet on rear: 2500mm
It is strongly recommended that the flue
terminal faces away from walls to reduce the
possibility of wetting occuring.
600mm
2500mm
600mm
BASE
FRONT
FRONT
2500mm
50mm
45mm85mm
600mm
10mm
2500mm
FRONT FRONT
10mm
50mm
Plan
view
Plan
view
Plan
view
600mm min

FLUE TERMINAL POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
18
PRE -
INSTALLATION
Minimum dimensions of flue terminal positions for oil-fired appliances:
TERMINAL POSITION B(H)
A 1Directly below an opening, air brick, opening windows, etc 600mm
B 1Horizontally to an opening, air brick, opening window, etc 600mm
C Below a plastic/painted gutter, drainage pipe or eaves if 75mm
combustible material protected
D 2Below a plastic/painted gutter, drainage pipe or eaves without 600mm
protection to combustible material
E From vertical sanitary pipework 300mm
F From an external or internal corner or from a surface or boundry 300mm
alongside the terminal
G Above ground or balcony level 300mm*
H From a surface or boundary facing the terminal 2500mm**
I Fro m a t er m in a l fa c ing t h e te r mi n al 2500mm**
K Horizontally from a terminal on the same wall 750mm
B(H) Balanced Horizontal flue
1 An opening means an openable
element, such as an openable
window, or a permanent opening
such as a permanently open air vent.
Notwithstanding the dimensions
above, a terminal should be at least
300mm from combustible material,
e.g. a window frame.
2 A way of providing protection of
combustible material would be to fit
a heat shield at least 750mm wide.
FLUE TERMINAL POSITIONS
• Flue terminals must be positioned to avoid
combustion products entering into buildings.
• The flue must be fitted and terminated in
accordance with the recommendations of
B S5410 .
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a
nuisance.
• Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the flue
outlet which could be regarded as a
nuisance, for example, near security lighting.
• There should be no restriction preventing the
clearance of combustion products from the
terminal.
• The air inlet/outlet duct and the terminal of
the boiler must not be closer than 25mm to
any combustible material. Detailed
recommendations on protection of
combustible materials are given in BS 5410:1
• A protective terminal guard must be fitted if
the terminal is 2m or less above a surface
where people have access.
The guard must be spaced equally (minimum
50mm) around the flue and fixed with plated
screws.
• The following additional guidelines (from part
L Exceptions Guidance Document) are
recommended when determining the flue
outlet position:
• Avoid discharging flue gases into car ports
or narrow passageways.
• *Minimum distance of the flue terminal from
above ground is 2100mm where directed to a
public footpath, private access route or a
frequently used area and 2500mm from a
car parking area.
• **Minimum distance of the flue terminal to a
facing wall, fence, building or property
boundary is 2500mm.

FLUE TERMINAL POSITIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
19
PRE -
INSTALLATION
Minimum dimensions of flue terminal positions for oil fired appliances:
TERMINAL POSITION CF RS(H) RS
A1 2 Directly below an opening, air brick, opening window, etc N/A 600mm N/A
B1 2 Horizontally to an opening, air brick, opening window, etc N/A 600mm N/A
C Below a plastic/painted gutter, drainage pipe or eaves if N/A 75mm N/A
combustible material protected
D3Below a plastic/painted gutter, drainage pipe or eaves without N/A 600mm N/A
protection to combustible material
E From vertical sanitary pipework N/A 300mm N/A
F From an external or internal corner or from a surface or boundary N/A 300mm N/A
alongside the terminal
G Above ground or balcony level N/A 300mm* N/A
H From a surface or boundary facing the terminal N/A 600mm** N/A
J From a terminal facing the terminal — 1200**mm —
K Vertically from a terminal on the same wall N/A 1500mm N/A
L Horizontally from a terminal on the same wall — 750mm —
M Above the point of highest intersection with the roof 600mm — 600mm
N From a vertical structure on the side of the terminal 750mm — 750mm
O Above a vertical structure less than 750mm from the side of the terminal 600mm — 600mm
P From a ridge terminal to a vertical structure on the roof 1500mm — N/A
Q Above or to the side of any opening on a flat or sloping roof 300mm — 300mm
R Below any opening on a sloping roof 1000mm — 1000mm
Key: — Not applicable, N/A Not allowed, CF Conventional flue, RS(H) Room Sealed Horizontal flue, RS(V) Room Sealed Vertical
flue.
Notes:
1.Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or
entering into buildings.
2.Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc.
3.Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and
extending 300mm higher and wider than the tank is provided between the tank and the terminating position.
4.Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastics or has a
combustible or painted surface, then a heat shield of at least 750mm wide should be fitted.
5.If the lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has
access, the terminal should be protected by a guard.
6.Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the
case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire
retardant material and close wire in the vicinity of the flue.
7.It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R.
8.Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the
manufacturer of the plastic components.
FLUE TERMINAL POSITIONS
• Flue terminals must be positioned to avoid
combustion products entering into buildings.
• The flue must be fitted and terminated in
accordance with the recommendations of
B S5410 .
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a
nuisance.
• Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the flue
outlet which could be regarded as a
nuisance, for example, near security lighting.
• There should be no restriction preventing the
clearance of combustion products from the
terminal.
• The air inlet/outlet duct and the terminal of
the boiler must not be closer than 25mm to
any combustible material. Detailed
recommendations on protection of
combustible materials are given in BS 5410:1
• A protective stainless steel terminal guard,
Part No: 7 716 190 050, must be fitted if
the terminal is 2m or less above a surface
where people have access.
See 'Contact Information' on the back cover
for flue guard information.
• The following additional guidelines (from part
L Exceptions Guidance Document) are
recommended when determining the flue
outlet position:
• Avoid discharging flue gases into car ports
or narrow passageways.
• *Minimum distance of the flue terminal from
above ground is 2100mm where directed to a
public footpath, private access route or a
frequently used area and 2500mm from a
car parking area.
• **Minimum distance of the flue terminal to a
facing wall, fence, building or property
boundary is 2500mm.
O
P
boundary
F
J
H
B
A
G
E
M
C, D
N
F
F
K
L
boundary
Q
Q
Q
R
Q
Q
Q
Q
Pitched roof
Flat roof

PLUME MANAGEMENT INSTALLATION & SERVICING INSTRUCTIONS FOR GREENSTAR HEATSLAVE II EXTERNAL 12/18-18/25-25/32
6 720 805 210-01
20
PRE -
INSTALLATION
IMPORTANT: All horizontal sections must
rise away from the boiler by 52mm per
metre (3°) to allow the condensate to
drain back to the boiler.
Plume Management:
1. The flue damper can be fitted into the flue
system, however, if the system has already
been fitted the manifold access cover can be
removed and the damper inserted into the
flue inner tube. Take care not to damage the
Flue Overheat Thermostat Phial.
Plume lengths:
Greenstar Heatslave External II 12/18 & 18/25:
Maximum length of plume management system
M = 5000mm
Greenstar Heatslave External II 25/32:
Maximum length of plume management system
M = 4000mm
Additional bends:
The plume management system always
employs 2 bends, a maximum of 2 further
bends can be used in addition to the first bend
exiting the flue system and the terminal bend.
Adding bends to the plume management
system reduces the actual plume management
length. Each bend has an equivalent straight
lenght and must be factored into the overall
effective length:
90° bend is equivalent to 1000mm.
45° bend is equivalent to 500mm.
2.The system can exit the boiler from the left
and right and rear of the appliance but must
be supported by brackets to an adjacent wall
or permanent structure.
PLUME MANAGEMENT
1
2