Worcester Greenstar utility 32-50kW User manual

GREENSTAR UTILITY
32/50kW & 50/70kW
FLOOR STANDING OIL-FIRED CONDENSING BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
GB/IE
8-716-10 -711a (04.05)
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB/IE
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND HOT
WATER CYLINDERS
Patent pending:
Application number 0327645.8
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
GB/IE
INSTRUCTION MANUAL
GB/IE

INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
INSTALLATION &
SERVICING INSTRUCTIONS
8-716-10 -711a (04.05)
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER BOSCH 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 & 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.
IF YOU ARE IN ANY DOUBT CONTACT WORCESTER BOSCH TECHNICAL HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER
BOSCH.
PLEASE LEAVE THESE INSTRUCTIONS WITH THE USER OR WITH THE APPLIANCE
AFTER INSTALLATION OR SERVICING.
WORCESTER BOSCH:
MAIN RECEPTION: 01 05 754624
MAIN FAX: [phone]
TECHNICAL: 08705 266241
SERVICE: 08547 256206
SPARES: 01 05 752571
LITERATURE: 01 05 752556
TRAINING: 01 05 752526
SALES: 01 05 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 017 550811
www.fernox.com
SENTINEL 0151 420 5 5
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARDS:
TOWER FLUE COMPONENTS
VALE RISE, TONBRIDGE, TN 1TB
OIL FIRING TECHNICAL ASSOCIATION:
OFTEC 0845 6585080
www.oftec.org
CONVENTIONAL FLUE MANUFACTURERS:
INTERACTIVE (Flue Systems) Ltd.
[e-mail]
Selkirk Manufacturing Ltd.
www.selkirk.co.uk
SYMBOLS USED IN THIS MANUAL:
ABBREVIATIONS USED IN THIS MANUAL:
Ø Diameter
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional flue
RS Room sealed flue
N/A Not allowed
SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom
OFTEC Oil Firing Technical Association for the Petroleum Industry
Store the appl ance n a dry area pr or to
nstallat on.
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that more than one person is
involved in the transfer of the packaged
appliance from the van to the point of installation.
It is advised that no attempt should be made
to move the packaged appliance without the
use of a suitable truck.
A all imes he correc me hod for handling
heavy objec s should be s ric ly 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.
Domestic hot water
Central heating
Electricity supply

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH CONTENTS
SAFETY &
REGULATIONS
FAULT FINDING
& DIAGRAMS
APPLIANCE
INFORMATION
PRE-
IN STALLATION
IN STALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
CONTENTS
1
SAFETY & REGULATIONS
SAFETY PRECAUTIONS & SYMBOLS 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LAYOUT & COMPONENTS 5
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 6
MAINS SUPPLIES 7-8
WATER SYSTEMS & PIPEWORK -10
CONDENSATE & PRESSURE RELIEF PIPEWORK 11
BOILER LOCATION & CLEARANCES 12-13
FLUE OUTLET POSITIONS 14
CONVENTIONAL FLUE 15
ROOM SEALED FLUE OPTIONS 16
INSTALLATION
UNPACKING THE BOILER 17
PIPEWORK POSITIONS & FLUE OPENING 18
BOILER PANEL REMOVAL 1
FLUE INSTALLATION 20
COMBUSTION CHAMBER 21
PIPEWORK CONNECTIONS 22
OIL BURNER & PUMP 23
REFIT COMPONENTS 24
ELECTRICS 25-27
COMMISSIONING
PRE-COMMISSIONING CHECKS 28
FILLING THE SYSTEM 2
STARTING THE APPLIANCE 30-32
WATER TREATMENT 33
FINISHING COMMISSIONING 34
SERVICING & SPARES
INSPECTION AND SERVICE 35-38
SHORT PARTS LIST 3
CONVERSION KITS
N/A
FAULT FINDING & DIAGRAMS
FAULT FINDING 40-41
8-716-10 -711a (04.05)

SAFETY &
REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
2SAFETY PRECAUTIONS &
INSTALLATION REGULATIONS
8-716-10 -711a (04.05)
OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:
Extinguish any naked flames
Open windows and doors
Isolate the electrical supply
Isolate the fuel supply to the boiler
Contact boiler engineer.
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 1 88). Where applicable, the CE mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do no 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, (halogenated
hydrocarbons containing chlorine or fluorine compounds) 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.
Failure to install appliances correctly could lead
to prosecution.
The appliance should be installed by a competent
person. The person installing the appliance should
be aware of the 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, of 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& 2: Code of practice for Oil Fired
Boilers.
BS 7 : part 5: Specification for Oil Storage
Tanks.
BS 75 3: Code of Practice for treatment of water
in domestic hotwater central heating systems.
BS 544 : part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 5 55: 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 72 1: Thermoplastic pipes and associated
fittings for hot and cold water for domestic
purposes and heating installations inbuildings.
BS 7074: part 1: Application, selection and
installation of expansion vessels and ancillary
equipment for sealed water systems.
BS 7671: IEE Wiring Regulations, current edition.
The Building Regulations Part J and L1 England
and Wales; Part F and Part J Section III Scotland;
Part L and Part F Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
To ensure that the installation will perform to the
highest standards, the system and components
should conform to those mentioned in these
instructions.

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 3
GENERAL INFORMATION
GENERAL INFORMATION
8-716-10 -711a (04.05)
STANDARD PACKAGE:
A - Floor standing oil fired condensing boiler
B - Literature pack
C - Hardware pack including:
Condensate trap
Oil isolating valve
A
B
815mm
7mm
520mm
C

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
32/50kW 50/70kW
28 28
50 51
30 30
11
26 40
52 104
76 106
130 130
100/150 100/150
10 10
1½ 1½
28 28
1½ 1½
1½ 1½
21.5 21.5
230 230
50 50
1 0 220
60/82 60/82
55
100 100
110 110
120 120
100 100
3.0 (A) 2.5 (A)
20 20
270 280
4
TECHNICAL DATA
TECHNICAL DATA 8-716-10 -711a (04.05)
DESCRIPTION UNITS
Fuel
Kerosene sec
Cen ral Hea ing
Primary water capacity (total) litres
Maximum static head metres
Minumum static head metres
Water side resistance (20°C difference) mbar
Waterside resistance (10°C difference) mbar
Flue
Exit flue gas mass flow kg/hr
Conventional flue (minimum diameter required) mm
Room sealed flue (diameter) mm
Pipework connec ions
Fuel line (compression) mm
CH flow inch BSP
CH return mm
CH vent inch BSP
CH make-up inch BSP
Condensate (polypropylene) mm
Elec rical
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption W
Thermos a s
Boiler flow temperature range (cut out) °C
CH control thermostat differential °C
Boiler high limit thermostat set point (+ 0-6°C) °C
Boiler manual reset overheat thermostat (cut out) °C
Flue reset overheat thermostat (+ 0-6°C) °C
General Da a
Maximum hearth temperature °C
SEDBUK (Band) %
Appliance protection rating IP
Weight (excluding packaging) kg

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 5
LAYOUT & COMPONENTS
LAYOUT & COMPONENTS
8-716-10 -711a (04.05)
The diagram opposite shows the controls in the
servicing position and excludes the top,front and
RH side casing panels.
1 CH THERMOSTAT CONTROL
2 RESET BUTTON BOILER OVERHEAT
3 RESET BUTTON FLUE OVERHEAT
4 CONTROL BOX ASSEMBLY
5 CASING SIDE PANEL
6 FIRE VALVE CLIP
7 CONTROL, AUTOMATIC HIGH LIMIT &
MANUAL HIGH LIMIT THERMOSTATS
8 CABLE CLAMP
FLUE MANIFOLD ACCESS COVER
10 CH RETURN PIPE
11 MANUAL RESET FLUE OVERHEAT
THERMOSTAT
12 FLUE MANIFOLD
13 FLUE GAS SAMPLING POINT
14 SECONDARY HEAT EXCHANGER
15 CH FLOW CONNECTION LEFT & RIGHT
HAND SIDE
16 OPTIONAL COLD FEED/DRAIN LEFT &
RIGHT HAND SIDE
17 CONDENSATE OUTLET
18 SECONDARY TO PRIMARY HEAT
EXCHANGER RETURN PIPE
1 PRIMARY HEAT EXCHANGER
20 BASE PLATE
21 COMBUSTION CHAMBER ACCESS DOOR
22 TRAY
23 UPPER FRONT PANEL
24 STERLING 133 BURNER (32/50kW) /
STERLING 146 BURNER (50/70kW)
i) Control box
ii) Motor
iii) Air intake casing
iv) Oil pump
v) Blast tube
4
5
678
10
11 12 13 14 15
16
12
3
17
18
1
20
24
i
ii
iii
iv
v
21
22
23

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
6
CLEANING PRIMARY SYSTEMS
CLEANING PRIMARY SYSTEMS
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: All he following pre-ins alla ion sec ions mus be read and requiremen s
me before s ar ing boiler or flue ins alla ion.
8-716-10 -711a (04.05)
IMPORTANT:
Debris from he sys em can damage he
boiler and reduce efficiency. Failure o comply
wi h he guidelines for he use of wa er
rea men wi h he appliance will invalida e
he appliance warran y.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS IN
GOOD WORKING ORDER
USE THE EXISTING BOILER/CIRCULATING
PUMP WHERE POSSIBLE OR USE A POWER
FLUSHING MACHINE TO AID THE CLEANSING
PROCEDURE BEFORE INSTALLING A NEW
BOILER.
FOR GUIDANCE REFER TO BS 75 3.
CLEANING THE PRIMARY SYSTEM:
Fill the system with cold mains water to the
recommended pressure and check for leaks
Open all drain cocks and drain the system
Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions
Circulate the flushing agent before the boiler is
fired up
Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions
Drain and thoroughly flush the system to remove
the flushing agent and any debris

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
7
MAINS SUPPLIES
MAINS SUPPLIES
ELECTRIC SUPPLY:
 Supply: 230V - 50Hz
 Cable: PVC insulated 0.75mm² (24 x 0.2mm)
temperature rated to 0°C
 Protection IP20
 External 5A fuse to BS1362
 The appliance must be earthed
 All pipes to the boiler must be cross-bonded
 It must be possible to isolate the appliance from
the electric supply with at least a 3mm contact
separation in all 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 electricity supply.

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
8
MAINS SUPPLIES
MAINS SUPPLIES
OIL SUPPLY:
 Plastic or steel tanks should be installed to
BS5410. A steel tank should conform to BS7 :
part 5 and arranged with a slope of 1 in 24 away
from the outlet valve with a sludge cock at its
lower end.
 Do no use galvanised s eel anks or pipework
for he oil supply sys em.
 Do no use soldered join s on he oil supply
pipework as his could cause a hazard in he
even of a fire.
a) S ngle p pe grav ty 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 addition the
oil level must be at least level with 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 p pe sub-grav ty 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 the oil storage tank
(A).
c) S ngle p pe suct on l ft w th de-aerator:
Maximum suction height 3.5 metres. 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 valve/s fitted in the base of the tank to the
suction line removed to assist purging air from the
oil line.
P pework:
Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump
(J).
Lay 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.
Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage tank
(A) as possible.
Fit an oil filter (C) to the oil supply pipe, near the
oil storage tank. If there is doubt about the
internal condition of the oil supply pipe, fit an
additional oil filter close to the boiler.
Fit a fire valve in accordance with BS5410. The
fire valve (D) should be fitted externally to the
building with a fire detection element (F) located
within the appliance case.
A capillary type valve provides a neat and simple
installation. Alternatively, a fusible link or electrical
system may be used.
Under no circums ances should a combina ion
isola ing/fire valve be used as he sole fire
pro ec ion device.
The table and illustration above is a guide only and does not in any way override the de-aerator
manufacturers instructions.
A - oil storage tank
B - isolating valve
C - oil filter
D - fire valve to BS5410
E - external wall
F - fire detection element
G - oil burner
H - oil supply pipe
J - oil pump
K - full base (plastic tanks)
L - non-return valve
M - de-aerator
HEAD(m) 10mmØ 12mmØ
0.5 12 30
1.0 25 6
1.5 37 1
2.0 4 100
HEAD(m) 10mmØ 12mmØ
2.5 62 100
3.0 74 100
3.5 87 100
4.0 100
Note: All dimesions are in metres unless stated otherwise.
The maximum pipe run figures are based on using copper pipe with an inside diameter
of mm less than the Ø.
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
HEAD(m) 10mmØ 12mmØ
050100
0.5 44 100
1.0 38 5
1.5 32 80
HEAD(m) 10mmØ 12mmØ
2.0 26 66
2.5 20 50
3.0 14 37
3.5 8 22
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
(m) 8mmØ 8mmØ 8mmØ 10mmØ
0 100 55 26 100
0.5 5 45 23 100
1.0 80 40 20 0
1.5 70 35 17 75
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
(m) 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
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
FUEL FLOW RATE FUEL FLOW RATE
B
A
DB
F
C
BC
G
J
4m (13ft) max.
KE
H
DB
L
L H
E
3.5m (11.5ft) max.
BCJ
FG
a)
b)
150mm
B
A
C
K
c)
B
A
M
B
CD H
KE
FG
J
3.5m (11.5ft) max.

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
PLASTIC PIPEWORK:
 Any plastic pipework must have a polymeric
barrier 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. The pipework from the
boiler to the blending valve must be in copper
or steel (protected from corrosion).
 Do no use plas ic pipework on sealed
sys ems.
PRIMARY SYSTEM/CONNECTIONS/VALVES:
Do no use galvanised pipes or radia ors.
 All system connections, taps and mixing valves
must be capable of sustaining a pressure up to
3 bar
 Radiator valves should conform to BS2767:10
 All other valves should conform to BS1010
 On new installations TRVs must be used on all
radiators except the radiator where the room
thermostat is sited, this must be fitted with
lockshield valves and left open. All installations
should have TRV's fitted to radiators within the
sleeping accommodation
 An automatic bypass valve must be connected
between the heating flow and return where TRV's
are used on all radiators
 Drain cocks are required at all the lowest points
on the system
 Air vents are required at all the high points on
the system.
OPEN VENT PRIMARY SYSTEM:
 The cold feed (F) and expansion tank (E) must
be positioned to provide a static head (S) of at
least 1 metre above the highest point in the
heating system to the water level in the expansion
tank (E)
 The heating vent (H) and cold feed (F) pipes
must rise continuously from the appliance.
 The heating vent pipe (H) must be at least
22mmØ and 350mm above the waterline in the
cold feed and expansion tank (E).
FULLY PUMPED SEALED PRIMARY SYSTEM:
 A pressure relief valve (P) (spring loaded safety
valve set to operate at 3 bar) must be fitted to
the heating flow pipe as close as possible to
the boiler
 An expansion vessel (B) should be fitted to the
heating return pipe close to the boiler and
pressurised for the system volume according to
the instructions supplied with the vessel
 A pressure gauge (G) (3 bar min.) must be fitted
to the heating flow pipe
 An automatic air vent (N) must be fitted.
9
WATER SYSTEMS & PIPEWORK
WATER SYSTEMS & PIPEWORK
TYPICAL OPEN VENT SYSTEM:
S
350mm min.
1000mm min.
FH
150mm max.
E
A
D
R R
R R
D
C
T
TL TL
JK
M
K
LTL
A - appliance
B - expansion vessel
C - automatic bypass valve
D - drain cock
E - expansion tank
F - cold feed 15mmØ min
G - pressure gauge
H - heating vent 22mmØ min
J - circulating pump
K - zone valve
L - lockshield valve
M - hot water cylinder
N - automatic air vent
P - pressure relief discharge
R - radiators
S - static head
T - TRV
U - to filling system
TYPICAL SEALED SYSTEM:
A
D
B
P
D
C
TLTL
TL TL
G
JK
M
N
U
R R
R R

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
FILLING PRIMARY SYSTEMS:
 Filling the system must comply with one of the
methods shown opposite diagram shown
opposite
 The filling point must be at low level and must
never be a permanent direct fixing to the mains
water supply
 Filling loops must be WRAS approved.
10
WATER SYSTEMS & PIPEWORK
WATER SYSTEMS & PIPEWORK
Heating return
Hose
return
Non return
valve
Non return
valve
Test cock
Stop
cock
Water main
supply
Stop
cock
Temporary hose
Heating return Auto air
vent Non return
valve
Stop
cock
Make up
vessel
1000mm above
the highest point
of the system

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
11
CONDENSATE &
PRESSURE RELIEF PIPEWORK
CONDENSATE &
PRESSURE RELIEF PIPEWORK
CONDENSATE PIPEWORK:
A condensate trap is supplied with the boiler for
external installation.
The condensate pipe must be a minimum of
21.5mmØ polypropylene pipe
The condensate pipework must fall at least
50mm per metre towards the outlet and should
take the shortest practicable route and not
exceed 3 metres outside the building
The pipework must follow one of the options
shown opposite:
a - In ernal was e drainage sys em
b - Soil/ven s ack
c - Ex ernal drainage sys em
d - Ex ernal condensa e absorp ion poin
Use waterproof pipe insulation in exposed
positions and for external pipework
IMPORTANT: Condensa e pipework mus
no leak and mus discharge in o a
condensa e rap filled wi h wa er before he
boiler is s ar ed o preven he possibili y of
po en ially harmful flue produc s escaping
via he condensa e rou e.
A -Condensate from boiler
B -Sink
C -21.5mmØ plastic polypropylene condensate
pipe
D -Gulley
E -Internal soil and vent stack
F - Condensate trap (75mm min)
G -300mm x 100mmØ sealed plastic tube
H -Ground level
J - Drainage holes 50mm from base of tube
(12mmØ at 25mm centres) facing away from
building
K -Limestone chippings
PRESSURE RELIEF PIPEWORK:
IMPORTANT: The pressure relief valve is a
safe y device for he boiler and if ac iva ed
may discharge boiling wa er or s eam
hrough he relief valve drain pipe.
Care should aken when si ing he ou le
pipe so ha i does no cause an obs ruc ion
or discharge above a window, en rance or
o her public access where i could cause a
hazard.
The pressure relief drain pipe (M) 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 (M) should be finished with a partial bend,
near the outlet to face the external wall (as
shown) to help prevent freezing
L - Outside wall
M - Drain pipe
N - External drain
Invert
75mm
min.
75mm min.
a
bc
E
A
A
BC
C
F
F
D
450 min.
75mm min.
A
C
F
D
d
75mm min.
A
C
F
25mm
min.
400mm
min.
500mm min.
G
K
J
H
M
N
L
M

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
12
BOILER LOCATION &
CLEARANCES
BOILER LOCATION & CLEARANCES 8-716-10 -711a (04.05)
This boiler is only suitable for installing internally
within a property at a suitable location onto a fixed
rigid non-combustible surface at the same size as
the boiler and capable of supporting the boiler
weight.
The boiler is not suitable for external installation
unless a suitable enclosure is provided.
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
a: INSTALLATION & SERVICE CLEARANCES:
Diagram (a) shows the minimum space required to
install & service the boiler..
A r supply - CF (Convent onal flue):
An adequate supply of free air must be delivered
to the boiler for combustion purposes through a
permanent inlet, such as an air brick, into the area
where the boiler is situated.
b: COMPARTMENTS:
Follow the requirements of BS5410 and note:
Minimum clearances must be maintained
An access door is required to install, service
and maintain the boiler and any ancillary
equipment
If fitting the boiler into an airing cupboard use
a non-combustible perforated material (maximum
hole sizes of 13mm) to separate the boiler from
the airing space.
Vent ng compartments:
Ventilation must be provided for boilers fitted
into compartments as described in BS 5410
A minimum of 2 air vents must be fitted, one at
low level and another at high level onto the same
wall using the same air for circulation.
Free air must not be taken from a room or internal
space containing a bath or shower and must
not communicate with a protected area such as
a hall, stairway, landing, corridor, lobby, shaft
etc.
Air vents must allow access for clean free air
and must be sited to comply with the flue terminal
position requirements.
Air ducting runs must not exceed 3m.
Low level air vents must be less than 450mm
from the floor.
A warning label must be added to the vents with
a statement to the effect: ''Do not block this
vent. Do not use for storeage''.
Internal* ventilation
High
Level (D)
Low
Level (C)
kW
External** ventilation
High
Level (D)
Low
Level (C)
32/50 4 5 743 248 4 5
50/70 715 1073 358 715
32/50 4 5 4 5 248 248
50/70 715 715 358 358
Internal* ventilation
High
Level (D)
Low
Level (C)
kW
External** ventilation
High
Level (D)
Low
Level (C)
600mm
300mm
10mm
10mm
540mm
1415mm
12 7mm
a: INSTALLATION & SERVICE CLEARANCES
Convent onal flue appl ances:
Minimum area of air inlet for combustion:
248cm² for 32/50kW appliances
358cm² for 50/70kW appliances.
*Internal air to and from a space/room inside the building. **External air to and from directly outside the building
Convent onal flue: Room Sealed flue:
MINIMUM AIR VENT AREA (cm²) FOR APPLIANCES INSTALLED IN A COMPARTMENT:

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
13
BOILER LOCATION & CLEARANCES
BOILER LOCATION &
CLEARANCES
600mm
2250mm
600mm
2250mm
600mm
600mm radius
750mm
750mm
A
A
A - Bath or shower cubicle (zone 0)
SHOWER / BATHROOMS:
The boiler mus no be installed in zones 0, 1 or 2
or in the shaded areas shown on the diagrams
opposite.
IMPORTANT: conven ional flued boilers mus
no be fi ed in a ba hroom.
IMPORTANT: any swi ch or appliance con rol
using mains elec rici y mus no be able o
be ouched by a person using he ba h or
shower.
Elec rical swi ches, fused spur and socke
ou le s mus no be si ua ed in he ba hroom.
1 1 23
2
3
1 1 23
2
3
0
0

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
 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
BS5410
 The flue must not cause an obstruction.
 Discharge from the flue outlet must not be a
nuisance.
 Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the flue
outlet which could be regarded as a nuisance,
for example, near security lighting.
 There should be no restriction preventing the
clearance of combustion products from the
terminal.
 The air inlet/outlet duct and the terminal of the
boiler must not be closer than 25mm to any
combustible material. Detailed recommendations
on protection of combustible materials are given
in BS 5410:1
 A protective 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 to the wall with
plated screws.
See 'Contact Information' on the inside front 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 to a facing
wall, fence, building or property boundary is
2500mm
 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.
14
FLUE OUTLET POSITIONS
FLUE OUTLET POSITIONS
Minimum dimensions (mm) of flue erminal posi ions for oil-fired appliances:
TERMINAL POSITION CF RS(H) RS(V)
A Below an opening (1, 2) N/A 600 N/A
B Horizontally to an opening (1, 2) N/A 600 N/A
C Below a plastic/painted gutter, drainage pipe or eaves if combustible
material protected
N/A 75 N/A
D Below a balcony or a plastic/painted, gutter, drainage pipe or eaves without
protection to combustible material (3)
N/A 600 N/A
E From vertical sanitary pipework N/A 300 N/A
F From an external or internal corner or from a surface or boundary alongside
the terminal
N/A 300 N/A
G Above ground or balcony level N/A 300 N/A
H From a surface or boundary facing a terminal N/A 600 N/A
J From a terminal facing the terminal  1200 
K Vertically from a terminal on the same wall N/A 1500 N/A
L Horizontally from a terminal on the same wall  750 
M Above the highest point of an intersection with the roof 600  600
N From a vertical structure on the side of the terminal 750  750
O Above a vertical structure less than 750mm from the side of the terminal 600  600
P From a ridge terminal to a vertical structure on the roof 1500  N/A
 Not applicable
N/A Not allowed
CF Conventional flue
RS(H) Room Sealed Horizontal flue
RS(V) Room Sealed Vertical 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.
3 A way of providing protection of combustible material would be to fit a heat shield at least
750mm wide.
P
O
boundary
F
J
H
B
A
G
E
M
C, D N
F
F
K
L
boundary

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-10 -711a (04.05)
Open (conventional) flued appliances must not
be installed in a bedroom, bathroom or bedsitting
room
The flue system must be in accordance with
BS5410 : Parts 1 & 2 and the current Building
Regulations
The flue must be constructed of materials suitable
for the use of condensing combustion products
External flue systems must be of the insulated
type
Brick and masonry chimneys must be lined with
a suitable non-combustible material and properly
jointed to withstand the effects of the working
temperature (min. 120°C) of the appliance and
any condensate which may form
All flue joints must be sealed to prevent the
leakage of condensate and combustion products
Ensure that joints are made so that the
condensate runs away and is not collected within
the joint
NOTE: The flue can be increased in size from the
boiler take off point providing the joint is correctly
sealed. Never reduce the flue diameter from the
boiler take off point
The flue should be vertical and contain as few
bends as possible, a maximum of two 135°
bends should be used
The flue outlet must be extended beyond the
eaves of the building and where possible, above
the apex
Fit a suitable anti down-draught terminal where
down draughts are experienced.
Manuafacturers of conventional flue systems suitable
for this appliance are listed under 'Contact
Information' on the inside front cover.
15
CONVENTIONAL FLUE
CONVENTIONAL FLUE
A - Boiler
B - Flue
C - Max. 2 bends at 135°
D - Anti down-draught terminal
E - Chimney
C
B
A
D
E

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
16 ROOM SEALED FLUE OPTIONS 8-716-10 -711a (04.05)
ROOM SEALED FLUE OPTIONS
The diagrams (opposi e) show he componen s
used and he maximum flue leng h (L) from he
boiler ou le o he ou side wall /roof of he
building for each flue configura ion.
 To achieve the maximum flue length (L), a flue
section will have to be reduced in length.
 Only the flue terminal or straight flue extensions
can be reduced in length by cutting.
 The flue terminal end can be fitted from the
inside or outside of the building.
IMPORTANT:
All horizon al sec ions mus rise away from
he boiler by 52mm per me re (3°)
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 0°
D - Flue bend 45°
E - Vertical Terminal
F - 0° inner elbow - inner flue to boiler
G - Air intake box
Calculat ng the flue length:
Measure the total flue length required, noting that
the maximum straight flue length including the
terminal is:
Horizontal 100/150mmØ: 3000mm (excluding
220mm of terminal extending outside the building)
Vertical 100/150mmØ: 6000mm
Then reduce the total straight flue length for each
extra flue bend (excluding the flue elbow) by:
1000mm for 0°
500mm for 45°
Flue Extens on lengths:
Horizontal & Vertical 100/150mmØ: 1000mm
Flue Term nal lengths:
Horizontal 100/150mmØ: 1100mm
Vertical 100/150mmØ: 12 0mm
o ou side wall.
L = 5000mm
150mmØ x5
L
L = 5000mm
150mmØ x5
L
L = 6000mm
150mmØ x6
L
L
L = 2000mm
L = 630mm L
L = 3000mm
150mmØ x4
L
L
L = 2000mm
150mmØ x2
L = 2000mm
150mmØ x2
L = 3000mm
L
150mmØ x3
L
150mmØ x2
BE
CD
F
F
F
F
F
G
G
G
G
G
G
G
G
G
C
E
B
D
B
E
E
B
C
A
A
B
A
C
B
A
D D
B
A
B
A
D
B
G
A

IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 17
UNPACKING THE BOILER
UNPACKING THE BOILER
8-716-10 -711a (04.05)
IMPORTANT: All the prev ous Pre-Installat on sect ons must be read and
requ rements met before start ng bo ler or flue nstallat on.
Unpack ng:
1 Cut the ties securing the carton to the pallet
taking care not to pierce the carton or cause
personal injury
2 Lift carton up and away from the boiler
Remove the plastic bag and upper front
protection cover from the boiler and place safely
aside
3 Lift the top panel (A) upwards to disengage
the ball stud connections (B) to remove
4 Extract the ancilliary items (a) & (b)
5 Pull the upper front panel (C) forwards to
disengage the ball stud connectors
6 Remove securing screws (D) from front panel
(E)
Pull front panel (E) up and away from the
supporting ledge on the boiler and store away
from the working area
7 Remove the bolts securing the boiler to the
transport pallet
A all imes he correc me hod for handling
heavy objec s should be s ric ly 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
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE OR EXTERNAL INSTALLATION.
a - Hardware pack
b - Literature pack
b
3
1
2
C
6
a
E
5
D
7
4
A
B

IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
18
PIPEWORK POSITIONS &
FLUE OPENING
PIPEWORK POSITIONS &
FLUE OPENING
8-716-10 -711a (04.05)
CAUTION: Ensure there are no p pes,
electr c cables, damp proof course or other
hazards before dr ll ng.
SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
PIPEWORK POSITIONS:
A to E (opposite) show the pipe positions from the
front of the boiler:
A - CH flow/heating vent 1½''Ø
B - Primary cold feed/drain 1½''Ø
C - CH return 28mmØ copper
D - Flue outlet
NOTE: For servicing purposes, keep the condensate
and pressure relief discharge pipes away from
components and pipework connections.
FLUE OPENING:
Follow the diagram opposite to mark the centre
of the flue (1, & 2) for rear opening, (2 & 3) for
side opening or (1 & 4) for top opening.
** IMPORTANT: for horizon al flues, increase
his heigh by 52mm for every 1000mm of
horizon al leng h ha he flue opening is
away from he boiler
NOTE: all horizontal flue sections must rise away
from the boiler by 5 mm per metre to ensure that
condensate flows back into the boiler for safe
discharge via the condensate waste pipe.
Make an opening (E, F or G) through the wall
using a core drill or similar at a size relative to
the wall thickness as shown below:
150mmØ flue:
Wall hickness Flue hole size
150 - 240mm 175mmØ
240 - 330mm 185mmØ
330 - 420mm 1 5mmØ
420 - 500mm 205mmØ
Clear away any debris
G
E
EF G
F
B
25
100
624
4
8 5
C
D
704
25
C
D
A
B
A
B
A
6
77
87 26
All dimensions in mm
100
2
1
3
8 5**
+
4