Worcester GREENSTAR UTILITY User manual

GREENSTAR UTILITY
18/25kW
FLOOR STANDING OIL-FIRED CONDENSING BOILER
CONVENTIONAL FLUE & ROOM SEALED FLUE
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC
HOT WATER CYLINDERS
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
GB/IE
8-716-106-2 6a (08.0 )
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB
Patent pending:
Application number 032764 .8
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
Patent pending:
Application number 032764 .8
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
GB/IE
INSTRUCTION MANUAL
GB

INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
INSTALLATION &
SERVICING INSTRUCTIONS
8-716-106-2 6a (08.0 )
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 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: 0190 7 4624
MAIN FAX: [phone]
TECHNICAL: 0870 266241
SERVICE: 08 47 2 6206
SPARES: 0190 7 2 71
LITERATURE: 0190 7 2 6
TRAINING: 0190 7 2 26
SALES: 0190 7 2640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 0811
www.fernox.com
SENTINEL 01 1 420 9 9
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARDS:
WORCESTER BOSCH
Part Number: 7-716-190-0 0
CONVENTIONAL FLUE MANUFACTURERS:
INTERACTIVE (Flue Systems) Ltd., 01908 69887
Selkirk Manufacturing Ltd. (SF Ltd.), 01271 326633
CONDENSATE PUMP MANUFACTURERS:
ASPEN 01323 848842
OIL FIRING TECHNICAL ASSOCIATION:
OFTEC 084 6 8 080
www.oftec.org
SYMBOLS USED:
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 app iance in a dry area prior to
insta ation.
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.
At ll times the correct method for h ndling
he vy 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.
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 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LAYOUT & COMPONENTS
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 6
MAINS SUPPLIES 7-8
WATER SYSTEMS & PIPEWORK 9-10
CONDENSATE & PRESSURE RELIEF PIPEWORK 11
BOILER LOCATION & CLEARANCES 12-13
FLUE OUTLET POSITIONS 14
CONVENTIONAL FLUE 1
ROOM SEALED FLUE OPTIONS 16
INSTALLATION
UNPACKING THE BOILER 17
PIPEWORK POSITIONS & FLUE OPENING 18
BOILER PANEL REMOVAL 19
FLUE INSTALLATION 20
COMBUSTION CHAMBER 21
PIPEWORK CONNECTIONS 22
OIL BURNER & PUMP 23
REFIT COMPONENTS 24
ELECTRICS 2 -27
COMMISSIONING
PRE-COMMISSIONING CHECKS 28
FILLING THE SYSTEM 29
STARTING THE APPLIANCE 30-32
WATER TREATMENT 33
FINISHING COMMISSIONING 34
SERVICING & SPARES
INSPECTION AND SERVICE 3 -38
SHORT PARTS LIST 39
CONVERSION KITS
N/A
FAULT FINDING & DIAGRAMS
FAULT FINDING 40-41
8-716-106-2 6a (08.0 )

SAFETY &
REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
2SAFETY PRECAUTIONS &
INSTALLATION REGULATIONS
8-716-106-2 6a (08.0 )
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
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.
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 410: part 1: Code of practice for Oil Fired
Boilers.
BS 799: part : Specification for Oil Storage
Tanks.
BS 7 93: Code of Practice for treatment of water
in domestic hot water central heating systems.
BS 449: part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 9 : 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 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.
Where no specific instruction is given reference
should be made to the relevant codes of practice.

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 3
GENERAL INFORMATION
GENERAL INFORMATION
8-716-106-2 6a (08.0 )
STANDARD PACKAGE:
A - Floor standing oil fired condensing boiler.
B - Literature pack.
C - Hardware pack including:
Condensate trap.
600mm
8 mm
370mm
A
B
C

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
18/25kW
24.
30
1
7
2.6
40
10
1
22
1
1
21.
230
0
1
/81
9
10
110
<100
92.9
20
120
4
TECHNICAL DATA
TECHNICAL DATA 8-716-106-2 6a (08.0 )
DESCRIPTION UNITS
Centr l He ting
Primary water capacity (total) litres
Maximum static head metres
Minimum static head metres
Water side resistance (20°C difference) mbar
Max. permissible sealed system operating pressure bar
Flue
Exit flue gas mass flow kg/hr
Pipework connections
Fuel line (compression) mm
CH flow inch BSP
CH return mm
CH vent (Optional) inch BSP
CH drain inch BSP
Condensate (polypropylene) mm
Electric l
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption W
Thermost ts
Boiler flow temperature range (cut in/cut out) °C
CH control thermostat differential °C
Boiler high limit thermostat set point °C
Boiler manual reset overheat thermostat set point °C
Flue reset overheat thermostat set point °C
Gener l D t
Maximum hearth temperature °C
SEDBUK (Band A) %
Appliance protection rating IP
Weight (excluding packaging) kg

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 5
LAYOUT & COMPONENTS
LAYOUT & COMPONENTS
8-716-106-2 6a (08.0 )
The diagram opposite excludes the top,front and
RH side casing panels.
1 CONTROL BOX ASSEMBLY
2 CASING SIDE PANEL
3 FLUE 'KNOCK-OUT' PANEL
4 CLIP - POWER CABLE
CLIP - FIRE SENSOR
6 CASING SUPPORT PANEL
7 CONTROL & MANUAL RESET HIGH LIMIT
THERMOSTATS
8 OVERHEAT THERMOSTAT (AUTOMATIC
RESET)
9TRAY
10 SECONDARY HEAT EXCHANGER
11 MANUAL RESET FLUE OVERHEAT
THERMOSTAT
12 FLUE GAS SAMPLING POINT
13 FLUE MANIFOLD ACCESS COVER
14 AIR INLET CASING
1 MANUAL AIR VENT - SECONDARY HEAT
EXCHANGER
16 HEAT EXCHANGER FLOW PIPE
17 DRAIN - SECONDARY HEAT EXCHANGER
18 REAR CABINET SUPPORT BRACKET
19 CONDENSATE OUTLET
20 FUEL ISOLATING VALVE
21 PRIMARY HEAT EXCHANGER
22 BASE PLATE
23 COMBUSTION CHAMBER ACCESS DOOR
24 OVERHEAT RESET BUTTON
2 FLUE OVERHEAT RESET BUTTON
26 DATA LABEL
27 TEMPERATURE CONTROL
28 TOP FRONT PANEL
29 STERLING 0 BURNER
i) Control box
ii) Motor
iii) Air intake casing
iv) Oil pump
v) Combustion head
30 LOCK-OUT INDICATOR/RESET BUTTON
31 CLIP - AIR INTAKE HOSE
32 AIR INTAKE HOSE
3
67
2
4
13
23
24
14
2
26
28
29
1
30
22
31
12
i)
1
32
ii)
iii)
iv)
v)
27
8910
11
16
17
18
19
20
21

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
6
CLEANING PRIMARY SYSTEMS
CLEANING PRIMARY SYSTEMS
IMPORTANT:
Debris from the system c n d m ge the
boiler nd reduce efficiency. F ilure to comply
with the guidelines for the use of w ter
tre tment with the ppli nce will inv lid te
the ppli nce w rr nty.
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.
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.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: All the following pre-inst ll tion sections must be re d nd requirements
met before st rting boiler or flue inst ll tion.
8-716-106-2 6a (08.0 )

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 6a (08.0 )
7
MAINS SUPPLIES
MAINS SUPPLIES
ELECTRIC SUPPLY:
 Supply: 230V - 0Hz.
 Cable: PVC insulated 0.7 mm² (24 x 0.2mm)
temperature rated to 90°C.
 Protection IP20.
 External A 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
8-716-106-2 6a (08.0 )
The table and illustration above is a guide only and does not in any way override the de-aerators
manufacturers instructions.
AF
BC
G J
4m (13ft) max.
B
A
DB
CB
E
K
3. m (11. ft) max.
K
1 0mm
L
L
B
A
M
B
F
C
G
J
K
3. m (11. ft) max.
E
E
D
A - Oil storage tank
B - Isolating valve
C - Oil filter
D - Fire valve to BS 410
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
HEAD 10mmØ 12mmØ
0. 12 30
1.0 2 69
1. 37 91
2.0 49 100
HEAD 10mmØ 12mmØ
2. 62 100
3.0 74 100
3. 87 100
4.0 99 100
a)
b)
c)
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.
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
HEAD 10mmØ 12mmØ
0 0 100
0. 44 100
1.0 38 9
1. 32 80
HEAD 10mmØ 12mmØ
2.0 26 66
2. 20 0
3.0 14 37
3. 8 22
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
HEAD 2. kg/h kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
0 100 26 100
0. 9 4 23 100
1.0 80 40 20 90
1. 70 3 17 7
HEAD 2. kg/h kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
2.0 60 30 14 6
2. 4 2 11 0
3.0 3 1 8 3
3. 2 10 20
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
H
H
H
8
MAINS SUPPLIES
OIL SUPPLY:
 Plastic or steel tanks should be installed to
BS 410. A steel tank should conform to BS799:
part and have a slope of 1 in 24 away from
the outlet valve with a sludge cock at its lower
end.
 Do not use g lv nised steel t nks or pipework
for the oil supply system.
 Do not use soldered joints on the oil supply
pipework s this could c use h z rd in the
event of fire.
a) Sing e 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 addition 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) Doub e pipe sub-gravity feed system:
Maximum suction height 3. metres. Non-return
valves must be fitted to the inlet and return oil line
between the oil pump (J) and oil storage tank (A).
c) Sing e pipe suction ift with de-aerator
Maximum suction height 3. 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 tan fitted with a de-aerator using
an internal non-return valve should have any non-
return valve/s fitted in the base of the tan to the
suction line removed to assist purging air from the
oil line.
Pipework
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 (recommended paper filter
element) close to the boiler, but not inside the
boiler casing.
Fit a fire valve in accordance with BS 410. The
fire valve (D) should be fitted externally to the
building with the fire valve sensor (F) located
within the appliance case.
A capillary type valve provides a neat and simple
installation. Alternatively, a fusible lin or electrical
system may be used.
Under no circumst nces should combin tion
isol ting/fire v lve be used s the sole fire
protection device.
F
C
G
J
FUEL FLOW RATE FUEL FLOW RATE
MAINS SUPPLIES
300mm min.
B DB C

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 6a (08.0 )
9
WATER SYSTEMS & PIPEWORK
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
 Any plastic pipework must have a polymeric
barrier with 1000mm (minimum) length of copper
or steel pipe connected to the boiler.
 Do not use plastic pipework on sealed systems.
 Plastic pipework used for underfloor heating
must be correctly controlled with a thermostatic
blending valve limiting the temperature of the
circuits to approx. 0°C. The pipework from the
boiler to the blending valve must be in copper
or steel (protected from corrosion).
PRIMARY SYSTEM/CONNECTIONS/VALVES:
Do not use g lv nised pipes or r di tors.
 All system connections, taps and mixing valves
must be capable of sustaining a pressure of 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 high points on the
system.
OPEN VENT PRIMARY SYSTEM:
 The feed and expansion cistern (E) must be
positioned to provide a static head (S) of at least
1 metre above the highest point in the heating
system to the water level in the feed and
expansion cistern (E).
 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.
 No valve shall be fitted in the open vent pipe (H)
or the feed and expansion pipe (F).
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 or onto one of the boiler top 1" BSP
outlets.
 An expansion vessel (B) must 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 or one of the boiler 1"
BSP outlets.
 An automatic air vent (N) must be fitted.
TYPICAL SEALED SYSTEM:
TYPICAL OPEN VENT SYSTEM:
A - Appliance
B - Expansion vessel
C - Automatic bypass valve
D - Drain cock
E - Feed and expansion cistern
F - Feed and expansion
1 mmØ min
G - Pressure gauge
H - Open 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
A
D
R R
R R
B
P
D
C
TLTL
TL TL
E
S
1000mm min.
FH
G
JK
M
N
A
D
R R
R R
D
C
TLTL
TL TL
JK
M
1 0mm max.
K
U

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 6a (08.0 )
10
WATER SYSTEMS & PIPEWORK
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 loops must be WRAS approved.
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
8-716-106-2 6a (08.0 )
11
CONDENSATE &
PRESSURE RELIEF PIPEWORK
Invert
4 0 min.
7 mm
min.
7 mm min.
7 mm min.
M
N
L
M
a
bc
D
E
A
A
C
A
BC
D
C
F
F
F
CONDENSATE &
PRESSURE RELIEF PIPEWORK
CONDENSATE PIPEWORK:
The condensate pipe must be a minimum of
21. mmØ polypropylene pipe.
The condensate pipework must fall at least
0mm 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:
- Intern l w ste dr in ge system
b - Soil/vent st ck
c - Extern l dr in ge system
d - Extern l condens te bsorption point
Use waterproof pipe insulation in exposed
positions and for external pipework.
IMPORTANT: Condens te pipework must
not le k nd must disch rge into
condens te tr p filled with w ter before the
boiler is st rted to prevent the possibility of
potenti lly h rmful flue products esc ping
vi the condens te route.
A -Condensate from boiler
B -Sink
C -21. mmØ polypropylene condensate pipe
D -Gully
E -Internal soil and vent stack
F - Condensate trap (7 mm min)
G -300mm x 100mmØ sealed plastic tube
H -Ground level
J - Drainage holes 0mm from base of tube
(12mmØ at 2 mm centres) facing away from
building
K -Limestone chippings
PRESSURE RELIEF PIPEWORK:
IMPORTANT: The pressure relief v lve is
s fety device for the boiler nd if ctiv ted
m y disch rge boiling w ter or ste m
through the relief v lve dr in pipe.
C re should t ken when siting the outlet
pipe so th t it does not c use n obstruction
or disch rge bove window, entr nce or
other public ccess where it could c use
h z rd.
The pressure relief drain pipe (M) should be
at least 1 mm 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.
Use waterproof pipe insulation in exposed
positions and for external pipework.
L - Outside wall
M - Drain pipe
N - External drain
2 mm
min.
400mm
min.
00mm min.
d
G
K
J
H
7 mm min.
A
C
F

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
12
BOILER LOCATION &
CLEARANCES
BOILER LOCATION & CLEARANCES 8-716-106-2 6a (08.0 )
 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 must be installed on a flat level surface
to ensure condensate does not enter the primary
heat exchanger.
 The boiler is not suitable for external installation
unless a suitable enclosure is provided.
 Roof space installations must fully conform to
BS 410 part 1 section 4.6.9
Open f ue mode (CF):
 In order to ensure clean and efficient combustion
an adequate supply of air must be delivered to
the combustion chamber.
 To provide sufficient air a suitable inlet must be
provided into the room or space in which the
boiler is situated, minimum size 110cm² for
18/2 kW appliances.
An air bric or other form of continuous air supply
may have to be built into the installation in order
to ensure an adequate supply of air.
 If the appliance is to be installed in a confined
space or compartment two air vents are required,
one at high level and one at low level.
The minimum free area of each vent is shown
opposite and depends whether the air is ta en
from another room or from outside the building.
 Where the air is taken from another room that
room must contain an air inlet as described
above.
Room sea ed ba anced f ue mode (RS):
The appliance does not require a separate vent for
combustion air.
 Installation in cupboards or compartments require
permanent vents for cooling purposes, one at
high level and one at low level, either direct to
outside air or to a room.
 Both vents must pass to the same room or be
on the same wall to the outside air.
The minimum air vent free area is given in the table
opposite.
a: INSTALLATION CLEARANCES:
Diagram (a) shows the minimum space
recommended to inst ll the boiler only.
b: SERVICE CLEARANCES:
Diagram (b) shows the minimum space required to
service the boiler only.
The boiler is suitable for installing under a wor top
providing that the front of the boiler is not enclosed
and the wor top above the boiler (min. 10mm
clearance) is easily removable to access the loc
out reset and allow boiler maintenance.
* Remove the flue ' noc -out' panel sections if this
clearance is less than 75mm.
Internal
1
ventilation
High
Level
Low
Level
kW
External
2
ventilation
High
Level
Low
Level
18/2 220 330 110 220 18/2 220 220 110 110
Internal
1
ventilation
High
Level
Low
Level
kW
External
2
ventilation
High
Level
Low
Level
600mm
300mm
100mm
100mm
70mm
1200mm
11 mm
a: RECOMMENDED
INSTALLATION CLEARANCES
b: SERVICE CLEARANCES
600mm
300mm
mm*
mm*
380mm
1200mm
11 mm
1Internal air to and from a space/room inside the building. 2External air to and from directly outside the building
Conventiona f ue: Room Sea ed f ue:
MINIMUM AIR VENT AREA (cm²) FOR APPLIANCES INSTALLED IN A COMPARTMENT:

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 6a (08.0 )
13
BOILER LOCATION & CLEARANCES
BOILER LOCATION &
CLEARANCES
600mm
22 0mm
600mm
22 0mm
600mm
600mm radius
7 0mm
7 0mm
A
A
A - Bath or shower cubicle (zone 0)
c: COMPARTMENTS:
Follow the requirements of BS 410 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 material (if perforated,
maximum hole sizes of 13mm) to separate the
boiler from the airing space.
Venting compartments:
There must be sufficient clearance around the
appliance to allow proper circulation of ventilation
air. The clearances required for installation and
servicing will normally be adequate for ventilation.
 Ventilation must be provided for boilers fitted
into compartments as described in BS 410.
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 4 0mm
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 storage'.
SHOWER / BATHROOMS:
The boiler must not be installed in zones 0, 1 or 2
or in the shaded areas shown on the diagrams
opposite.
IMPORTANT: convention l flued boilers must
not be fitted in b throom.
IMPORTANT: ny switch or ppli nce control
using m ins electricity must not be ble to
be touched by person using the b th or
shower.
Electric l switches, fused spur nd socket
outlets must not be situ ted in the b throom.
1 1 23
2
3
1 1 23
2
3
0
0

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 6a (08.0 )
 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
BS 410.
 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 2 mm to any
combustible material. Detailed recommendations
on protection of combustible materials are given
in BS 410:1.
 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
0mm) 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 above
ground is 2100mm where directed to a public
footpath, private access route or a frequently used
area and 2 00mm from a car parking area.
 **Minimum distance of the flue terminal to a
facing wall, fence, building or property boundary
is 2 00mm.
FLUE OUTLET POSITIONS
14 FLUE OUTLET POSITIONS
1 An opening means an openable element, such as an openable window, or a permanent
opening such as a permanently open air vent.
2 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
Minimum dimensions (mm) of flue termin l positions for oil-fired ppli nces:
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 7 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 1 00 N/A
L Horizontally from a terminal on the same wall  7 0 
M Above the highest point of an intersection with the roof 600  600
N From a vertical structure on the side of the terminal 7 0  7 0
O Above a vertical structure less than 7 0mm from the side of the terminal 600  600
P From a ridge terminal to a vertical structure on the roof 1 00  N/A
 Not applicable
N/A Not allowed
CF Conventional flue
RS(H) Room Sealed Horizontal flue
RS(V) Room Sealed Vertical flue

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
8-716-106-2 6a (08.0 )
15
CONVENTIONAL FLUE
CONVENTIONAL FLUE
A - Boiler
B - Flue
C - Max. 2 bends at 13 °
D - Anti down-draught terminal
E - Chimney
C
B
A
D
E
 Open (conventional) flued appliances must not
be installed in a bedroom, bathroom or bedsitting
room.
 The flue system must be in accordance with
BS 410 : Part 1 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 (minimum rating of material 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 ta e off point providing the joint is correctly
sealed. Never reduce the flue diameter from the
boiler ta e off point.
 The flue should be vertical and contain as few
bends as possible, a maximum of two 13 °
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.
Manufacturers of conventional flue systems suitable
for this appliance are listed under 'Contact
Information' on the inside front cover.

PRE-
IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
16 ROOM SEALED FLUE OPTIONS 8-716-106-2 6a (08.0 )
ROOM SEALED FLUE OPTIONS
The di gr ms (opposite) show the components
used nd the m ximum flue length (L) for e ch
flue configur tion.
 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 horizont l sections must rise w y from
the boiler by 52mm per metre (3°) to llow
the condens te to dr in b ck to the boiler.
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 90°
D - Flue bend 4 °
E - Vertical Terminal Kit (incl. 90° elbow)
Ca cu ating the f ue ength:
Measure the total flue length required, noting that
the maximum straight flue length including the
terminal is:
Horizontal 80/12 mmØ: 4000mm (excluding
120mm of terminal extending outside the building).
Vertical 80/12 mmØ: 6000mm (including the
vertical flue kit 90° elbow).
Then reduce the total straight flue length for each
extra flue bend (excluding the vertical flue kit 90°
elbow) by:
1000mm for 90°
00mm for 4 °
F ue Extension engths:
Horizontal & Vertical 80/12 mmØ: 1000mm overall
length.
Effective length when engaged into soc ets within
the flue run is 950mm.
F ue Termina engths:
Horizontal 80/12 mmØ: 720mm
Vertical 80/12 mmØ: 1080mm + cage.
to outside w ll.
E
E
E
E
L = 000mm
12 mmØ x
L
B
L = 000mm
12 mm x4
L
D
D
B
L = 6000mm
12 mmØ x6
L
B
L
L = 2000mm
12 mmØ x2
C
B
A
L = 140 - 390mm L
A
L = 4000mm
12 mmØ x4
L
B
A
L
L = 3000mm
12 mmØ x3
C
B
A
L = 3000mm
12 mmØ x3
L = 3000mm
D D
B
A L
12 mmØ x3
B
A
C
L
B
CD
A
x2

IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH 17
UNPACKING THE BOILER
UNPACKING THE BOILER
8-716-106-2 6a (08.0 )
Unpacking:
1 Cut the ties securing the carton taking care
not to pierce the carton or cause personal injury.
2 Open the top flaps of carton and 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 Pull base of front panel (E) away from the
boiler to disengage ball stud connectors.
Lift front panel (E) upwards off the top
supporting ledge and store safely away from the
working area.
At least two or more persons are required to
move the boiler, taking care not to damage the
boiler, panels or the floor.
At ll times the correct method for h ndling
he vy 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.
IMPORTANT: A the previous Pre-Insta ation sections must be read and
requirements met before starting boi er or f ue insta ation.
1
3
E
2

IN STALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER BOSCH
18
PIPEWORK POSITIONS &
FLUE OPENING
PIPEWORK POSITIONS &
FLUE OPENING
8-716-106-2 6a (08.0 )
CAUTION: Ensure there are no pipes,
e ectric cab es, damp proof course or other
hazards before dri ing.
SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
PIPEWORK POSITIONS:
A to D (opposite) show the pipe positions from the
front of the boiler:
A - CH flow/heating vent 1''Ø BSP
B - Primary drain/cold feed 1''Ø BSP
C - CH return 22mmØ copper
D - Flue outlet
E - Condensate outlet 21. mmØ
NOTE: For servicing purposes, eep the condensate
and pressure relief discharge pipes away from
components and pipewor 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 horizont l flues, incre se
this height by 52mm for every 1000mm of
horizont l length th t the flue opening is
w y from the boiler
NOTE: all horizontal flue sections must rise away
from the boiler by 52mm per metre to ensure that
condensate flows bac into the boiler for safe
discharge via the condensate waste pipe.
Make an opening (F, G or H) through the wall
using a core drill or similar at a size relative to
the wall thickness as shown below:
125mmØ flue:
W ll thickness Flue hole size
1 0 - 240mm 1 mmØ
240 - 330mm 160mmØ
330 - 420mm 16 mmØ
420 - 00mm 170mmØ
Clear away any debris.
H
F
FGH
G
B
10 190
All dimensions in mm
10
18 10
00
67
7 2
C
D
0
2
C
D
A
B
A
B
A
2
1
3
7 2**
+
4
412
E