greenstar regular and system oil-fi red condensing boiler...
TRANSCRIPT
Technical and Specifi cation Information Greenstar Camray series
Greenstar Utility series
Greenstar Danesmoor series
Greenstar Camray External series
Greenstar regular and system oil-fi red condensing boiler range
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Worcester and you. Making a difference.
As part of the Bosch Group, Worcester
products are designed and manufactured to
provide customers with the highest levels of
quality and reliability which are synonymous
with the Bosch name.
As part of Europe’s largest supplier of
heating products, Worcester, Bosch Group
has UK-based resources and support
capabilities to offer you the value-added
solutions you require. Worcester employs
a nationwide network of Service Engineers
and technically trained Field Sales
Managers, supported by an experienced
technical services team which is able to
provide comprehensive support and advice
from designing system layouts through
to installation.
Worcester is dedicated to providing high
performance, energy effi cient heating
and hot water systems for a wide range
of installations. Our oil manufacturing
heritage stretches back to the foundation of
the company in 1962 and during this period
we have built a reputation for manufacturing
products which offer the end user the
highest levels of quality and reliability.
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Contents Page
The Greenstar regular & system boiler range 4 - 7
Inside story 8 - 19
Site preparations and guidance 20 - 26
The Worcester Greenstar System Filter 27
Condensate pipework 28 - 29
Worcester CondenseSure auxiliary siphon 30 - 31
Horizontal and vertical flue terminal positioning 32 - 33
Horizontal fluing options (internal models) 34 - 38
Vertical fluing options (internal models) 39 - 41
Greenstar Danesmoor wall mounted internal boiler range
vertical fluing options 42 - 43
Horizontal fluing options (external models) 44
Oilfit external flue system 45 - 47
Plume management terminal positioning and system options 48 - 51
Conventional flue 52
Oilfit flexible flue liner 53 - 54
Installation requirements 55 - 58
Accessories 59 - 63
Worcester training 64 - 66
After-sales 67
“At Worcester we recognise the vital role you
play in the specification and installation of
energy efficient appliances in homes across
the UK. We will continue to invest in our
products, people, facilities and added value
services to ensure you have all you require in
order to deliver only the best solutions to
your customers’ requirements.”
Carl Arntzen,
Managing Director,
Bosch Thermotechnology Ltd.
The reception and main entrance at our Worcester headquarters
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The Greenstar regular and system oil-fi red condensing boiler rangeThe Greenstar Camray and Danesmoor series are part of
a market-leading range of high effi ciency boilers which is
good news for the environment and excellent news for
specifi ers, installers and consumers. They offer excellent
fl ow rates and are ideal for customers who are looking to
minimise fuel consumption, without sacrifi cing heating and
hot water performance.
Greenstar oil-fi red regular and system boilers offer outputs
between 12 to 70kW and are specifi cally designed for use
with either a vented or sealed system. They are ideally
suited to our range of Greenstore hot water cylinders which
allow your customer to benefi t from mains pressure hot
water, rapid re-heat times and excellent heat retention.
Every appliance is operationally tested before it leaves
the factory as part of Worcester’s rigorous quality
control procedure. When you install a Worcester
oil-fi red boiler, you can rest assured that your customer
is receiving the best quality components and highest
levels of workmanship.
Highly effi cient condensing technology
The secondary heat exchanger of the Greenstar range
extracts more energy from the oil and, when compared with
a non-condensing boiler, can cut heating and hot water bills
by over £400 a year†. All Greenstar condensing boilers are
able to deliver this energy-saving performance by extracting
additional latent heat from the exhaust gases – a highly
effi cient use of energy which also signifi cantly reduces
carbon dioxide emissions into the atmosphere.
Greenstar Camray and Danesmoor condensing boilers have
a seasonal effi ciency of over 90% (SEDBUK 2005 value),
effi ciently producing heat for both your customers' heating
and hot water demands. This is in comparison to standard
effi ciency boilers which achieve around 78% effi ciency,
highlighting how a Greenstar boiler can cut heating and hot
water bills.
†Source: Energy Saving Trust: Based on replacing a G-rated oil-fired boiler with an A-rated oil-fired condensing boiler and a full set of controls in a typical 3 bedroom semi-detached home with an average oil price of 6.02p/kWh.
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Greenstar Camray Kitchen
The Greenstar regular and system oil-fired range at a glanceGreenstar model Camray 12/18 models Camray 18/25 models Camray 25/32 models
Part No.
Kitchen regular 7 716 100 105 7 716 100 106 7 716 100 107
Kitchen system 7 716 100 121 7 716 100 122 7 716 100 123
Utility regular 7 716 100 108 7 716 100 109 7 716 100 110
Utility system 7 716 100 111 7 716 100 112 7 716 100 113
SEDBUK 2005 (all models) 93.1% 93.2% 94.2%
Dimensions (h x w x d) All Kitchen/Utility models
855x370x600mm 855x370x600mm 855x370x600mm
Output kW to central heating (CH)
Min 12kW 18kW 25kW
Max 18kW 25kW 30kW
Conventional CF or RS room sealed from one appliance
Greenstar model Camray 12/18 External models Camray 18/25 External models Camray 25/32 External models
Part No.External regular 7 716 100 114 7 716 100 115 7 716 100 116
External system 7 716 100 126 7 716 100 127 7 716 100 128
SEDBUK 2005 (all models) 93.1% 93.2% 94.2%
Dimensions (h x w x d) 950x565x780mm 950x565x780mm 950x565x780mm
Output kW to central heating (CH)
Min 12kW 18kW 25kW
Max 18kW 25kW 30kW
Balanced flue
Greenstar model Utility 32/50 Utility 50/70 Danesmoor WM 12/18 Danesmoor WM 18/25
Part No. 7 716 100 103 7 716 100 104 7 716 100 124 7 716 100 125
SEDBUK 2005 93.0% 92.5% 92.6% 92.8%
Model Utility regular Utility regular Kitchen regular Kitchen regular
Dimensions (h x w x d) 1012x520x815mm 1012x520x815mm 880x600x380mm 880x600x380mm
Output kW to central heating (CH)
Min 32kW 50kW 12kW 18kW
Max 50kW 70kW 18kW 25kW
Conventional CF or RS room sealed from one appliance
RS only RS only
6
Greenstar Camray and Danesmoor
regular and system boiler ranges
Greenstar internal models are ideally suited for installation
in a kitchen or a utility room.
Greenstar internal regular and system boilers feature:
• The same footprint as previous models, creating less
disturbance for replacement installations
• The option to add a plug-in 7 day twin-channel digital
programmer to kitchen models, to give fully automatic
control and eliminating the need for external wiring of
the programmer
• The ability to be installed under a removable
work surface.
Greenstar Camray External
regular and system boiler ranges
Where space in the home is at a premium a Greenstar
Heatslave External boiler is the ideal solution.
Whilst offering many of the features of the internal models,
Greenstar Camray External models also feature:
• A robust, durable external cabinet that blends in with the
garden and protects the appliance from the elements
• IP45 Ingress Protection – protecting the boiler from
water, dust and the environment
• A built-in frost thermostat which protects the appliance
from freezing.
The features of the Greenstar regular and system condensing boiler range
Special features
• All Greenstar oil-fi red boilers have an annual
effi ciency of over 90% (SEDBUK 2005 value),
ensuring optimum effi ciency
• Designed for easy installation and servicing
• Greenstar fl oor standing oil-fi red boilers feature a
5mm steel inner primary heat exchanger surface as
well as a 3mm outer. This, combined with a stainless
steel secondary heat exchanger, extracts additional
latent heat within the fl ue gases, ensuring an effi cient
and reliable product
• Years of development has enabled Worcester to produce
the optimum match between the burner and boiler,
ensuring maximum effi ciency as well as an exceptionally
clean and quiet operation
• Every Greenstar oil-fi red appliance carries
a full 2 year guarantee, as well as a 5 year*
guarantee on the primary heat exchanger
and a 10 year* guarantee on the secondary
heat exchanger.
*Terms and conditions apply.
*On the secondary heat exchanger.
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Operation
Greenstar Camray system boilers are supplied ready for
use with sealed primary water systems, and are fully
compatible with the entire range of Greenstore single coil
hot water cylinders.
Greenstar Camray and Danesmoor regular boilers are
suitable for open vented systems, requiring a minimum
head of 1m.
All models operate on 28 sec kerosene oil and feature a
Riello burner.
Applications
• The outputs offered by the range ensures installation
fl exibility, making Greenstar oil-fi red boilers ideally suited
to many sizes of domestic property
• All models are solar compatible and are ideally matched
to our range of Greenskies solar thermal panels and
Greenstore twin coil cylinders.
Fluing
Indoor appliances can be used with
either a room sealed concentric fl ue or
conventional (open) fl ue. A fl exi-fl ue liner
kit is available to enable the appliance to be fl ued
via a chimney. The room sealed fl ue ensures extremely
quiet operation.
The external appliances utilise a balanced fl ue system
in order to minimise the risk of lockouts caused by
strong winds.
A plume management kit is available for both internal and
external boilers.
Greenstar Oilfi t – the easy-fi t fl uing solution
• Multiple fl uing options with the ability to fl ue internal
fl oor standing boilers from the top, rear or side and
external boilers from the rear and side
• Conventional fl ue via the adaptor kit or fl exi-fl ue chimney
liner kit
• Room sealed fl ue lengths up to 12m vertically and
6m horizontally
• Quick-to-install push-fi t connections and telescopic
options which form a gas tight seal and in most cases
eliminate the need to cut the fl ue
• Easy-fi t installation that requires no special tools when
fi tting fl ue extensions, elbows and adaptors.
Greenstar Camray Utility
Greenstar Camray External
Greenskies Solar-Lux, Solar-Lifestyle, Solar-Lito, Solar-Lito Mini and Greenstore TC series
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Inside story – Greenstar Camray regular condensing boiler series
Greenstar Camray (kitchen) fascia
Temperature control Demand indicator Lock-out indicator Optional digital plug-in programmer
Flue overheat reset button
Boiler overheat reset button
Burner lead Baffle retainer access door
Flue gas analyser test point (behind control box)
Oil supply isolating valve
Burner
Deflector plate
Greenstar Camray (kitchen) shown
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Technical data
BoilerGreenstar
Camray regular(kitchen & utility) 12/18
Greenstar Camray regular
(kitchen & utility) 18/25
Greenstar Camray regular
(kitchen & utility) 25/32
Height 855mm 855mm 855mm
Width 370mm 370mm 370mm
Depth 600mm 600mm 600mm
Weight – lift 101kg 102kg 109kg
2005 SEDBUK value 93.1% / A rated 93.2% / A rated 94.2% / A rated
2009 SEDBUK value 90.9% 91.2% 91.7%
Solar compatible
Heating flow / return connections 1 inch BSP, 22mm 1 inch BSP, 22mm 1¼ inch BSP, 28mm
Condensate connection (polypropylene) 21.5mm 21.5mm 21.5mm
Oil connection 10mm 10mm 10mm
Primary water content 23 ltr 23 ltr 21 ltr
Output to central heating 12 - 18kW 18 - 25kW 25 - 30kW
Oil burner Riello RDB 1 Riello RDB 2.2 Riello RDB 2.2
Optional plug-in twin channel digital controls Kitchen models only Kitchen models only Kitchen models only
Primary feed/drain 1 inch BSP 1 inch BSP 1¼ inch BSP
Primary cold feed ¾ inch BSP ¾ inch BSP ¾ inch BSP
Maximum primary static head 30m 30m 30m
Minimum primary static head 1m 1m 1m
Water side resistance 20ºC 26mbar 52mbar 69mbar
Available pump head 20ºC N/A N/A N/A
Exhaust flue gas mass flow 29kg/hr 40kg/hr 51kg/hr
Control thermostat range 55/81ºC 55/81ºC 55/81ºC
Power supply 230V, 50Hz 230V, 50Hz 230V, 50Hz
Power consumption 150W 160W 160W
Flue reset overheat thermostat (cut out) 110ºC 110ºC 110ºC
Boiler manual reset overheat thermostat (cut out) 105ºC 105ºC 105ºC
Boiler high limit thermostat (cut out) 95ºC 95ºC 95ºC
Minimum diameter flue (CF) 100mm 100mm 130mm*
Minimum diameter flue (RS) 80/125mm 80/125mm 80/125mm (H) 100/150mm (V)
Maximum horizontal flue RS (125mm dia.) 4,000mm 6,000mm 4,000mm
Maximum vertical flue RS (125mm dia.) 8,000mm 8,000mm N/A
Maximum vertical flue RS (150mm dia.) N/A 10,000mm 8,000mm
Maximum hearth temperature <100ºC <100ºC <100ºC
*100mm when using ‘Oilfit’ flexible flue liner kit
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Inside story – Greenstar Utility regular condensing boiler series
Burner lead
Burner
Primary heat exchanger service
access door
Flue gasreset button
Overheat thermostat reset button
Temperature control
Flue gas analysis point
Service access door to secondary heat exchanger
Burner combustion air hose (RS only)
Multi-directional flue outlet box (RS only)
Burner control box
Thermostat pocket
Data label
Lock out reset button
Return
Flue gas overheat thermostat
Air vent to secondary heat exchanger
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Technical data
BoilerGreenstar regular
Utility 32/50Greenstar regular
Utility 50/70
Height 1,012mm 1,012mm
Width 520mm 520mm
Depth 815mm 815mm
Weight – lift 270kg 280kg
2005 SEDBUK value 93.0% / A rated 92.5% / A rated
2009 SEDBUK value 90.0% 90.5%
Solar compatible
Heating flow / return connections 1½ inch BSP/28mm 1½ inch BSP/28mm
Condensate connection (polypropylene) 21.5mm plastic pipe 21.5mm plastic pipe
Oil connection 10mm 10mm
Primary water content 50 ltr 51 ltr
Output to central heating 32 - 50kW 50 - 70kW
Oil burner Riello RDB 3.2 Riello RDB 4.2
Open primary vent 1½ inch BSP 1½ inch BSP
Primary cold feed 1½ inch BSP 1½ inch BSP
Maximum primary static head 30m 30m
Minimum primary static head 1m 1m
Water side resistance 20ºC 26mbar 40mbar
Exhaust flue gas mass flow 76kg/hr 106kg/hr
Power supply 230V, 50Hz 230V, 50Hz
Power consumption 190W 220W
Flue reset overheat thermostat (cut out) 120ºC 120ºC
Boiler manual reset overheat thermostat (cut out) 110ºC 110ºC
Boiler high limit thermostat (cut out) 100ºC 100ºC
Minimum diameter flue (CF) 130mm 130mm
Minimum diameter flue (RS) 100/150mm 100/150mm
Maximum horizontal flue RS (150mm dia.) 3,000mm 3,000mm
Maximum vertical flue RS (150mm dia.) 6,000mm 6,000mm
Maximum hearth temperature <100ºC <100ºC
Ingress protection rating IP20 IP20
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Inside story – Greenstar Danesmoor WM regular condensing boiler series
Greenstar Danesmoor WM fascia
Control panel
Secondary heat exchanger
Flue cowl
Burnerservice hook
Primary heat exchanger
Thermostat phial pockets
Drip tray
Condense trap
Riello RDB burner
Push fit flow and return burner air duct pipework connections
Optional digital plug-in programmer
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Technical data
BoilerGreenstar Danesmoor
WM 12/18Greenstar Danesmoor
WM 18/25
Height 880mm 880mm
Width 600mm 600mm
Depth 410mm 410mm
Weight – lift 72kg 72kg
2005 SEDBUK value 92.7% / A rated 92.8% / A rated
2009 SEDBUK value 90.7% 90.7%
Solar compatible
Heating flow / return connections 22mm copper 22mm copper
Condensate connection (polypropylene) 21.5mm plastic pipe 21.5mm plastic pipe
Oil connection 10mm 10mm
Primary water content 23 ltr 23 ltr
Output to central heating 12 - 18kW 18 - 25kW
Oil burner Riello RDB 1 Riello RDB 2.2
Optional plug-in twin channel digital controls
Maximum primary static head 30m 30m
Minimum primary static head 1m 1m
Water side resistance 20ºC 30mbar 69mbar
Exhaust flue gas mass flow 29kg/hr 40kg/hr
Control thermostat range 55/81ºC 55/81ºC
Power supply 230V, 50Hz 230V, 50Hz
Power consumption 150W 160W
Flue reset overheat thermostat (cut out) 110ºC 110ºC
Boiler manual reset overheat thermostat (cut out) 105ºC 105ºC
Boiler high limit thermostat (cut out) 95ºC 95ºC
Minimum diameter flue (RS) 80/125mm 80/125mm
Maximum horizontal flue RS (125mm dia.) 4,000mm 4,000mm
Maximum vertical flue RS (125mm dia.) 6,000mm 6,000mm
Ingress protection rating IP20 IP20
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Inside story – Greenstar Camray System condensing boiler series
Greenstar Camray Utility System fascia
Temperature control
Flue overheatreset button
(under control box)
Boiler overheat reset button
Burner lead
Pressure relief valve
Expansion vessel
System pressure gauge
Baffle retainer access door
Circulating pump
Expansion vessel bracket
Burner
Flue gas analyser test point (behind control box)
Greenstar Camray Utility System shown
15
Technical data
Boiler
Greenstar Camray System
(kitchen & utility) 12/18
Greenstar Camray System
(kitchen & utility) 18/25
Greenstar Camray System
(kitchen & utility) 25/32
Height 855mm 855mm 855mm
Width 370mm 370mm 370mm
Depth 600mm 600mm 600mm
Weight – lift 109kg 111kg 118kg
2005 SEDBUK value 93.1% / A rated 93.2% / A rated 94.2% / A rated
2009 SEDBUK value 90.9% 91.2% 91.7%
Solar compatible
Heating flow / return connections 22mm 22mm 28mm
Condensate connection (polypropylene) 21.5mm 21.5mm 21.5mm
Oil connection 10mm 10mm 10mm
Primary water content 30 ltr 30 ltr 28 ltr
Output to central heating 12 - 18kW 18 - 25kW 25 - 30kW
Oil burner Riello RDB 1 Riello RDB 2.2 Riello RDB 2.2
Optional plug-in twin channel digital controls Kitchen models only Kitchen models only Kitchen models only
Maximum primary static head 30m 30m 30m
Minimum primary static head 1m 1m 1m
Water side resistance 20ºC N/A N/A N/A
Available pump head 20ºC 5.7 mH2O 4.9 mH2O 4.1 mH2O
Exhaust flue gas mass flow 29kg/hr 40kg/hr 51kg/hr
Control thermostat range 55/81ºC 55/81ºC 55/81ºC
Power supply 230V, 50Hz 230V, 50Hz 230V, 50Hz
Power consumption 255W 265W 265W
Flue reset overheat thermostat (cut out) 110ºC 110ºC 110ºC
Boiler manual reset overheat thermostat (cut out) 105ºC 105ºC 105ºC
Boiler high limit thermostat (cut out) 95ºC 95ºC 95ºC
Minimum diameter flue (CF) 100mm 100mm 130mm*
Minimum diameter flue (RS) 80/125mm 80/125mm 80/125mm (H) 100/150mm (V)
Maximum horizontal flue RS (125mm dia.) 4,000mm 6,000mm 4,000mm
Maximum vertical flue RS (125mm dia.) 8,000mm 8,000mm N/A
Maximum vertical flue RS (150mm dia.) N/A 10,000mm 8,000mm
Maximum hearth temperature <100ºC <100ºC <100ºC
Ingress protection rating IP20 IP20 IP20
*100mm when using ‘Oilfit’ flexible flue liner kit
16
Inside story – Greenstar Camray External regular condensing boiler series
Flue gas analyser test point
Flue overheatreset button
Baffle retainer access door
Burner
Burner lead
Condensate trap (supplied as accessory)
Boiler overheat reset button
Greenstar Camray External fascia
Temperature control Service mode switch
17
Technical data
BoilerGreenstar Camray
External 12/18Greenstar Camray
External 18/25Greenstar Camray
External 25/32
Height 950mm 950mm 950mm
Width 565mm 565mm 565mm
Depth 780mm 780mm 780mm
Weight – lift 114kg 115kg 122kg
2005 SEDBUK value 93.1% / A rated 93.2% / A rated 94.2% / A rated
2009 SEDBUK value 90.9% 91.2% 91.7%
Solar compatible
Heating flow / return connections 1 inch BSP, 22mm 1 inch BSP, 22mm 1¼ inch BSP, 28mm
Condensate connection (polypropylene) 21.5mm 21.5mm 21.5mm
Oil connection 10mm 10mm 10mm
Primary water content 23 ltr 23 ltr 21 ltr
Output to central heating 12 - 18kW 18 - 25kW 25 - 30kW
Oil burner Riello RDB 1 Riello RDB 2.2 Riello RDB 2.2
Optional plug-in twin channel digital controls – – –
Open primary vent 1 inch BSP 1 inch BSP 1¼ inch BSP
Primary cold feed ¾ inch BSP ¾ inch BSP ¾ inch BSP
Condensate trap Accessory kit supplied Accessory kit supplied Accessory kit supplied
Maximum primary static head 30m 30m 30m
Minimum primary static head 1m 1m 1m
Water side resistance 20ºC 26mbar 52mbar 69mbar
Available pump head 20ºC N/A N/A N/A
Exhaust flue gas mass flow 29kg/hr 40kg/hr 51kg/hr
Control thermostat range 55/81ºC 55/81ºC 55/81ºC
Power supply 230V, 50Hz 230V, 50Hz 230V, 50Hz
Power consumption 150W 160W 160W
Flue reset overheat thermostat (cut out) 110ºC 110ºC 110ºC
Boiler manual reset overheat thermostat (cut out) 105ºC 105ºC 105ºC
Boiler high limit thermostat (cut out) 95ºC 95ºC 95ºC
Flue diameter 80/125mm 80/125mm 80/125mm, 100/150mm
Maximum high level horizontal flue RS (125mm dia.) 2,000mm 5,000mm 2,000mm
Maximum vertical flue RS (125mm dia.) 7,000mm 7,000mm N/A
Maximum vertical flue RS (150mm dia.) N/A 9,000mm 7,000mm
Maximum hearth temperature <100ºC <100ºC <100ºC
Ingress protection rating IP45 IP45 IP45
18
Inside story – Greenstar Camray External System condensing boiler series
Pressure relief valve
Flue gas analysertest point
Baffle access door
Burner
Burner lead
Combustion air inlet tube
Circulation pump
Condensate trap (supplied as accessory)
Greenstar Camray External fascia
Temperature control
Service mode switch
Pressure gauge
19
BoilerGreenstar Camray
External System 12/18Greenstar Camray
External System 18/25Greenstar Camray
External System 25/32
Height 950mm 950mm 950mm
Width 565mm 565mm 565mm
Depth 780mm 780mm 780mm
Weight – lift 133kg 134kg 152kg
2005 SEDBUK value 93.1% / A rated 93.2% / A rated 94.2% / A rated
2009 SEDBUK value 90.9% 91.2% 91.7%
Solar compatible
Heating flow / return connections 22mm 22mm 28mm
Condensate connection (polypropylene) 21.5mm 21.5mm 21.5mm
Oil connection 10mm 10mm 10mm
Primary water content 23 ltr 23 ltr 21 ltr
Output to central heating 12 - 18kW 18 - 25kW 25 - 30kW
Oil burner Riello RDB 1 Riello RDB 2.2 Riello RDB 2.2
Optional plug-in twin channel digital controls – – –
Condensate trap Accessory kit supplied Accessory kit supplied Accessory kit supplied
Maximum primary static head 30m 30m 30m
Minimum primary static head 1m 1m 1m
Available pump head 20ºC 5.7 mH2O 4.9 mH2O 4.1 mH2O
Exhaust flue gas mass flow 29kg/hr 40kg/hr 51kg/hr
Control thermostat range 55/81ºC 55/81ºC 55/81ºC
Power supply 230V, 50Hz 230V, 50Hz 230V, 50Hz
Power consumption 255W 265W 265W
Flue reset overheat thermostat (cut out) 110ºC 110ºC 110ºC
Boiler manual reset overheat thermostat (cut out) 105ºC 105ºC 105ºC
Boiler high limit thermostat (cut out) 95ºC 95ºC 95ºC
Flue diameter 80/125mm 80/125mm 80/125mm or 100/150mm
Maximum high level horizontal flue RS (125mm dia.) 2,000mm 5,000mm 2,000mm
Maximum vertical flue RS (125mm dia.) 7,000mm 7,000mm N/A
Maximum vertical flue RS (150mm dia.) N/A 9,000mm 7,000mm
Maximum hearth temperature <100ºC <100ºC <100ºC
Ingress protection rating IP45 IP45 IP45
Technical data
20
Site preparations and guidance (internal models)
Flue system
The Greenstar Camray regular (kitchen) and Utility, System
(kitchen) and System Utility, Danesmoor WM and Utility
appliances can be connected to either a conventional fl ue
system or a multi-directional, room sealed balanced fl ue.
In either case either the conventional fl ue adaptor or the
appropriate RS fl ue kit needs to be specifi ed.
The Greenstar Camray External appliances can be
connected to the Greenstar Oilfi t External fl ue system
providing balanced fl uing options at low-level, high level or
vertical outlets. The Oilfi t External fl ue system can also be
used on internal models.
All materials used on open fl ue systems must be able to
sustain the corrosive elements present within the fl ue gases
from condensing boilers. Worcester’s Oilfi t fl exible fl ue liner
is available in a variety of lengths from 8m to 15m and is
suitable for the Greenstar Camray range† (see installation
manual for further details or contact our Technical Support
Department). For other fl ue systems, guidance on the
suitability of appropriate materials should be sought from
the fl ue manufacturer. Worcester can supply a fl exible fl ue
liner suitable for CF chimney installations.
Siting of appliance
Greenstar Camray regular (kitchen) and Utility, System
(kitchen), System Utility and Danesmoor Utility oil-fi red
appliances are not suitable for external installation unless
a suitable enclosure is provided. The fl oor must be fi rm
and level.
The fl oor on which the boiler is to be mounted should be
capable of supporting an overall weight of approximately
140kg (Camray) or 300kg (Danesmoor Utility). All models
have a hearth temperature of below 100°C. The boilers do
not therefore require a constructional hearth.
The appliances should however be positioned on a
non-combustible solid base as near to the fl ue location
point as possible: care should be taken to ensure that the
appliance is level.
The Greenstar Camray External appliances are suitable for
external installation only. The boilers should be sited on a
fi rm and level, non-combustible base capable of supporting
the boiler's weight.
For all external boilers consideration should be given to
the location of the appliance and its fl ue outlet in relation
to windows, doors and air vents. Care should be taken to
ensure that pipework leaving the appliance and entering the
building should not be exposed and the appliance should
be sited as close to the dwelling as possible.
Wall mounted models are supplied with a wall mounting
frame and the primary pipework can be installed prior to
the installation of the appliance. The wall must be capable
of supporting the weight of the appliance, accessories and
water content approximately 135kg. The appliance is not
suitable for external installation unless a suitable enclosure
is provided.
†Excluding external models
21
600mm
1,200mm 570mm
300mm
100mm
100mm1,155mm
Installation clearances for Greenstar Camray regular (kitchen) and Utility, System (kitchen) and System Utility
Installation and service clearances
The minimum clearances shown below should be allowed
for installation and servicing.
1,200mm 380mm
10mm or 300mm**
5mm*
5mm*
600mm
1,155mm
Service, maintenance and repair clearances for Greenstar Camray regular (kitchen) and Utility, System (kitchen) and System Utility
*Note: Remove the flue ‘knock-out’ panel sections if this clearance is less than 75mm.
**Note: Top: 300mm for maintenance and repairTop: 10mm for annual service check
600mm
1,415mm 720mm
300mm
100mm
100mm1,297mm
Installation clearances for Greenstar Utility
600mm
1,415mm 540mm
300mm
10mm
10mm1,312mm
Service, maintenance and repair clearances for Greenstar Utility
1,010mm 620mm
1,380mm
300mm
10mm
600mm
200mm
10mm
Installation and service clearances for Greenstar Danesmoor WM
22
Compartment installationFollow the requirements of BS 5410 and note:
• Minimum clearances must be maintained
• An access door is required to install, service and
maintain the boiler and any ancillary equipment,
i.e. condensate trap
• If fi tting 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.
Compartment ventilation
• Ventilation must be provided for boilers fi tted into
compartments as described in BS 5410
• A minimum of 2 air vents must be fi tted, one at low level
(C) and another at high level (D) onto the same wall using
the same air (E) 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 fl ue terminal
position requirements
• Air ducting runs must not exceed 3 metres.
• Low level air vents must be less than 450mm from
the fl oor
• 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”.
Internal ventilation External ventilation
Compartment ventilation
A Compartment
B Boiler
C Low level vent
D High level vent
E Air supply
Conventional flue†
Minimum air vent area (cm2) for appliances installed in a compartment
Internal ventilation* External ventilation**
kW High level (D)
Low Level (C)
High level (D)
Low Level (C)
12/18 143 214 72 143
18/25 220 330 110 200
25/32 275 413 138 275
32/50 495 743 248 495
50/70 715 1,073 368 715
WM 12/18 198 297 99 198
WM 18/25 275 413 138 275
*Internal air to and from a space/room inside the building.**External air to and from directly outside the building.† Due to changes to BS 5410 and modern building design, these figures no
longer incorporate the adventitious ventilation allowance.
Room sealed flue†
Minimum air vent area (cm2) for appliances installed in a compartment
Internal ventilation* External ventilation**
kW High level (D)
Low Level (C)
High level (D)
Low Level (C)
12/18 143 143 72 72
18/25 220 220 110 110
25/32 275 275 138 138
32/50 495 495 248 248
50/70 715 715 358 358
WM 12/18 198 198 99 99
WM 18/25 275 275 138 138
Air supply
CF (conventional 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.
Combustion air must not be taken from bathroom or
bedroom areas.
Minimum area of air inlet for combustion*
kW Area
12/18 72cm2
18/25 110cm2
25/32 138cm2
32/50 248cm2
50/70 258cm2
WM 12/18 99cm2
WM 18/25 138cm2
* Due to changes to BS 5410 and modern building design, these figures no longer incorporate the adventitious ventilation allowance.
23
600mm
600mm
2,250mm
600mm
600mm radius
750mm
750mm
2,250mm
2,250mm12 21
11 22 2,250mm
0
0
Conventional flued boilers must not be fitted in
a bathroom.
Important: bathroom locations and clearances
• The boiler must not be installed in zones 0, 1 or 2
• Any switch or appliance control using mains electricity
must not be within reach of a person using the bath
or shower
• Electrical switches, fused spurs and socket outlets must
not be situated in the bathroom
• A boiler fi tted with a non-mechanical timer or with
no timer in the boiler can be installed in Zone 2 or
outside the shaded area
• A boiler with a mechanical timer or RF mechanical timer
with a room thermostat must only installed outside the
shaded area
• Additional Residual Current Device (RCD) protection may
be required.
Refer to the latest IEE wiring regulations.
Casing dimensions
370mm
855mm
600mm
Greenstar Camray regular (kitchen) and Utility, System (kitchen) and System Utility
520mm
1,012mm
815mm
Greenstar Utility
880mm
380mm
600mm410mm
30mm
Greenstar Danesmoor WM
24
Pipework connections
The diagrams below show the fl ue and pipe outlets (mm):
Note: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections.
185
RS -155CF - 170
459
60
755
C
E
550
25
C
E
A
B
A
B
A
B
FRONT VIEW SIDE VIEW
D D
284
532
282
F F
GG
Greenstar Camray System & Utility System models
459
284
60
DD
C C
A A A
E E
B BB
FRONT VIEW SIDE VIEW
25185
RS – 155CF – 170
755
550
Greenstar Camray (kitchen) and Utility models
Flue and pipe connections
Key Description 12/18 & 18/25 25/32
A CH flow/open vent 1" dia. BSP 1¼" dia. BSP
B Primary feed/drain ¾" dia. ¾" dia.
C CH return 22mm dia. plain copper
28mm dia. plain copper
D Flue outlet
E Condensate outlet 21.5mm dia. 21.5mm dia.
Flue and pipe connections
Key Description 12/18 & 18/25 25/32
A Open vent 1" dia. BSP 1¼" dia. BSP
B Primary feed/drain ¾" dia. ¾" dia.
C CH return 22mm dia. plain copper
28mm dia. plain copper
D Condensate outlet 21.5mm dia. 21.5mm dia.
E Flue outlet
F CH flow 22mm dia. 28mm dia.
G Pressure relief pipe 15mm dia. 15mm dia.
Greenstar Utility models
Flue and pipe connections
Key Description 32/50 & 50/70
A CH flow/open vent 1½" dia. BSP
B Primary feed/drain 1½" dia. BSP
C CH return 28mm dia. plain ended copper
D Flue outlet
188.5mm
191mm
C
108mm (B)153.5mm (D)
74.5mm (A)
FRONT VIEW SIDE VIEW
E
96.5mm
503.5mm
Greenstar Danesmoor WM models
Flue and pipe connections
Key Description 12/18 & 18/25
A Flow 22mm dia. copper
B Return 22mm dia. copper
C Primary drain hose connection ½" BSP
D Condensate outlet 21.5mm dia.
E Flue outlet 80/125mm dia.
2525**Rear clearance flue outlet on side *Rear clearance flue outlet on rear
Site preparations and guidance (external models)
Siting of appliance
Appliances should not be installed where there is a
potential for excessive ground water coverage.
Appliances are only suitable for installing externally at a
suitable location onto a fi xed, permanent rigid surface.
There must be suffi cient hard standing around the
appliance to allow for servicing.
Appliances must be installed on a fl at, level surface to
ensure that condensation does not enter the primary heat
exchanger. Tarmac and wood hard standings are
not recommended.
Flue system
Appliances can only be connected to the Oilfi t External
room sealed balanced fl ue (see pages 45-47).
Installation and service clearances
The minimum clearances shown below should be allowed
for installation and servicing. It is strongly recommended
that the fl ue terminal faces away from walls to reduce the
possibility of “wetting” occurring.
600mm
2,500mm600mm
BASE
FR
ON
T
600mm min.
FRONT
2,500mm*
45mm85mm
600mm
Planview
50mm**
10mm
600mm
2,500mm
FRONT
Plan view
FRONT
2,500mm10mm
600mm
Plan view
50mm**
26
Casing dimensions
565mm
950mm
780mm
Greenstar Camray External and Greenstar Camray External System
Pipework connections
The diagrams below show the fl ue and pipe outlets (mm):
Note: For servicing purposes, keep the condensate and pressure relief discharge pipes away from components and pipework connections.
295
490
102793
254
91
105
259
259
171
Condensate
Flue
Services
PRV
Fire valve capillary& drain access
REAR
Rear serviceports belowthis line areNOT SUITABLEFOR EXTERNALSYSTEMMODELS.
Rear
490
793
590
466
105 94 55
263
659669704714
559
224
Flue
Services
PressureRelief Valve
Condensate
Oil
Fire valve capillary & drain access
Right side
Flue and pipe connections
Description 12/18 & 18/25 25/32
CH flow/open vent 1" dia. BSP 1¼" dia. BSP
Primary feed/drain ¾" dia. ¾" dia.
CH return 22mm dia. plain copper
28mm dia. plain copper
Flue outlet 80/125mm dia.80/125mm &
100/150mm dia.
Condensate outlet 21.5mm dia. 21.5mm dia.
490
791
590
463
159124 90 55
659679699719
Flue
Services
Condensate
PressureReliefValve
Oil
Left side
27
The Worcester Greenstar System FilterModern condensing boilers are precision engineered and
designed to run with a clean water heating system. Over
time, dirty system water will damage a boiler and its
components, causing failures and shortening the life of the
overall system.
Damaged boiler and system
components
• Blockages in primary
heat exchanger
• Increased wear on pumps
• Blocked valves.
Reduced effi ciency
• Energy effi ciency loss
equivalent to a boiler being
reduced from A rated
effi ciency to D rated, resulting in fuel wastage
• Blocked radiators can reduce effi ciency and
heating comfort.
A highly effective solution
from the brand you can trust
The Worcester Greenstar
System Filter has been
specifi cally designed to
combat the damaging
effects of system debris
and pollutants, allowing
homeowners to protect their
boiler or heat pump for a
fraction of its cost. The fi lter is suitable for 22mm piped
heating systems.
At the centre of this innovative design is a highly powerful
magnet that removes the magnetic debris (magnetite) that
is present in the heating system water. The central location
of the magnet ensures that magnetite is collected quickly
and retained, maximising the overall protection. Any
non-magnetic debris is caught by the twin-action cyclonic
trap, a proven technology that offers a capacity to collect
up to 200g of magnetite a year.
The Greenstar System Filter has been extensively
tested in simulated systems, proving its effectiveness
in removing: iron oxide, magnetite, limescale particles,
casting sand, welding debris, non-magnetic metal fl akes,
paint particles and other system pollutants.
Features Benefits
Highly effective filter
Safeguards the boiler against damage and protects the efficiency of the system. Saves up to 6% a year on energy bills*
Prevent blockages in radiators A warmer home and quieter system
High powered internal magnetProven technology that can capture up to 200g of magnetite
Cylindrical design Increased performance – better installation options
Twin-action – magnetic and non-magnetic filtration
Instantly effective against a wide range of system debris
No power consumption or moving parts
No electrical wiring connection or supply needed. Zero running costs and no failure of components
Can be installed under the boiler or away from the appliance
Flexibility
One-way valve for adding system chemicals
Removes the need to isolate a section of the system when carrying out servicing and maintenance
Worcester, Bosch Group specification and design
Reliability of components and filter
*Independent research carried out by GASTEC at CRE
The Greenstar System Filter is easy to install and service
Heat exchanger damaged by system debris and pollutants
Installation
The fi lter can be installed almost anywhere in a heating
system, however to maximise the effectiveness it should be
placed before the boiler and after the last radiator.
Product infoPart number 7 716 192 609
NEW
28
Important points to consider when siting a condensate
drainage pipe:
• Where a new or replacement boiler is being installed,
access to an internal “gravity discharge” point should
be one of the factors considered in determining
boiler location
• The condensate pipe must be a minimum of 22mm dia.
plastic pipe
• The condensate pipework 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.
Internal connections
In order to minimise risk of freezing during prolonged cold
spells, the following methods of installing a condensate
drainage pipe should be adopted, in order of priority.
Wherever possible, the condensate drainage pipe should
be routed and terminated so that the condensate drains
away from the boiler under gravity to a suitable internal
foul water discharge point such as an internal soil and vent
stack. A suitable permanent connection to the foul waste
pipe should be used. (see fi g. 1)
Condensate pipework
Condensatedischarge from boiler
Universalconnector
Soil andvent stack
22mm dia. Min. 450mmand up to three storeys
Fig. 1 Disposal to soil vent stack – internal and external models. For external models increase pipe size and insulate pipework.
Alternatively if the fi rst option is not possible an internal
kitchen or bathroom waste pipe, washing machine waste
pipe etc. can be used. (see fi g. 2)
22mm dia.
Condensatedischarge from boiler
Universalconnector
Visible air breakat plug hole
Sink or basin with integrated overflow
75mm sinkwaste trap
75mmmin.
Fig. 2 Disposal to a waste pipe (internal models)
Condensatedischarge from boiler
Universalconnector 22mm dia.
Visible air breakat plug hole Sink or
basin with integrated overflow
75mm sinkwaste trap
75mmmin.
Condensatepump
Fig. 3 Condensate pump disposal (internal models)
Condensate pump
Where “gravity discharge” to an internal termination is not
physically possible, or where very long internal runs would
be required to reach a suitable discharge point, condensate
should be removed using a proprietary condensate pump,
of a specifi cation recommended by the boiler or condensate
pump manufacturer.
The pump outlet pipe should discharge to a suitable
internal foul water discharge point such as an internal soil
and vent stack, internal kitchen or bathroom waste pipe,
washing machine waste pipe etc. A suitable permanent
connection to the foul waste pipe should be used.
(see fi g. 3 and 4)
Universalconnector
22mm dia.Condensatedischarge from boiler
Pipeworktransition Insulate &
increase pipe size to 32mm
25
mm
min
.
Condensatepump
Fig. 4 Condensate pump to external disposal (internal models)
29
Condensatedischarge from boiler Universal
connector
Pipeworktransition
Insulate &increase pipe size to 32mm
Externalrain waterpipe intofoul water
External air break
Air gap
PVCu strapon fitting
43mm 90ºmale/female bend
22mm dia.
Fig. 6 Disposal into a rainwater down pipe – internal and external models. For external models increase pipe size and insulate pipework.
UNSUITABLE FOR CLAY SOIL TYPES
22mm dia. 400mm min.
25mm min.
500mm min.
25mm
25mm25mm
50mm
300mm
100mm dia.
Drainageholes12mm dia.
100mmdia. min.plasticpipe
Pipeworktransition
Condensatedischarge from boiler
Universalconnector
Insulate &increase pipesize to 32mm
100mm dia.min. plasticpipeLimestonechippings
Drainageholes
Bottom of sealed tube
Fig. 5 Soak away – internal and external models. For external models increase pipe size and insulate pipework.
For full technical information on pipe size, insulation
and different condensate pipework methods please
see Installation, Commissioning and Servicing
Instruction Manual.
In addition to the condensate discharge options illustrated
on these pages and in the Installation, Commissioning
and Servicing Instruction Manual, the new Worcester
CondenseSure auxiliary siphon provides an innovative
alternative for the prevention of freezing for externally run
discharge condensate (see over for details).
External connections
Freezing conditions
• Pipework length should be kept to a minimum and the
route as vertical as possible
• A CondenseSure auxiliary siphon may be used to reduce
the risk of freezing
• Where pipework is subjected to extreme cold or wind
chill, a weather proof insulation should be used.
Condensate waste
• Care should be taken when siting a soak away to avoid
obstructing existing services.
If no other discharge method is possible then the use of
an externally run condensate drainage pipe terminating at
a suitable foul water discharge point, or purpose-designed
soak away, may be considered (see fi g. 5).
If this method is chosen then the following measures
should be adopted:
• The external run be kept as short as possible and not
exceed 3m
• A CondenseSure auxiliary siphon may be used to reduce
the risk of freezing
• The pipe should be run internally as far as possible
before going externally and the pipe diameter should be
increased to 32mm before it passes through the wall to
the exterior. The pipe should be insulated using suitable
waterproof and weather resistant insulation
• The external pipe should take the shortest and least
exposed route to the discharge point, and should “fall”
as steeply as possible away from the boiler, with no
horizontal runs in which condensate might stand
• The use of fi ttings, elbows etc. should be kept to a
minimum and any internal “burrs” on cut pipework
should be removed so that the internal pipe section is
as smooth as possible.
Fitting an external air break
• Refer to Fig 6. When a rain water down pipe, that goes
directly into a sewer that carries both rainwater and
foul water, is used to dispose of condensate an air break
must be installed in the 43mm pipework, between the
boiler condensate outlet and the drainpipe, outside
the property, to avoid fl ooding during adverse
weather conditions.
30
With climate change and extreme weather variations
becoming increasingly common, and very cold winters with
temperatures as low as -20°C being experienced, practices
such as externally run condensate discharge pipework are
now being questioned.
The CondenseSure auxiliary siphon has been designed to
allow a more fl exible approach to boiler siting.
Tested to extreme temperatures
CondenseSure has been extensively tested under
simulated extreme weather conditions and proved its
effectiveness in preventing frozen condensate at -15ºC
for a sustained period of 48 hours.
CondenseSure principle of operation
Within most condensing boilers there is an internal
siphon which holds around 100ml of condensate before
being released down the condensate discharge pipe. A
typical A-rated condensing boiler will generate up to 2
litres of condensate an hour (dependant on output and
temperature) and this will result in the in-built siphon
discharging approximately every 3 minutes. With this
frequency of discharge it is unlikely that the condensate
pipework is ever empty of condensate, consequently
increasing the potential for freezing of the pipework in
prolonged sub-zero temperatures.
The CondenseSure siphon connects to the boiler
condensate discharge outlet and collects the condensate
into a larger volume before releasing it into the
discharge pipe.
With this expanded siphonic operation, the discharge from
the CondenseSure is every 15 to 20 minutes, resulting in:
• Increased velocity and fl ow rate
• With only 3 to 4 siphonic actions per hour,
the condensate pipework is empty for longer
• Signifi cantly decreased or even eliminated
freezing potential.
A universal fi tting for new and existing installations
Although developed specifi cally for Worcester Greenstar
gas- and oil-fi red boilers, the Worcester CondenseSure
has the added advantage of being able to be fi tted to
any make of condensing boiler for both new and retrofi t
installations. CondenseSure can provide a simple solution
which eliminates the need for re-siting both the new boiler
and the system pipework when replacing an existing
non-condensing appliance. CondenseSure can easily be
fi tted to existing installations to provide peace of mind in
extreme weather conditions.
The Worcester CondenseSure auxiliary siphon NEW
The CondenseSure insulating jacket helps to retain the temperature of the condensate.
Features Benefits
No power consumptionNo electrical wiring connection or supply needed, meaning zero running costs
No moving parts No failure of components
Can be installed on new or existing installations
Suitable for any gas- or oil-fired condensing boilers
Can be attached to 22mm heating flow pipework
Uses ‘free’ energy from the pipe to heat the condensate
Under boiler or remote installation
Flexibility
No electrical connections No electrician needed
No pipe insulation neededCost saving and aesthetically pleasing
31
Fitting to a combi boilerEase of installation
CondenseSure has been designed for ease of
installation in mind and is suitable for most boiler
applications. For maximum effectiveness it should
be installed immediately beneath the boiler where
it is clipped on to the boiler’s heating fl ow pipe and
connected to its siphonic trap. If this is not practical,
CondenseSure can be wall-mounted away from the
boiler and connected to a 32mm condensate discharge
pipe. However, this will sacrifi ce the benefi t of warming
the condensate prior to discharge and therefore slightly
reduce its performance.
Additional installation considerations include:
• Keeping any external pipework as short as possible
• Minimising the number of bends and connections
• Removal of burrs after cutting pipe
• Removal of surplus solvent from the
interior of the pipe.
CondenseSure has no working parts to breakdown,
does not use any energy and has no electrical connections,
so there is no Part P requirement.
1. Foam backing with double-sided tape
2. Siphon mounting screws
3. Siphon body
4. Foam insert (used with regular or system boilers)
5. Foam cover
6. CH fl ow pipe
7. Boiler DHW outlet pipe
1
2
2
3
4
5
6 7
A typical installation using CondenseSure
Condensatedischarge from boiler
Universalconnector
External pipework3000mm max.
CondenseSure
2.5º fall min.
32mm OD pipe
CondenseSure clips onto the 22mm heating flow pipe using the ‘free’ heat to raise the condensate temperature.
Product infoPart number 7 716 192 746
CondenseSure installation parameters
The CondenseSure will protect an externally run condensate
discharge pipe from freezing for 48 hours at -15°C providing
the following installation parameters are met:
• The externally run pipe length does not exceed 3 metres
• There is a fall on the discharge pipe of at least 2.5 degrees
• The discharge pipe diameter is not less than 32mm
in diameter.
Whilst it is not necessary to insulate the pipework it may
be a consideration if longer lengths or if lower external
temperatures are expected.
32
Horizontal and vertical flue terminal positioning
All measurements in millimetres
Key to illustration
1. 600mm distance to a boundary, unless it will cause a
nuisance. BS 5410: Part 1 recommends that care is
taken when siting terminals in relation to boundaries.
2. 600mm below eaves, balconies, this can be reduced to
75 mm, as long as the fl ue terminal is extended to clear
any overhang.
3. 600mm horizontally or vertically to an opening, air brick
or opening window.
4. 1,500mm vertically from a terminal on the same wall.
5. 750mm horizontally from a fl ue on the same wall.
6. 300mm to an internal or external corner.
7. Details of conventional fl ue adaptors.
1,500
Boundary
Conventional flue
750
750
3
24
5 6
81
9
Velux odormer win
Window
HEATSLAVE 12/18GREENSTARHEATSLAVE 12/18GREENSTAR
300
600600
600
600
100mm/103mmConventional Flue AdaptorPart No. 7-716-190-036
Up to 18/25kW output:
80mm ø
100 or 103mm øoptions.
100mm/103mmConventional Flue AdaptorPart No. 7-716-190-036
25/32kW output WorcesterCF Flexible flue liner only:
80mm ø
100mm ø
130mmConventional Flue AdaptorPart No. 7-716-190-036 & 7-716-190-065
25/32kW output:
100mm ø
130mm ø
80mm ø
7
600
130mmConventional Flue AdaptorPart No. 7-716-190-049
32/50kW output & over:
100mm ø
130mm ø
Note
• All measurements are the minimum clearances required.
• Use suitable brackets and fi ttings to support the fl ue
at approximately one metre intervals and at a change
of direction.
• Terminals must be positioned so to avoid combustion
products entering the building.
• In spite of the dimensions given here, the terminal must
not be closer than 300mm to combustible material, in
the case of a thatched roof double this dimension.
• Terminals must be positioned so to avoid products of
combustion accumulating in stagnant pockets around
the building or entering the building.
• Terminals must be at least 1.8m from an oil storage tank
unless a wall with of at least 30 minutes fi re resistance
and extending 300mm wider and higher than the tank is
between the tank and the terminal.
33
2m
1m
52mm 104mm
2,500
Drainpipe
Externaloil boiler
750
13
14
15
or ndow
HEATSLAVE 12/18GREENSTAR
300
300
600
10
11
12
8. Minimum 600mm straight fl ue before any bend on a
conventional fl ue.
9. 750mm between a vertical structure and a fl ue terminal.
10. 1,000mm below a Velux or dormer window, 300mm
above or to either side of the Velux or dormer window
or any opening on a sloping roof.
11. 600mm above the highest point of an intersection with
a roof.
12. Any fl ue must fall back towards the boiler by 3° or
52mm for every metre of fl ue so that the condensate
drains back to the boiler for disposal.
13. 300mm to any vertical sanitary pipework or drain pipe.
14. Flue clearance must be at least 300mm above ground
or balcony level. Terminal guards must be fi tted if the
fl ue is less than 2 metres from the ground or if a person
could come into contact with the fl ue terminal.
15. 2,500mm between terminals facing each other.
34
Greenstar regular & system boiler range horizontal fl uing options (internal models)The Greenstar regular and system boiler range has a
125mm diameter telescopic horizontal room sealed fl ue
system including a plume management kit. The following
diagrams detail the permissible maximum lengths.
Horizontal room sealed fl ue
Flue diameter 125mm 150mm
Minimum flue length 12/18 140mm N/A
18/25 140mm N/A
25/32 140mm N/A
32/50 N/A 140mm
50/70 N/A 140mm
Maximum flue length 12/18 4,000mm N/A
18/25 6,000mm* N/A
25/32 4,000mm N/A
32/50 N/A 3,000mm
50/70 N/A 3,000mm
125mm dia. standard telescopic flue kit (460 - 670mm)
1 x telescopic terminal assembly
1 x internal fi nishing plate(s)
1 x external weather seal
1 x fl ue clamp
Part No. 7 716 190 064
125mm dia. short telescopic flue kit (350 - 460mm)
1 x telescopic terminal assembly
1 x internal fi nishing plate(s)
1 x external weather seal
1 x fl ue clamp
Part No. 7 716 190 062
150mm dia. standard flue kit
1 x terminal assembly
1 x bend
1 x wall plate(s)
1 x air hose
1 x airbox assembly
Part No. 7 716 190 043
Accessories
* Flue damper (Part No. 7 716 190 101) required when flue length exceeds 2m high level horizontal, 4m low level horizontal rear, 3m low level horizontal side
The following criteria should be noted when planning
the installation:
• The concentric fl ue system must be inclined at
3º (52mm per metre) from the appliance, to allow
condensate to drain back into the boiler
• A white plume of condensation will be emitted from
the terminal because the appliance operates at high
effi ciency. Care must be taken when selecting the fl ue
terminal position
• To achieve a maximum fl ue length, one of the extension
fl ue kits will need to be cut so that the permitted
maximum fl ue length is not exceeded
• Horizontal fl ue options 1-6 illustrate common fl ue
installations. Other confi gurations of the fl ue system are
possible up to, and not exceeding, the stated maximum
fl ue lengths.
Components Part No. Description
125mm diameter
7 716 190 064Standard telescopic flue kit (460 - 670mm)
7 716 190 062Short telescopic flue kit (350 - 460mm)
7 716 190 033 1,000mm flue extension
7 716 190 097 600mm short flue extension
7 716 190 034 90º bend
7 716 190 035 45º bends (pair)
7 716 191 174 Support bracket
7 716 190 101 Flue damper
7 716 190 050 Flue terminal guard
150mm diameter (Greenstar Utility only)
7 716 190 043 Standard flue kit
7 716 190 045 1,000mm extension flue kit
7 716 190 046 90º bend
7 716 190 047 45º bends (pair)
7 716 190 051 Flue terminal guard80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
3535
Option 1: Standard rear flue assembly
Components
Part No. 125mm 7 716 190 064
Part No. 150mm 7 716 190 043
Maximum lengths (mm) & no. of components required
Greenstar Camray series
125mm 360 1
Greenstar Utility series
150mm 880 1
Option 2: Extended rear flue assembly
Components
Part No. 125mm 7 716 190 064 7 716 190 033
Part No. 150mm 7 716 190 043 7 716 190 045
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 & 25/32 series
125mm 4,000 1 up to 4
Greenstar Camray 18/25
125mm 6,000* 1 up to 6
Greenstar Utility series
150mm 3,000 1 up to 3
Option 3: Extended rear flue assembly using a 90º bend
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Part No. 150mm 7 716 190 043 7 716 190 045 7 716 190 046
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 & 25/32 series
125mm 3,000 1 up to 3 1
Greenstar Camray 18/25
125mm 5,000* 1 up to 5 1
Greenstar Utility series
150mm 2,000 1 up to 2 1
*Flue damper required when flue length exceeds 4,000mm
*Flue damper required when flue length exceeds 3,000mm
Option 4: Extended rear flue assembly using two 45º bends
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 035
Part No. 150mm 7 716 190 043 7 716 190 045 7 716 190 047
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 & 25/32 series
125mm 3,000 1 up to 3 2
Greenstar Camray 18/25
125mm 5,000* 1 up to 5 2
Greenstar Utility series
150mm 2,000 1 up to 2 2
*Flue damper required when flue length exceeds 3,000mm
Notes:Flue length is measured from the side/top of the boiler to the outside wall for the Greenstar Oilfit flue kits 125mm and 150mm.All components for the left horizontal and right horizontal outlet come within the Greenstar Oilfit horizontal flue kit (150mm) for the Greenstar Utility 32/50 and 50/70 models.
Note: The short fl ue extension (600mm) may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 097).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
36
Option 5: Side flue extension
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Part No. 150mm 7 716 190 043 7 716 190 045 7 716 190 046
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 & 25/32 series
125mm 3,000 1 up to 3 1
Greenstar Camray 18/25
125mm 5,000* 1 up to 5 1
Greenstar Utility series
150mm 3,000 1 up to 2 1
*Flue damper required when flue length exceeds 3,000mm
Option 6: High level horizontal discharge
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Part No. 150mm 7 716 190 043 7 716 190 045 7 716 190 046
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 & 25/32 series
125mm 2,000 1 up to 3 1
Greenstar Camray 18/25
125mm 5,000* 1 up to 5 1
Greenstar Utility series
150mm 2,000 1 up to 2 1
*Flue damper required when flue length exceeds 3,000mm
Notes:Flue length is measured from the side/top of the boiler to the outside wall for the Greenstar Oilfit flue kits 125mm and 150mm.All components for the left horizontal and right horizontal outlet come within the Greenstar Oilfit horizontal flue kit (150mm) for the Greenstar Utility 32/50 and 50/70 models.
Note: The short fl ue extension (600mm) may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 097).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
37
Greenstar Danesmoor Wall Mounted Internal boiler range horizontal fl uing optionsThe Greenstar Danesmoor WM regular boiler range has a
125mm diameter telescopic horizontal room sealed fl ue
system including a plume management kit. The following
diagrams detail the permissible maximum lengths.
Horizontal room sealed fl ue
Flue diameter 125mm
Minimum flue length 160mm
Maximum flue length 4,000mm
125mm dia. standard telescopic flue kit (460 - 670mm)
1 x telescopic terminal assembly
1 x internal fi nishing plate(s)
1 x external weather seal
1 x fl ue clamp
Part No. 7 716 190 064
125mm dia. short telescopic flue kit (350 - 460mm)
1 x telescopic terminal assembly
1 x internal fi nishing plate(s)
1 x external weather seal
1 x fl ue clamp
Part No. 7 716 190 062
Accessories
Note: The telescopic fl ue kit does not include 90° bend
required for horizontal fl uing.
The following criteria should be noted when planning
the installation:
• The concentric fl ue system must be inclined at
3º (52mm per metre) from the appliance, to allow
condensate to drain back into the boiler
• A white plume of condensation will be emitted from
the terminal because the appliance operates at high
effi ciency. Care must be taken when selecting the fl ue
terminal position
• To achieve a maximum fl ue length, one of the extension
fl ue kits will need to be cut so that the permitted
maximum fl ue length is not exceeded
• Horizontal fl ue options 1-5 illustrate common fl ue
installations. Other confi gurations of the fl ue system are
possible up to, and not exceeding, the stated maximum
fl ue lengths.
Components Part No. Description
125mm diameter
7 716 190 064Standard telescopic flue kit (460 - 670mm)
7 716 190 062Short telescopic flue kit (350 - 460mm)
7 716 190 033 1,000mm flue extension
7 716 190 097 600mm short flue extension
7 716 190 034 90º bend
7 716 190 035 45º bends (pair)
7 716 191 174 Support bracket
80/125mm
45º bend 500mm
90º bend 1,000mm
Note: The maximum flue length must be reduced by the
following amounts for each bend used.
38
Note: The short fl ue extension (600mm) may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 097).
80/125mm
45º bend 500mm
90º bend 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
Option 1: Standard horizontal flue assembly
Components
Part No. 125mm 7 716 190 064 7 716 190 034
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 670 1 1
Option 2: Extended horizontal flue assembly
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 4,000 1 up to 4 1
Option 3: Extended horizontal flue assembly with a second 90º bend
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 3,000 1 up to 3 2
Option 4: Extended flue assembly horizontal and upwards
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 4,000 1 up to 4 1
Option 5: Extended flue assembly horizontal and upwardsusing a second 90º bend
Components
Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 3,000 1 up to 3 2
39
Greenstar regular & system boiler range vertical fl uing options (internal models)
The Greenstar regular and system boiler range has the
choice of 2 differently sized vertical room sealed fl ue
systems, 125mm and 150mm. Both systems have different
maximum lengths. The following diagrams detail the
permissible lengths.
Vertical room sealed fl ue
125mm dia. vertical balanced flue kit
Greenstar Camray 12/18 & 25/32
1 x flue terminal assembly
1 x bend
1 x clamp bracket
1 x fire stop plate
1 x pipe clamp
1 x drill pack
Part No. 7 716 190 032
150mm dia. vertical balanced flue kit
Greenstar Camray 18/25 & 25/32 and
Greenstar Utility 32/50 & 50/70 models
1 x fl ue terminal assembly
1 x bend
1 x bend support bracket
1 x fi re stop plates
1 x fl ue spigot
1 x airbox assembly
Part No. 7 716 190 044
Accessories
Flue diameter 125mm 150mm
Minimum flue length 12/18 1,080mm N/A
18/25 1,080mm N/A
25/32 1,080mm N/A
32/50 N/A 1,275mm
50/70 N/A 1,275mm
Maximum flue length (inc. terminal) 12/18 8,000mm N/A
18/25 8,000mm 10,000mm*
25/32 N/A 8,000mm
32/50 N/A 6,000mm
50/70 N/A 6,000mm
Flue terminal assembly diameter 138mm 163mm* Flue damper (Part No. 7 716 190 101) required
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
Components Part No. Description
125mm diameter
7 716 190 032 Vertical balanced flue kit
7 716 190 033 1,000mm flue extension
7 716 190 097 600mm short flue extension
7 716 190 034 90º bend
7 716 190 035 45º bends (pair)
7 716 191 174 Support bracket
7 716 190 101 Flue damper
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
150mm diameter
7 716 190 044Vertical balanced flue kit (Greenstar Utility)
7 716 190 059Vertical balanced flue kit (Greenstar Camray)
7 716 190 045 1,000mm flue extension
7 716 190 046 90º bend
7 716 190 047 45º bends (pair)
The following criteria should be noted when planning
the installation:
• To achieve a maximum fl ue length, one of the extension
fl ue kits will need to be cut so that the permitted
maximum fl ue length is not exceeded
• The concentric fl ue system must be inclined at
3º (52mm per metre) from the appliance, to allow
condensate to drain back into the boiler
• Because the appliance operates at high effi ciency a
white plume of condensation will be emitted from the
terminal. Care must be taken when selecting the fl ue
terminal position.
40
Option 1: Vertical balanced flue system minimum height
Components
Part No. 125mm 7 716 190 032
Part No. 150mm 7 716 190 044
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 & 18/25 series
125mm 1,080 1
Greenstar Camray 25/32 series
125mm 1,080 1
150mm 1,080 1
Greenstar Utility series
150mm 1,290 1
Option 2: Vertical balanced flue system maximum height
Components
Part No. 125mm 7 716 190 032 7 716 190 033
Part No. 150mm 7 716 190 044 7 716 190 045
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series
125mm 8,000 1 up to 8
Greenstar Camray 18/25 series
125mm 8,000 1 up to 8
150mm 10,000* 1 up to 10
Greenstar Camray 25/32 series
150mm 8,000 1 up to 8
Greenstar Utility series
150mm 6,000 1 up to 6
* Flue damper (Part No. 7 716 190 101) required
Note: The short fl ue extension (600mm) may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 097).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
Option 3: Vertical balanced flue system with two 90º bends
Components
Part No. 125mm 7 716 190 032 7 716 190 033 7 716 190 034
Part No. 150mm 7 716 190 044 7 716 190 045 7 716 190 046
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series
125mm 6,000 1 up to 6 2
Greenstar Camray 18/25 series
125mm 6,000 1 up to 6 2
150mm 8,000* 1 up to 8 2
Greenstar Camray 25/32 series
150mm 6,000 1 up to 6 2
Greenstar Utility series
150mm 4,000 1 up to 4 2
* Flue damper (Part No. 7 716 190 101) required
4141
Option 4: Vertical balanced flue system with two 45º bends
Components
Part No. 125mm 7 716 190 032 7 716 190 033 7 716 190 035
Part No. 150mm 7 716 190 044 7 716 190 045 7 716 190 047
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series
125mm 7,000 1 up to 7 2
Greenstar Camray 18/25 series
125mm 7,000 1 up to 7 2
150mm 9,000* 1 up to 9 2
Greenstar Camray 25/32 series
150mm 7,000 1 up to 7 2
Greenstar Utility series
150mm 5,000 1 up to 5 2
* Flue damper (Part No. 7 716 190 101) required
Option 5: Vertical balanced flue system side discharge
Components
Part No. 125mm 7 716 190 032 7 716 190 033 7 716 190 034
Part No. 150mm 7 716 190 044 7 716 190 045 7 716 190 046
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series
125mm 7,000 1 up to 7 1
Greenstar Camray 18/25 series
125mm 7,000 1 up to 7 1
150mm 9,000* 1 up to 9 1
Greenstar Camray 25/32 series
150mm 7,000 1 up to 7 1
Greenstar Utility series
150mm 5,000 1 up to 5 1
* Flue damper (Part No. 7 716 190 101) required
Note: The short fl ue extension (600mm) may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 097).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
Option 6: Vertical balanced flue system rear discharge
Components
Part No. 125mm 7 716 190 032 7 716 190 033
Part No. 150mm 7 716 190 044 7 716 190 045
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series
125mm 8,000 1 up to 8
Greenstar Camray 18/25 series
125mm 8,000 1 up to 8
150mm 10,000* 1 up to 10
Greenstar Camray 25/32 series
150mm 8,000 1 up to 8
Greenstar Utility series
150mm 6,000 1 up to 6
* Flue damper (Part No. 7 716 190 101) required
42
Greenstar Danesmoor Wall Mounted Internal boiler range vertical fl uing options The Greenstar Danesmoor WM boiler range has a 125mm
diameter vertical room sealed fl ue system. The following
diagrams detail the permissible lengths.
Vertical room sealed fl ue
Flue diameter 125mm
Minimum flue length 1,080mm
Maximum flue length (inc. terminal) 6,000mm
Flue terminal assembly diameter 125mm
Flue terminal assembly length 1,080mm
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
Components Part No. Description
125mm diameter
7 716 190 032 Vertical balanced flue kit
7 716 190 033 1,000mm flue extension
7 716 190 097 600mm short flue extension
7 716 190 034 90º bend
7 716 190 035 45º bends (pair)
7 716 191 174 Support bracket
7 716 191 090 Flashing – flat roof
7 716 191 091 Flashing – pitched roof
125mm dia. vertical balanced flue kit
1 x flue terminal assembly
1 x bend
1 x clamp bracket
1 x fire stop plate
1 x pipe clamp
1 x drill pack
Part No. 7 716 190 032
Accessories
The following criteria should be noted when planning
the installation:
• To achieve a maximum fl ue length, one of the extension
fl ue kits will need to be cut so that the permitted
maximum fl ue length is not exceeded
• The concentric fl ue system must be inclined at
3º (52mm per metre) from the appliance, to allow
condensate to drain back into the boiler
• Because the appliance operates at high effi ciency a
white plume of condensation will be emitted from the
terminal. Care must be taken when selecting the fl ue
terminal position.
43
Option 1: Vertical balanced flue system minimum height
Components
Part No. 125mm 7 716 190 032
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 1,080 1
Option 4: Vertical balanced flue system with two 45º bends
Components
Part No. 125mm 7 716 190 032 7 716 190 033 7 716 190 035
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 5,000 1 up to 5 2
Option 2: Vertical balanced flue system maximum height
Components
Part No. 125mm 7 716 190 032 7 716 190 033
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 6,000 1 up to 6
Option 3: Vertical balanced flue system with two 90º bends
Components
Part No. 125mm 7 716 190 032 7 716 190 033 7 716 190 034
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor WM series
125mm 4,000 1 up to 4 1*
*Only order 1 additional 90º bend – vertical kit includes a 90º bend
Note: The short fl ue extension (600mm) may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 097).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
44
Greenstar Camray regular & system boiler range horizontal fl uing options (external models)Horizontal room sealed fl ue
80/125mm dia. low level horizontal balanced flue kit
1 x terminal assembly
Part No. 7 716 190 084
Accessories
*Note: To flue to the left or right hand sides only
Components Part No. Description
125mm diameter
7 716 190 084Low level horizontal balanced flue kit
7 716 190 034 90º bend (internal only)
7 716 190 050 Flue terminal guard
Low-level rear
Components
Part No. 125mm 7 716 190 084 7 716 190 050
Maximum lengths (mm) & no. of components required
Greenstar Camray External series
125mm 175mm 1 1
FRONT
TOPVIEW
240mm175mm
Low-level left
Components
Part No. 125mm 7 716 190 084 7 716 190 034 7 716 190 050
Maximum lengths (mm) & no. of components required
Greenstar Camray External series
125mm 175mm 1 1* 1
TOPVIEW
FRONT
240mm
175mm
Low-level right
Components
Part No. 125mm 7 716 190 084 7 716 190 034 7 716 190 050
Maximum lengths (mm) & no. of components required
Greenstar Camray External series
125mm 175mm 1 1* 1
*Note: To flue to the left or right hand sides only
TOPVIEW
FRONT240mm
175mm
45
Horizontal terminal option
Components
Part No. 125mm 7 716 190 057 7 716 190 054
Maximum lengths (mm) & no. of components required
Greenstar Camray series & Greenstar Danesmoor Wall Mounted
125mm 2,000* 1 up to 2
*From the boiler casing, (the horizontal kit bend is ignored when calculating the flue length).
Oilfi t external fl ue system
Greenstar Oilfi t external fl ueBalanced fl ue terminal and extensions
The Greenstar Oilfi t External fl ue system can be used with
the external models and to continue fl ues from internal
models outside the building.
There are two terminal types, vertical which is suitable for
all models and horizontal suitable for all Camray internal
models and the 12/18 and 18/25 Camray External models.
Horizontal terminals only:
The terminal outlet must face directly away from the wall
or no more than 45º from this direction. All fl ue clearances
must be measured from the end of the terminal in the
direction the terminal is facing during use.
Each extension must be supported using the wall clamps
supplied or a suitable alternative.
Reduce the total straight fl ue length for each extra fl ue
bend by:
• 1,000mm for each 90º bend
• 500mm for each 45º bend.
45° max 45° max
90°
Plan view
90° ± 45°
Components Part No. Description
80/125mm diameter
7 716 190 057 Horizontal external flue kit
7 716 190 054 External flue extension
7 716 190 098 600mm external flue extension
7 716 190 055 External 90º bend
7 716 190 056 External 45º bends (pair)
Flue diameter 80/125mm
Greenstar Camray 12/18
Maximum flue length 2,000mm
Greenstar Camray 18/25
Maximum flue length 5,000mm
Greenstar Camray 25/32
Maximum flue length 2,000mm
Greenstar Danesmoor WM
Maximum flue length 4,000mm
Greenstar Utility 32/50 & 50/70
Maximum flue length 2,000mm
80/125mm dia. horizontal external flue kit
Greenstar Camray series and
Greenstar Danesmoor Wall Mounted
1 x terminal assembly
1 x 80/125 weather seal
1 x external bend
1 x external cabinet fl ue seal and plate
1 x clamp bracket
1 x drill pack
Part No. 7 716 190 057
Accessories
46
Balanced fl ue terminal and extensions
Vertical terminals only:
• The terminal must extend beyond the roof or wall by
600mm.
• The terminal must be at least 600mm horizontally from
any vertical structure.
• Each extension must be supported using the wall clamps
supplied or a suitable alternative.
80/125mm dia. vertical external flue kit
Greenstar Camray 12/18 & 18/25 and
Greenstar Danesmoor Wall Mounted
1 x terminal assembly
1 x 80/125 weather seal
1 x external bend
1 x external cabinet fl ue seal and plate
1 x clamp bracket
1 x drill pack
Part No. 7 716 190 053
100/150mm dia. vertical external flue kit
Greenstar Camray 25/32
1 x terminal assembly
1 x 100/150 weather seal
1 x 80/125 mm to 100/150mm adaptor
1 x external bend
1 x external cabinet fl ue seal and plate
1 x clamp bracket
1 x drill pack
Part No. 7 716 190 058
Accessories
600m
m
600m
m
Flue diameter 80/125mm 100/150mm
Greenstar Camray
Maximum flue length 12/18 8,000mm –
18/25 8,000mm 10,000mm*
25/32 – 8,000mm
Greenstar Danesmoor WM
Maximum flue length 12/18 6,000mm –
18/25 6,000mm –*From the boiler casing, (the vertical kit bend is ignored when calculating the flue length) maximum 2m of horizontal flue.
Reduce the total straight fl ue length for each extra fl ue
bend by:
• 1,000mm for each 90º bend
• 500mm for each 45º bend.
Components Part No. Description
80/125mm diameter
7 716 190 053 Vertical external flue kit
7 716 190 054 External flue extension
7 716 190 098 600mm external flue extension
7 716 190 055 External 90º bend
7 716 190 056 External 45º bends (pair)
100/150mm diameter
7 716 190 058 Vertical external flue kit
7 716 190 060 External flue extension
7 716 190 061 External 45º bends (pair)
7 716 190 101 Flue damper
Note: The 600mm external fl ue extension may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 098).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
Flue extension lengths:
Vertical 1,000mm overall length. Effective length when
engaged into sockets within the fl ue run is 950mm.
Flue terminal lengths:
Vertical 80/125mm dia.: 185mm + cage
47
Top outlet*
Components
Part No. 125mm 7 716 190 053 7 716 190 054
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series & Danesmoor WM 12/18
125mm 8,000 1 up to 8
Greenstar Camray 18/25 series & Danesmoor WM 18/25
125mm 8,000 1 up to 8
150mm 10,000** 1 up to 10
Greenstar Camray 25/32 series
150mm 8,000 1 up to 8
Greenstar Camray External series
125mm N/A N/A N/A
150mm N/A N/A N/A
*Top outlet not available on Greenstar Camray External models.** Flue damper (Part No. 7 716 190 101) required
Side outlet
Components
Part No. 125mm 7 716 190 053 7 716 190 054 7 716 190 055
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series & Danesmoor WM 12/18
125mm 6,000 1 up to 6 2
Greenstar Camray 18/25 series & Danesmoor WM 18/25
125mm 6,000 1 up to 6 2
150mm 8,000* 1 up to 8 2
Greenstar Camray 25/32 series
150mm 6,000 1 up to 6 2
Rear outlet
Components
Part No. 125mm 7 716 190 053 7 716 190 054 7 716 190 056
Maximum lengths (mm) & no. of components required
Greenstar Camray 12/18 series & Danesmoor WM 12/18
125mm 7,000 1 up to 7 2
Greenstar Camray 18/25 series & Danesmoor WM 18/25
125mm 7,000 1 up to 7 2
150mm 9,000* 1 up to 9 2
Greenstar Camray 25/32 series
150mm 7,000 1 up to 7 2
* Flue damper (Part No. 7 716 190 101) required
* Flue damper (Part No. 7 716 190 101) required
Note: The 600mm external fl ue extension may be used
as an alternative to the standard 1,000mm extension on
80/125mm fl ue installations as required up to the maximum
fl ue lengths stated (Part No. 7 716 190 098).
80/125mm 100/150mm
45º bend 500mm 500mm
90º bend 1,000mm 1,000mm
Note: The maximum flue length must be reduced by the following amounts for each bend used.
48
Plume management terminal positioning
Door
Balcony
Boundary
Drainpipe
2
4
5
1
600
200
200
300
600600
300
150
150
150 150
600
Window Window
25
300Window
±45°
Flue exhaustoutlet
Air intake
6
100
2,500
7
3
All measurements in millimetres
Note
• All measurements are the minimum clearances required
• Terminals must be positioned so to avoid combustion
products entering the building
• Support the fl ue at approximately one metre intervals
and at a change of direction, use suitable brackets
and fi ttings.
Key to illustration
1. 600 mm distance to a boundary, unless it will cause
a nuisance. BS 5410: Part 1 recommends that care is
taken when siting terminals in relation to boundaries.
2. Internal/external corners the air intake can be reduced
to 150mm providing the fl ue exhaust outlet has a
300mm clearance.
3. Vertical sanitary pipe: 25mm to the fl ue air intake and
300mm to the fl ue exhaust outlet.
4. Clearance no less than 200mm from the lowest point of
the balcony or overhang, installations in car ports are
not recommended.
5. 1,200mm from an opening in a car port on the same wall
i.e. door or window leading into dwelling. 600mm to a
surface facing a terminal.
6. Using a plume management kit the air intake
measurement can be reduced to 150mm providing the
fl ue exhaust outlet has a 600mm clearance. Plume kits
running horizontally must have a 10 degree fall back to
the boiler for proper disposal of condensate.
For details on specifi c lengths see relevant boiler
Technical & Specifi cation manual.
7. 2,500mm between air intake and facing terminal.
49
Plume management system options
Greenstar Camray & Danesmoor WM (internal) series
Plume management system
80mm dia. plume management kit
1 x terminal bend
1 x extension 500mm
1 x outlet assembly
1 x clamp pack
Part No. 7 716 190 092
Accessories
Components Part No. Description
80mm diameter
7 716 190 092 Plume management kit
7 716 190 093 1,000mm extension
7 716 190 095 90º bend
7 716 190 094 45º bend (pair)
Plume management system measuring
Note: All boilers have a maximum permissible
plume management length – see table below.
500mm (min) (M)
L (max)
5,000mm (max) (M)
L (max)
Flue length(L)
Max. number of bends
Plume length(M)
Max. number of bends
160 - 2,000mm 2 500 - 5,000mm 3
2,001 - 3,000mm 2 500 - 3,500mm 3
3,001 - 4,000mm 2 500 - 2,000mm 3500mm (M)
Standard plume management system
The fl ue terminal outlet has built-in stops to limit rotation
for horizontal fl uing to allow condensate to run back into
the boiler for safe disposal. Do not attempt to force beyond
the limit stops.
All plume management sections must rise by at least
173mm per metre (10º) from the terminal to ensure that
condensate fl ows back into the boiler.
45°V
Direction of flue products, the angle of the terminal bend must be more than 45° fromthe wall or structure
Plume terminal
At least 1,500mm from any opening in the building
Opening in the building i.e. air brick, window.
Re-directing flue discharge from an 80mm dia. plume management outlet
™
Additional bends
Adding bends to the plume management system reduces
the actual plume management length. Each bend has an
equivalent straight length and must be factored into the
overall effective length.
• 90° bend is equivalent to 1,000mm
• 45° bend is equivalent to 500mm.
50
Plume management system
Components
Part No. 80mm 7 716 190 092
Maximum lengths (mm) & no. of components required
Greenstar Camray, Danesmoor WM & Camray External series
80mm 500 1
Plume management system with angled termination
Components
Part No. 80mm 7 716 190 092 7 716 190 093
Maximum lengths (mm) & no. of components required
Greenstar Camray, Danesmoor WM & Camray External series
80mm 5,000 1 5 Plume management system with extensions
Components
Part No. 80mm 7 716 190 092 7 716 190 093
Maximum lengths (mm) & no. of components required
Greenstar Camray, Danesmoor WM & Camray External series
80mm 5,000 1 5
Plume management system with extensions and 45º bend
Components
Part No. 80mm 7 716 190 092 7 716 190 093 7 716 190 094
Maximum lengths (mm) & no. of components required
Greenstar Camray, Danesmoor WM & Camray External series
80mm 5,000 1 5 1
Plume management system with extensions and two 45º bends
Components
Part No. 80mm 7 716 190 092 7 716 190 093 7 716 190 094
Maximum lengths (mm) & no. of components required
Greenstar Camray, Danesmoor WM & Camray External series
80mm 5,000 1 5 1
5151
Greenstar Camray External seriesPlume management on Greenstar Camray External boilers
The plume management kit can be used on the
Greenstar Camray External 18/25 and 25/32 models in
conjunction with the external low level horizontal fl ue kit
(Part No. 7 716 190 084). The Camray External 12/18 is
not suitable for use with plume management.
±45°
M
Min. 150mm
Plume length (M) Maximum number of bends
500 - 5,000mm 2
52
Conventional flueOpen (conventional) fl ued appliances must not be installed
in a bedroom, bathroom or bedsitting room.
• The fl ue system must be in accordance with BS 5410 and
the current Building Regulations.
• The fl ue must be constructed of materials suitable for use
with condensing combustion products.
• External fl ue 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 fl ue 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 fl ue can be increased in size from the boiler
take off point providing the joint is correctly sealed. Never
reduce the fl ue diameter from the boiler take off point.
• Because the fl ue operates at a lower temperature on a
condensing boiler compared to that of a conventional
appliance, the fl ue draught will be lower. Typically
the draught will be between 0.5mmwg and 4.4mmwg,
measured with the fl ue warm but the burner not fi ring. The
actual fi gure will vary depending on weather conditions,
fl ue height and position.
• The fl ue should be vertical and contain as few bends as
possible, a maximum of two 135° bends should be used.
• The fl ue 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.
To convert the appliance to a conventional fl ue system the
vertical fl ue adaptor needs to be specifi ed:
Greenstar Camray 12/18 & 18/25 models
CF flue adaptor kit
Part No. 7 716 190 036
Greenstar Camray 25/32
CF flue adaptor kit
Part No. 7 716 190 036
100 to 130mm adaptor
Part No. 7 716 190 065
Greenstar Utility 32/50 & 50/70 models
CF flue adaptor kit
Part No. 7 716 190 049 (not available for Danesmoor WM)
The fl ue must be constructed of materials suitable for the
use of condensing combustion products.
Conventional flue sizing
Output Diameter
12/18 100/103mm
18/25 100/103mm
25/32 130mm
32/50 130mm
50/70 130mm
C
B
A
D
E
A Boiler
B Flue
C Maximum 2 bends at 135º
D Anti down-draught terminal
E Chimney
53
Oilfi t fl exible fl ue liner
The Oilfi t fl exible fl ue liner allows an installation into
a position where a standard effi ciency appliance had
previously been installed. It achieves this by enabling a
Greenstar condensing boiler to be open fl ued up a chimney.
The continuous fl exible fl ue is installed from the roof,
providing a condensate proof lining for the chimney.
A roof terminal, extension pieces and a fl ue adaptor are all
included within the kit.
Conventional flexible flue liner kit
100mm dia. Oilfit flexible flue liner kit
Greenstar Camray
1 x chimney cowl
1 x terminal
1 x support collar
1 x support bracket assembly
1 x centralising spacer
1 x flexible to rigid adaptor kit (includes liner & seal)
1 x flexible liner
1 x rigid to flexible adaptor kit (includes liner & seal)
Part No. 7 716 190 076 (8m)
Part No. 7 716 190 077 (12m)
Part No. 7 716 190 078 (15m)
130mm dia. Oilfit flexible flue liner kit
Greenstar Utility 32/50 & 50/70 models
1 x chimney cowl
1 x terminal
1 x support bracket assembly
1 x centralising spacer
1 x fl exible to rigid adaptor kit (includes liner & seal)
1 x fl exible liner
1 x rigid to fl exible adaptor kit (includes liner & seal)
Part No. 7 716 190 079 (8m)
Part No. 7 716 190 080 (12m)
Part No. 7 716 190 081 (15m) (not available for
Danesmoor WM)
Components Part No. Description
100mm diameter – Camray 12/18, 18/25, 25/32
7 716 190 076 Oilfit flexible flue liner kit (8m)
7 716 190 077 Oilfit flexible flue liner kit (12m)
7 716 190 078 Oilfit flexible flue liner kit (15m)
7 716 190 066 1,000mm extension kit*
7 716 190 067 500mm extension kit*
7 716 190 068 Telescopic extension*
7 716 190 069 45º bend*
7 716 190 036 Conventional vertical flue kit
7 716 190 074 Wall cover plate kit
130mm diameter – Utility 32/50, 50/70
7 716 190 079 Oilfit flexible flue liner kit (8m)
7 716 190 080 Oilfit flexible flue liner kit (12m)
7 716 190 081 Oilfit flexible flue liner kit (15m)
7 716 190 070 1,000mm extension kit*
7 716 190 071 500mm extension kit*
7 716 190 072 Telescopic extension*
7 716 190 073 45º bend*
7 716 190 049 Conventional vertical flue kit
7 716 190 075 Wall cover plate kit
*Stainless steel
Accessories
54
Typical installations
Open (conventional) fl ued appliances must not be installed
in a bedroom, bathroom or bed-sitting room.
Before installation commences it must be checked that:
• The chimney is structurally sound and free of obstructions
• The chimney has been thoroughly swept to remove
deposits since it was last used.
The fl exible fl ue pipe is only suitable for lining chimneys
that conform to the Building Regulations and it should not
be used as a chimney on its own or outside a masonry or
fl ueblock chimney.
All the fl exible liner and adaptors must be within the
chimney with rigid stainless steel fl ue pipe connecting to
the boiler.
The fi rst 600mm of the stainless steel fl ue pipe off the
boiler must be vertical with no bends or restrictions.
There must be at least a 25mm clearance between the
stainless steel fl ue pipe and any combustible material.
The data label must be secured onto the chimney or
chimney hearth using the plate provided.
If it is not possible to attach the plate to the chimney,
the plate can be attached, in a visible position, next to
the electricity consumer unit.
Do not attach the data plate or label to the fl ue system.
The terminal should not be modifi ed and an extra cowl
or cover must not be fi tted, the boiler is designed so that
any rain that enters the fl ue will be directed down to the
condensate drain.
Model Flue diameter Maximum flue length
Greenstar Camray series
12/18 100mm 15,000mm
18/25 100mm 15,000mm
25/32 100mm 15,000mm
Greenstar Utility series
32/50 130mm 15,000mm
50/70* 130mm 15,000mm *For 70kW adjust the first and second stage pump pressure to 125psi.a
Typical installations
Open (conventional) fl ued appliances must not be
installed in a bedroom, bathroom or bed-sitting room.
The fi rst 600mm of the stainless steel fl ue pipe off the
boiler must be vertical with no bends or restrictions.
Calculating the length:
L maximum = boiler maximum minus 1m*.
(Each 45º bend has a 0.5m equivalent fl ue length)
*If the chimney has an additional offset, then L will be reduced by an extra metre.**The top 45º bend may not be required if there is sufficient room in the chimney to turn the flexible liner through 45º within the chimney. The stainless steel section must be adequately supported.
L max
A
B
C
E
G
F
D
**
A Boiler
B Stainless steel vertical section(min. 600mm)
C Maximum 2 bends at 45°
D Fire stop plate/inspection plate
E Centralising spacer
F Flexible liner
G Chimney cowl
5555
Installation requirements
Installation regulations
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 effi ciency and trouble-free operation the appliance
must be commissioned by a qualifi ed 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 799: part 5: Specifi cation for Oil Storage Tanks.
BS 7593: Code of Practice for treatment of water in
domestic hot water central heating systems.
BS 5449: part 1: Specifi cation for forced circulation hot
water central heating for domestic premises.
BS 5955: part 8: Specifi cation for the installation of
thermoplastic pipes and associated fi ttings for use in
domestic hot and cold water services and heating systems.
BS 7291: Thermoplastic pipes and associated fi ttings 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.
Full British Standards requirements can be found on
the website.
The Building Regulations England and Wales, Scotland and
Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards
Sealed system installation
The Greenstar regular and system oil-fi red appliances
are designed for sealed systems, incorporating a pre-
plumbed expansion vessel, pressure relief valve set to
3bar, automatic air vent and pressure gauge. The expansion
vessel fi tted to the appliance will accommodate differing
system volumes depending on initial charge pressure and
system pre-pressurisation. Under certain circumstances
the system volume may be in excess of that catered for
by the expansion vessel provided. In this instance an
additional vessel should be fi tted as close as possible to
the return connection of the appliance. Filling of the system
can be from a make-up vessel, fi tted with a non-return
valve and mounted above the highest point in the system.
Alternatively, and to comply with the new Water Authority
requirements, the system may be fi lled through a temporary
hose connection to the mains water supply provided that
a double check valve assembly and test point are fi tted on
the system side of the temporary connection.
Radiator valves
Underfloor heating
• Plastic pipework used for underfloor heating must be
correctly controlled with a thermostatic blending valve
limiting the temperature of the circuits to approx. 50ºC
and a 20ºC temperature differential must be maintained
at the appliance.
Primary system/connections/valves
• Do not use galvanised pipes or radiators.
• All system connections, taps, showers and mixing valves
must be capable of sustaining a pressure up to 3bar
• Radiator valves should conform to BS 2767:10
• All other valves should conform to BS 1010
• On new installations TRVs must be used on all radiators
except the radiator where the room thermostat is
sited, this must be fi tted with a lockshield valve and
left open. All boiler replacement installations should
have TRVs fi tted to radiators at least within the
sleeping accommodation
• Drain cocks are required at all the lowest points on
the system
• Air vents are required at all the high points on the system.
56
Open vented primary systems
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
expansion tank (E).
The open vent pipe (H), feed and expansion pipe (F) must
rise continuously from the appliance.
The open vent pipe (H) must be at least 22mm dia.
Guarantee
Worcester oil-fi red appliances are offered with a 2 year*
guarantee on parts and labour from the date of installation if
the appliance is commissioned upon installation and the
regular service requirements are met. The primary heat
exchanger comes with a 5 year* guarantee and
the secondary heat exchanger is guaranteed for
10 years*. Ongoing service and maintenance
contracts can be arranged through the
Worcester Customer Service Department
if required.
*Terms and conditions apply.
A Appliance
C Automatic bypass valve
D Drain cock
E Feed and expansion cistern
F Feed and expansion 15mm dia. min
H Open vent 22mm dia. min
J Circulating pump
K Zone valve
L Lockshield valve
M Hot water cylinder
R Radiators
S Static head
T TRV
Typical open vent system
F
E
H
A
M
JC
K
K D D
T T
T TL L
L L
R
R
R
R
S1,000mm min.
150mm max.
Oil supply
Oil storage tank
4m
max
.
Full base (plastic tanks)
30
0m
mm
in.
Oil burner
Externalwall
Isolatingvalve
Isolatingvalve
Oil strainer& waterseparator
Oilsupplypipe
Fire valveto BS 5410
Oil pump
Isolatingvalve
Oil filter (16μm max. filtration size)
Fire valvesensor
Fig. 10 Single pipe system
57
The oil burner on the Greenstar regular and system
oil-fi red appliances is supplied with a single fl exible fuel
line from the oil pump which the installer connects the
main oil supply line to (via the oil isolation valve), within
the appliance. This enables the burner to be removed
without the need for disconnection of the fuel line.
The maximum permissible head is 4 metres. If the head is
greater, then a head breaking device must be incorporated
into the oil supply line.
The oil pump’s primary job is to pressurise the oil once in
the pump and force it out of the nozzle at high pressure to
atomise the fuel to ensure clean and effi cient combustion.
This same pump can also be converted to ‘draw’ up the
fuel line in cases where the oil tank is lower than the
appliance’s burner. This conversion is undertaken by the
installing engineer.
All oil pumps on Worcester appliances can easily be
converted to work on a two pipe system (details of
this operation are within the Installation and Servicing
instructions which come with the appliance).
More advice on fuel lines can be sought from OFTEC Book
Three and Technical sheet TI/134.
De-aeration devices
A de-aeration device is a container of oil about the size of
a pint glass with an automatic air vent on top and three
connections on the bottom. It saves running a return oil
pipe back to the tank from the burner as in Fig. 11. Its
function is to provide a reservoir of oil from which the
oil pump draws oil whilst venting any air in the oil to the
atmosphere preventing nuisance ‘lockout’ of the burner.
Not all the oil drawn is consumed and any excess is
returned to the de-aeration device, so whilst the burner is
fi ring there is a continuous fl ow and return of oil. The third
connection is for the main fuel line from the oil tank. There
is usually a non-return valve located in this connection to
prevent oil draining back towards the oil tank under gravity
and creating a vacuum. When the burner is fi ring the whole
fuel supply system is under negative pressure i.e. suction,
therefore it is imperative that all joints on the fuel supply
system are sound. Whilst there may be no obvious signs of
an oil leak externally, when the burner is fi ring it may be
possible for air to be drawn in through a bad joint, reducing
the pump’s capabilities, resulting in a lack of fuel to the
oil pump and nuisance ‘lockout’. This may manifest itself
as a very low level of oil or ‘foaming’ of the oil inside the
de-aeration device whilst the burner is trying to fi re.
Two pipe systems
Oil storage tank
Full base (plastic tanks)
3.5
m m
ax.
Oil supply pipe
150mm
Oil burner
Isolatingvalve
Fire valvesensor
Oil filter (16μm max. filtration size)
Oilpump
Externalwall
Fire valve to BS 5410
Non-return valveIsolatingvalve
Isolatingvalve
Oil strainer &water separator
Fig. 11 Two pipe system
Oil burner
Oil pump
Full base (plastic tanks)
3.5
m m
ax.
Oil storage tank
Isolatingvalve Isolating
valve
Fire valve sensor
External wall
Fire valveto BS 5410
De-aerator
Oil supply pipe
Oil strainer & waterseparator
Fig. 12 Single pipe lift system with de-aerator
58
Maximum allowable pipe run
Head 8mm inside dia. pipe (10mm OD copper)
10mm inside dia. pipe (12mm OD copper)
0m 50m 100m
-0.5m 44m 100m
-1.0m 38m 95m
-1.5m 32m 80m
-2.0m 26m 66m
-2.5m 20m 50m
-3.0m 14m 37m
-3.5m 8m 22m
Table 2: Double pipe sub-gravity feed system
Maximum allowable pipe run
Head 8mm inside dia. pipe (10mm OD copper)
10mm inside dia. pipe (12mm OD copper)
0.5m 12m 30m
1.0m 25m 69m
1.5m 37m 91m
2.0m 49m 100m
2.5m 62m 100m
3.0m 74m 100m
3.4m 87m 100m
4.0m 99m 100m
Table 1: Single pipe gravity feed system
Table 3: Single pipe suction lift with de-aerator
Maximum allowable run from tank to de-aerator
Fuel flow rate 2.5 (kg/h) 5 (kg/h) 10 (kg/h) 10 (kg/h)
Head 8mm dia. 8mm dia. 8mm dia. 10mm dia.
0m 100m 55m 26m 100m
0.5m 95m 45m 23m 100m
1.0m 80m 40m 20m 90m
1.5m 70m 35m 17m 75m
2.0m 60m 30m 14m 65m
2.5m 45m 25m 11m 50m
3.0m 35m 15m 8m 35m
3.5m 25m 10m 5m 20m
Most de-aeration devices are made of plastic and vent
to the atmosphere. For this reason they must always be
located externally, if sited internally they would constitute
a fi re hazard (see Fig. 12, page 57). Metal types do exist
which do not emit vapour. These can be located internally
or externally.
Top outlet oil tanks should have the non return valve
removed from the end of the oil feed pipe within the
tank if installed in conjunction with a de-aeration device.
Supply pipe
The oil supply pipe itself would normally be annealed
copper tube with a protective plastic coating which is easily
manipulated around bends and usually enables the fuel line
to be run in a continuous length without joints. If joints
must be used, they must be accessible, even if underground
(via an access duct) and should be of the manipulative
type. Plastic pipe specifi cally for oil lines does exist and is
acceptable but must only be used underground.
Galvanised pipe, fi ttings and soldered joints must not be
used in oil lines.
More advice on fuel lines can be sought from OFTEC Book
Three and Technical sheet TI/134.
Supply pipe sizing
The diameter of the oil supply pipe itself is subject to the
distance from the oil tank to the appliance and the head of
oil whether it be positive or negative.
Tables 1 and 2 give the required diameter of supply pipe
when cross referenced with the head. Table 3 gives the
diameter of the supply pipe when the use of a de-aeration
device is made.
Oil tanks
For further information on oil tank location please consult
the tank supplier.
Oil fi lters
Oil fi lters must always be incorporated in the oil supply line,
one on the outlet from the oil tank to fi lter deposits from
within the tank or fuel and one near the appliance to fi lter
deposits from within the fuel line itself. They are supplied
and fi tted by the installing engineer and are not part of the
boiler’s components. They should be able to be serviced
without the need for draining down the fuel supply line.
There must be suffi cient clearance below the fi lter to enable
servicing operations to be carried out easily. Filters must
comply to OFTEC standard OFS E104.
Fire valves
A fi re valve is an essential part of the oil supply system.
It is supplied and fi tted by the installing engineer and is
not part of the boiler’s components. Its purpose is to cut
off the fl ow of oil outside the building in the event of fi re
within the boiler area. The valve should be located at the
point of entry into the building of the fuel line. It must be
activated by a remote sensor located over the burner. A clip
is provided within the appliance for the sensor. Fire valves
must comply with OFTEC standard OFS E101.
5959
Digital plug-in 7 day twin channel programmer (kitchen models only)
Worcester Part No. 7 716 192 033
Greenstar Camray, Danesmoor WM & Greenstar Utility series accessories
Vertical flue kit(125mm dia.)
Worcester Part No. 7 716 190 032
Short telescopic flue kit (125mm dia.)
Worcester Part No. 7 716 190 062
Standard flue kit (150mm dia.)
Worcester Part No. 7 716 190 043
Standard telescopic flue kit (125mm dia.)
Worcester Part No. 7 716 190 064
Vertical flue kit(150mm dia.) –
Greenstar Utility
Worcester Part No. 7 716 190 044
Vertical flue kit(150mm dia.) –
Greenstar Camray & Greenstar Danesmoor WM
Worcester Part No. 7 716 190 059
1,000mm flue extension(125mm dia.)
Worcester Part No. 7 716 190 033
600mm flue extension(125mm dia.)
Worcester Part No. 7 716 190 097
Greenstar Oilfi t internal fl ue system Greenstar Camray, Greenstar Danesmoor WM & Greenstar Utility internal series
CondenseSure auxiliary siphon
Worcester Part No. 7 716 192 746
Greenstar System Filter
Worcester Part No. 7 716 192 609
60
45º bend(125mm dia.)
Worcester Part No. 7 716 190 035
45º bend(150mm dia.)
Worcester Part No. 7 716 190 047
90º bend(125mm dia.)
Worcester Part No. 7 716 190 034
90º bend(150mm dia.)
Worcester Part No. 7 716 190 046
Greenstar Oilfi t internal fl ue system continuedGreenstar Camray, Greenstar Danesmoor WM & Greenstar Utility internal series
Stainless steel flue terminal guard(150mm dia.)
Worcester Part No. 7 716 190 051
Stainless steel flue terminal guard(125mm dia.)
Worcester Part No. 7 716 190 050
Flat roof flashing kit(100mm & 125mm dia.)
Worcester Part No. 7 716 191 090
Pitched roof flashing kit(100mm & 125mm dia.)
Worcester Part No. 7 716 191 091
Conventional vertical flue kit (100mm dia.) –
Camray series
Worcester Part No. 7 716 190 036
Conventional vertical flue kit (130mm dia.) –Greenstar Utility series
Worcester Part No. 7 716 190 049
Conventional flue adaptor
(100 to 130mm dia.) –Greenstar Camray 25/32
Worcester Part No. 7 716 190 065
Support bracket(125mm dia.)
Worcester Part No. 7 716 191 174
1,000mm flue extension(150mm dia.)
Worcester Part No. 7 716 190 045
6161
Greenstar Oilfi t low level external fl ue systemGreenstar Camray External series
Low level horizontal flue kit (125mm dia.)
Worcester Part No. 7 716 190 084
90º bend*(125mm dia.)
Worcester Part No. 7 716 190 034
Stainless steel flue terminal guard
Worcester Part No. 7 716 190 050
Greenstar Oilfi t fl exible fl ue kit accessoriesGreenstar Camray & Greenstar Utility internal series
Stainless steel1,000mm extension kit
Worcester Part No. 100mm dia. 7 716 190 066130mm dia. 7 716 190 070
Stainless steel500mm extension kit
Worcester Part No. 100mm dia. 7 716 190 067130mm dia. 7 716 190 071
Oilfit flexible flue kit
Worcester Part No.100mm dia. 7 716 190 076 (8m) 7 716 190 077 (12m) 7 716 190 078 (15m)
130mm dia. 7 716 190 079 (8m) 7 716 190 080 (12m) 7 716 190 081 (15m)
Stainless steel telescopic extension
Worcester Part No. 100mm dia.
7 716 190 068130mm dia.
7 716 190 072
Stainless steel 45º bend
Worcester Part No. 100mm dia.
7 716 190 069130mm dia.
7 716 190 073
Wall cover plate kit
Worcester Part No. 100mm dia. flue
7 716 190 074130mm dia. flue
7 716 190 075
*Used inside boiler when fluing to the side
62
Greenstar Oilfi t external fl ue system accessories Greenstar Camray, Greenstar Danesmoor WM, Greenstar Utility internal & Greenstar Camray External series
Horizontal external flue kit (80/125mm dia.)
Worcester Part No. 7 716 190 057
Vertical external flue kit (80/125mm dia.)
Worcester Part No. 7 716 190 053
Vertical external flue kit (100/150mm dia.)
Worcester Part No. 7 716 190 058
1,000mm external flue extension (80/125mm dia.)
Worcester Part No. 7 716 190 054
External 90º bend (80/125mm dia.)
Worcester Part No. 7 716 190 055
External 45º bends (80/125mm dia.)
Worcester Part No. 7 716 190 056
External 45º bends (100/150mm dia.)
Worcester Part No. 7 716 190 061
1,000mm external flue extension (100/150mm dia.)
Worcester Part No. 7 716 190 060
600mm external flue extension (80/125mm dia.)
Worcester Part No. 7 716 190 098
6363
Plume management accessories Greenstar Camray, Greenstar Danesmoor WM, Greenstar Utility internal & Greenstar Camray External series
Plume management kit(80mm dia.)
Worcester Part No. 7 716 190 092
1,000mm extension(80mm dia.)
Worcester Part No. 7 716 190 093
90º bend(80mm dia.)
Worcester Part No. 7 716 190 095
45º bend(80mm dia.)
Worcester Part No. 7 716 190 094
Belfast
Wakefield
Clay Cross
Worcester
West Thurrock
Dundee
Dublin
Burnley
Durham
Wiltshire
Tredegar
Cambridge
Wrexham
Camborne
Johnstone
Borders
Elgin
WWWWWWWWWWWWWWWWWWWW
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The very best training programmes from Worcester Worcester has always placed great emphasis on technical
support and training for installers and service engineers.
Advances in heating technology, including the increasing use
of renewables, make the need for training greater than ever.
To ensure the highest levels of competence and expertise
in the installation of all Worcester products, we run
intensive training courses for installers, commissioning
engineers and operatives involved with servicing and
fault fi nding.
Courses available
Our training facilities offer a number of courses suitable
for the installer and commissioning engineers, and more
in-depth courses for the servicing and fault fi nding engineers.
Training centres throughout the UK
To enable us to meet the growing demand for training we
have invested in additional facilities at the award-winning
training academy at our Worcester headquarters. In addition
to the original academy there is now a new 400m2 unit, 25%
of which is devoted to an open-plan domestic training area
with life-size single-storey brick buildings. These feature
working Greenskies solar thermal systems which enable
installers to get up onto the roof of the building to get
more realistic training. There are bays full of all Greenstar
gas-fi red appliances, so installers can really get to grips
with the importance of system design. The additional space
also contains dedicated training areas for our renewable
and future products. The training centre also runs certifi ed
domestic and commercial ACS training and assessment.
Further academies are located at West Thurrock in Essex,
Wakefi eld and Clay Cross in Derbyshire, all offering our
full suite of courses. Please phone 01905 752526 for more
information about a course near you. Each course is run
by specialist trainers and is superbly equipped to deliver
a combination of classroom theory and practical hands-on
experience that’s second to none.
College-linked Learning
As well as offering training at our own centres, Worcester
has established close partnerships with many colleges
around the UK, equipping them with our latest products.
Call us on 01905 752526 to fi nd out when we will be
running the course of your choice at a college in your area.
Mobile training
To complement our training venues across the country,
we can also bring training to you.
We have mobile vehicles fully equipped with operational
Greenstar gas-fi red boilers, dry strip-down models and even
a Greensource air to air heat pump, ensuring that quality
training in a comfortable environment can be achieved on
your doorstep!
If it’s oil training you require, our 7.5 tonne mobile oil
vehicle is available throughout the country for hands-on
product training and OFTEC assessments.
Distance learning/web based learning
Worcester has produced a selection of Distance Learning
CD ROMs/DVDs which are packed with information.
Call 0844 892 9800 for your copies, or visit
www.worcester-bosch.co.uk for information
on Web Based Learning.
Get on course for a more profi table future now.
Call now for more information 01905 752526
65
Worcester’s oil manufacturing heritage stretches back to
the foundation of the company in 1962. Since then, we
have built a strong reputation for not only manufacturing
products at the highest levels of quality and reliability,
but also for training installers, commissioning engineers
and operatives.
The oil-fi red condensing boiler training courses are
extensive and include areas such as dismantling
a pressure jet burner, setting oil pump pressures,
maintenance and cleaning of condensate trap, relationship
between air and oil supplies and detection of intermittent
faults. Our Oil advanced fault fi nding course has been
designed for installers and heating engineers who are
already knowledgeable on our range of oil-fi red products,
but wish to further their experience and understanding of
fault fi nding techniques.
Worcester also runs OFTEC training. A requirement of
Building Regulations 2001 - Part L (England and Wales)
and Part J (Scotland) is that every boiler installation
must be self-certifi ed by an installer who is OFTEC
registered.
Oil-fired condensing boiler course
Greenstar Danesmoor, Heatslave & Camray high effi ciency
condensing oil-fi red boilers – pre-OFTEC training.
Oil advanced fault fi nding.
OFTEC training and assessment courses
OFTEC 101 & 105e, OFTEC 600a and OFTEC
101/105e/600a.
Oil-fi red product courses
Oil-firedCourse
Oil Advanced Fault Finding
OFTEC 101 & 105e
OFTEC600a
OFTEC 101/ 105e/600a
Duration 1 Day 1 Day 4 Days 1 Day 4 Days
Cost £65 £65 £350 £175 £500
Training course covers
Specification
Domestic/light commercial pressure jet commissioning, servicing and boiler
installation
Oil tank installation and associated controls
Combined OFTEC 101, 105e and 600a courses
Installation
Commissioning
Servicing
Maintenance
Course locations
Worcester
Clay Cross
Wakefield
West Thurrock
College Links*
Mobile*
*Please contact Worcester Training for specifi c colleges and mobile dates
To complement the above courses, Worcester also runs domestic ACS, unvented, underfloor, water treatment and
IDHEE domestic heating design courses.
Please note: to attend OFTEC courses you must have a minimum of 12 months’ experience installing/servicing oil boilers or have attended an OFTEC 50 course. For candidates with limited oil experience, our Greenstar one day oil-fi red course offers pre-OFTEC training. Consult with the trainer at the end of the session to see if you are ready to undertake OFTEC assessment. For experienced oil technicians, training is not a pre-requisite for OFTEC assessment.
66
Additional product and industry training courses The diversity of products in today’s heating industry gives
you the opportunity to expand your expertise, whilst
offering more choice to your customers. Worcester
provides comprehensive training from all its academies
on its entire range of technologies.
Gas-fi red condensing boiler courses
Greenstar CDi Classic gas-fired condensing
combi boilers.
Greenstar CDi Compact gas-fired condensing
combi boilers.
Greenstar Si & i Junior gas-fired condensing
combi boilers.
Greenstar system & regular gas-fired condensing boilers
(covers Greenstar Ri, Greenstar CDi Classic Regular,
Greenstar FS CDi Regular, Greenstar 30CDi Classic System
and Greenstar i System boilers).
Greenstar Highflow CDi & FS CDi regular floor standing
gas-fired condensing combi and
regular boilers.
Renewable product courses
Renewables overview.
Greenskies solar.
Greenskies advanced solar.
Introduction to heat pumps.
Greenstore LECP ground source heat pumps.
Greensource air to air heat pumps.
Greensource air to water heat pumps.
Greensource split air to water heat pumps.
Greenstar Plus hybrid heat pumps.
Accessories training courses
Greenfl oor heating.
Worcester controls.
We are here to provide you with training and assistance for
all areas of your business, not just product training. Call us
on 01905 752526 to order a full course training brochure
or to book yourself onto a training course, alternatively,
you can visit www.worcester-bosch.co.uk/training
Commercial product courses
Greenspring CWi47 water heater.
GB162 overview.
GB162 domestic.
GB162 commercial.
Greenstar Heat Distribution Unit.
Commercial ACS training and assessment – CODNCO1.
Industry focused courses
BPEC underfl oor heating installation.
Hot water systems & safety.
Chemical water treatment.
Construction skills F-Gas training/
assessment certifi cation.
IDHEE domestic heating design.
Domestic ACS training and assessment – reassessment.
CCN1 + 3 appliances.
MCS Made Easy.
67
A complete after-sales service
All the technical advice you needSpares
Genuine replacement parts for all supported Worcester
products are readily available from stock, or on a next day
delivery basis. Visit our website at www.worcester-bosch.
co.uk/spares to fi nd your local stockist.
Customer Technical Support
The Worcester Technical Helpline is a dedicated phone
line – committed to providing a comprehensive service to
complement the brand name and quality of our products.
Our experienced team of technical experts provides
answers to queries of a technical nature across the entire
Worcester range.
Worcester also has a pre-sales department, which provides
assistance in selecting a heating system to suit a particular
application, along with full guidance on installation. For
more information please contact the Technical Helpline
or alternatively visit our website where literature can be
downloaded at www.worcester-bosch.co.uk.
Technical
Tel: 0844 892 3366
Fax: 01905 752 741
Opening times
Monday – Friday: 7.00am – 8.00pm
Saturday: 8.30am – 4.00pm
Bank Holidays: 8.00am – 4.30pm
As part of the worldwide Bosch Group, Worcester strives to
maintain the highest possible standards of after-sales care.
In addition to the no-nonsense parts and labour
guarantee applicable to all Worcester products, you and
your customers have the assurance that every Worcester
product is manufactured to both the appropriate British
and European standards.
Worcester Contact Centre
Should you require support, our award winning Contact
Centre team, based at our head offi ce in Worcester, are
ready to take your calls. Whatever your query our contact
centre operators along with our nationwide team of
engineers are ready to help you.
Tel: 0844 892 9900
Opening times
Monday – Friday: 7.00am – 8.00pm
Saturday: 8.00am – 5.00pm
Sunday: 9.00am – 12 noon
Bank Holidays: 8.00am – 4.30pm
67
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
This leafl et is accurate at the date of printing, but may be superseded and should be disregarded if specifi cation and/or appearances are changed in the interest of continued improvement. The statutory rights of the consumer are not affected.
Part No. 8 716 113 356 D 04/13
Worcester, Bosch Group,
Cotswold Way, Warndon,
Worcester, WR4 9SW
BB
T2987
PAPERS MADE WITH100% CHLORINE FREE
BLEACHED PULPTM
www.worcester-bosch.co.uk
Calls to the listed 0844 numbers are charged at up to 3 pence per minute from BT land lines.
Calls from mobiles and some other networks may vary. Calls to and from Bosch Thermotechnology Ltd
may be recorded for training and quality assurance purposes.
Engineer Appointments
Email: [email protected]
or telephone 0844 892 3000
Enquiries
Email: [email protected]
or telephone 0844 892 3000
Guarantee Registration
To register your Worcester guarantee,
please visit our website or
telephone 0844 892 2552
Customer Service
Sales
Tel: 01905 752640
Fax: 01905 456445
Spare Parts
Tel: 01905 752576
Fax: 01905 754620
Technical Helpline (Pre & Post Sales)
Tel: 0844 892 3366
Fax: 01905 752741
Renewables Technical Helpline
Email: [email protected]
or telephone 0844 892 4010
Training
Tel: 01905 752526
Fax: 01905 752535
Literature
Email: [email protected]
or download instantly from our website
or telephone 0844 892 9800
Useful numbers
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