Greenstar Oil System and Regular Boilers Technical and Specification Information

Technical and Specification Information Greenstar Danesmoor regular series
Greenstar Danesmoor System series

Greenstar Danesmoor Utility series
Greenstar regular and system

oil-fired condensing boiler range
Includes
ErP
ratings
1
Worcester and you. Making a difference.
As part of the Bosch Group, Worcester experienced technical services team which
products are designed and manufactured to is able to provide comprehensive support
provide customers with the highest levels of and advice from designing system layouts
quality and reliability which are synonymous through to installation.
with the Bosch name.
Worcester is dedicated to providing high
Worcester is a part of Europe’s largest performance, energy efficient heating
supplier of heating products and with our and hot water systems for a wide range
UK-based resources as well as the Bosch of installations. Our oil manufacturing
Group's global infrastructure, we can offer heritage stretches back to the foundation of
you the value-added solutions you deserve. the company in 1962 and during this period
Worcester employs a nationwide network of we have built a reputation for manufacturing
Service Engineers and technically trained products which offer the end user the
Field Sales Managers, supported by an highest levels of quality and reliability.
2
The reception and main entrance
at our Worcester headquarters
Contents Page
The Greenstar regular and system boiler range 4-5
Key features of the range 6-9
ErP easy as ABC 10 - 11
Inside story 12 - 25
Site preparations and guidance 26 - 32
“At Worcester we recognise the vital role you
Installation requirements 33 - 36
play in the specification and installation of
energy efficient appliances in homes across The Worcester Greenstar System Filter 37
the UK. We will continue to invest in our Condensate pipework 38 - 39
products, people, facilities and added value The Worcester CondenseSure siphon 40 - 41
services to ensure you have all you require in
Horizontal and vertical flue terminal positioning 42 - 43
order to deliver only the best solutions to your
Horizontal fluing options (internal models) 44 - 45
customers’ requirements.”
Vertical fluing options (internal models) 46 - 47
Carl Arntzen, Fluing options (external models) 48
Managing Director, Plume management positioning and system options 49 - 51
Bosch Thermotechnology Ltd.
Conventional flue 52
Oilfit flexible flue liner 53 - 54
Accessories 55 - 58
Worcester training 59 - 61
After-sales 62
3
The Greenstar regular and system
oil-fired condensing boiler range
The Greenstar Danesmoor regular and Danesmoor System Highly efficient condensing technology
series are part of a market-leading range of high efficiency The secondary heat exchanger of the Greenstar range
boilers which is good news for the environment and extracts more energy from the oil and, when compared with
excellent news for specifiers, installers and consumers. a non-condensing boiler, can cut heating and hot water bills
They are ideal for customers who are looking to minimise by over £400 a year†. All Greenstar condensing boilers are
fuel consumption, without sacrificing heating and hot able to deliver this energy-saving performance by extracting
water performance. additional latent heat from the exhaust gases – a highly
efficient use of energy which significantly reduces carbon
Greenstar oil-fired regular and system boilers offer outputs dioxide emissions into the atmosphere.
between 12 to 70kW and are specifically designed for use
with either a vented or sealed system. The range includes Greenstar Danesmoor regular and Danesmoor System
floor standing internal and external models. They are ideally condensing boilers have a seasonal efficiency of over 90%
suited to our range of Greenstore hot water cylinders which (SEDBUK 2009 value), efficiently producing heat for both
allow your customers to benefit from mains pressure hot your customers' heating and hot water demands. This is in
water, rapid re-heat times and excellent heat retention. comparison to standard efficiency boilers which achieve
around 78% efficiency, highlighting how a Greenstar boiler
Every appliance is operationally tested before it leaves can reduce heating and hot water bills.
the factory as part of Worcester’s rigorous quality
control procedure. When you install a Worcester
oil-fired boiler, you can rest assured that your customer
is receiving the best quality components and highest
levels of workmanship.
†Source: Energy Saving Trust: Based on replacing a G-rated oil-fired boiler with an A-rated oil-fired condensing boiler
4 and a full set of controls in a typical 3 bedroom semi-detached home with an average oil price of 6.02p/kWh.
Greenstar Danesmoor regular model.
Kitchen courtesy of Alno Kitchens.
The Greenstar regular and system oil-fired range at a glance

Greenstar model 12/18 models 18/25 models 25/32 models
Danesmoor regular 7 731 600 053 7 731 600 054 7 731 600 055
Danesmoor Utility 7 731 600 056 7 731 600 057 7 731 600 058
Danesmoor System 7 731 600 062 7 731 600 063 7 731 600 064
Danesmoor System Utility 7 731 600 065 7 731 600 066 7 731 600 067
ErP Seasonal space heating energy efficiency class A / 91% A / 90% A / 91%
SEDBUK 2009 efficiency 91.1% 90.9% 90.7%
Dimensions (h x w x d)
855x370x600mm 855x370x600mm 855x370x600mm
All Kitchen/Utility models
Output kW to Min 12kW 18kW 25kW

central heating (CH) Max 18kW 25kW 32kW
Conventional CF or RS
room-sealed from one appliance D D D
Greenstar model 12/18 External models 18/25 External models 25/32 External models
Danesmoor External 7 731 600 059 7 731 600 060 7 731 600 061
Danesmoor System External 7 731 600 068 7 731 600 069 7 731 600 070
SEDBUK 2009 efficiency 91.1% 90.9% 90.7%
Dimensions (h x w x d) 950x565x780mm 950x565x780mm 950x565x780mm
Output kW to Min 12kW 18kW 25kW

central heating (CH) Max 18kW 25kW 32kW
Balanced flue D D D
Greenstar model Utility regular 32/50 Utility regular 50/70
Part No. 7 731 600 073 7 731 600 074
ErP Seasonal space heating energy efficiency class B / 89% B / 88%
SEDBUK 2009 efficiency 90.7% 90.5%
Model Utility regular Utility regular
Dimensions (h x w x d) 1012x520x815mm 1012x520x815mm
Output kW to Min 32kW 50kW

central heating (CH) Max 50kW 70kW
Conventional CF or RS
room-sealed from one appliance D D
5
Key features of the range
On the secondary
heat exchanger*.
Greenstar Danesmoor regular and Special features of our Greenstar Danesmoor internal
Danesmoor System internal boiler ranges and external models
Greenstar internal models are ideally suited for installation Worcester's return to the Danesmoor heritage has brought
in a kitchen or a utility room. a range of regular boilers that deliver the following
installer-focused features.
Greenstar internal regular and system boilers feature:
• The same footprint as previous models, creating less • Cross-firing burner with easy access to principle
disturbance for replacement installations components enabling annual service from the front
• An annual efficiency of over 90% (SEDBUK 2009 value), of the boiler
ensuring optimum efficiency • Easy to remove one-piece primary baffles made from
• A 5mm steel inner primary heat exchanger surface as special high temperature resistant stainless steel
well as a 3mm outer, increasing efficiency and reliability • Optimised hydraulic connections based on installer
• Years of Worcester innovation have developed the feedback – all connections fit on the inside of the boiler,
optimum match between the burner and the boiler, providing a flush finish to the exterior. A blanking plug is
ensuring maximum efficiency and an exceptionally clean provided for the flow tapping with the regular appliances
and quiet operation • An annual efficiency of over 90% (SEDBUK 2009 value),
• A full 2 year guarantee, as well as a 5 year* guarantee on ensuring optimum efficiency
the primary heat exchanger and a 10 year* guarantee on • Rigid cabinet with a cross brace that provides a
the secondary heat exchanger. convenient tray for nuts and bolts
• Greenstar Danesmoor boilers are up to 17kg lighter
Greenstar Danesmoor regular and than the previous Greenstar Camray
Danesmoor System External boiler ranges • Designed and tested to accept a 30°C return
Where space in the home is at a premium, a Greenstar temperature making the appliance ideal for modern
External boiler is the ideal solution. heating designs.
Whilst offering many of the features of the internal

models, Greenstar 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
• Balanced flue system ensures that the flame is
maintained even in exposed environments.
6 *Terms and conditions apply.
Operation Fluing
Greenstar Danesmoor System boilers are supplied ready for Floor standing indoor appliances can
use with sealed primary water systems, and can be installed be used with either a room-sealed
with the Worcester Greenstore range of twin and single coil concentric flue or conventional (open)
unvented cylinders. flue. A flexi-flue liner kit is available to enable the appliance
to be flued via a chimney. The room-sealed flue ensures
Greenstar Danesmoor regular boilers are suitable for open extremely quiet operation.
vented systems, requiring a minimum head of 1m. They
too can be installed with our Worcester Greenstore The external appliances utilise a balanced flue system
unvented cylinders. in order to minimise the risk of lockouts caused by
strong winds.
All models operate on 28 sec kerosene oil and feature a
Riello burner. A plume management kit is available for both internal and
external boilers.
Greenstar Oilfit – the easy-fit fluing solution

• Multiple fluing options with the ability to flue internal
floor standing boilers from the top, rear or side and
external boilers from the rear and side
• Conventional flue via the adaptor kit and flexi-flue
chimney liner kit
• Room-sealed flue lengths up to 8m vertically and
6m horizontally
• Quick-to-install push-fit connections and telescopic
options which form a gas-tight seal and in most cases
Greenstar Danesmoor Utility regular eliminate the need to cut the flue
• Easy-fit installation that requires no special tools when
Applications fitting flue extensions, elbows and adaptors.
The outputs offered within the range makes our Greenstar
oil-fired boilers suitable for a wide range of domestic
properties, as well as providing installation flexibility.
All models are solar compatible and are ideally matched
to our range of Greenskies solar thermal panels and
Greenstore TC twin coil cylinders.
Greenstar Danesmoor External regular
Greenskies Solar-Lux, Solar-Lifestyle, Solar-Lito

and Greenstore TC series
7
Why choose Worcester oil?
Given the competitive nature of the heating industry, Worcester

know that installers have an important decision to make when it
comes to selecting the best product for their customers. Many
By appointment to
installers are loyal to the Worcester brand and recognise the Her Majesty The Queen
Boiler Manufacturer
importance of the technical support and training Worcester offers. Worcester, Bosch Group T/A
Bosch Thermotechnology Ltd.
At Worcester, we pride ourselves on the hard work that goes on

behind the scenes to make sure you and your customers benefit
from much more than the best in high-efficiency boilers and
renewable technologies.
For example, within the product reliability department, every

Worcester Greenstar oil-fired boiler is tested. The testing procedure
certifies that every boiler has been put through its paces in the
most extreme of conditions to ensure they are robust enough to
stand up to the highest of demands and toughest of environments.
We collect information on each individual component when we

field trial our appliances, whilst also systematically noting any Andy Rose, ACR Heating Services
feedback from the service engineer who worked on the boilers.
This information, along with responses from installers, is constantly
processed to ensure all technical observations can be acted upon
“
9 out of 10
as a matter of urgency. It is this commitment that ultimately
professional installers would choose
ensures that Worcester products remain the best they can be. Worcester
for their own home”*
Did you know?

• For testing purposes Worcester has its own formula to • With over 100 people in the quality control team
replicate contaminated heating system water. This mix on-site, Worcester has more quality control engineers
contains iron dust, quartz sand, hemp fibre and other than salesmen.
impurities which are commonly found in system • As part of the global Bosch Group, Worcester has
water samples. access to world leading resources, including a corporate
• Test boilers are positioned on a shaker table for 3 hours research department and access to the very latest
before being set to vibrate across a range of frequencies manufacturing and product development processes.
to simulate 3,000 miles of worldwide transport. • Each new Worcester appliance design is ‘field trialled’
• Parts in the hydraulic circuit complete 300,000 water for at least 1 winter period. To benefit from winter
pressure cycles to ensure optimum performance conditions all year round, outside of the British winter,
is achieved. products are tested overseas.
• We have received a Royal Warrant in recognition of • Every boiler receives an end of line full functional test
supplying goods to Her Majesty, the Queen, an honour before it leaves the factory.
we have held since 2003.
8 *Source: Worcester Customer Satisfaction Index 2011

Designed with installation and
servicing in mind
In addition to our own extensive testing and research, we Simple servicing
also listen and respond to installers as part of our product The Greenstar Danesmoor range has serviceability at
development programme. its heart.
As a result of such feedback, we have brought about the Based on installer feedback, the Greenstar Danesmoor
following distinct features that benefit the installer. has been created to make servicing as simple and quick as
possible, with the layout enabling an annual service to take
Easy installation place completely from the front of the boiler.
The first thing that you will notice is that the Greenstar
Danesmoor models are between 13 and 17kg lighter than
the previous Greenstar Camray.
Cleaning the primary heat exchanger is now made easy

due to the one piece primary baffles which can be quickly
removed for cleaning via the combustion chamber door.
The baffles have been made from a specially selected
Greenstar Danesmoor regular
grade of temperature-resistant stainless steel. Testing has
shown that the baffle design should not stick allowing
The hydraulic connections have been optimised based hassle-free removal.
on the feedback received from our customers during the
development process. This plumbing arrangement allows
the installer to make all the connections within the cabinet
at the back of the boiler, saving time and hassle.
Further improvements include an oil line which is run

through the cabinet, as well as an oil isolation valve which
mounts on an easy-to-access bracket on the right hand side
of the primary heat exchanger. There is also space on the
bracket for the installation of a second oil isolation valve if
you are utilizing a twin pipe system.
Finally, the Greenstar Danesmoor boilers retain the

internal condensate trap from the previous models,
which utilises a simple condensate pipe connection.
The height of the trap removes the need for a condensate
pump in most instances. The secondary heat exchanger baffles continue to use the
folded mesh design that has been a marked success in
previous Greenstar oil-fired boilers.
9
What is ErP?
The ErP Directive, which is a new regulation
set by the European Union, is designed to drive
improvements in the efficiency and performance of
heating and hot water products. Its purpose is to
ensure that end users are aware of the level of
energy efficiency inherent within their appliances.
As such, the Directive will help improve the overall
efficiency of the housing stock, while enabling
homeowners to reduce their energy bills. The ErP
regulations cover boilers, combination boilers,
heat pumps and other heating appliances up
to 400kW.
What is Energy Labelling?

The Energy Labelling involves a label which we are
familiar with today on washing machines and
televisions at the point of sale. The Energy Labelling Model
Product A
name
regulations introduce Europe-wide energy labelling
requirements for boilers, combination boilers,
A++
water heaters and other heating products up to A+
CH A A
70kW and hot water cylinders under 500 litres. efficiency B
C
band D
E
F
How will the labelling scheme work? G
The new Energy Labelling Directive will introduce

new efficiency classes from A++ to G alongside Sound Maximum
the existing SEDBUK rating for boilers in the power kW heating
dB
domestic and light commercial sectors. level output
2015 811/2013
Most condensing boilers will fall within the
A band, which requires them to achieve more
than 90% seasonal efficiency, while renewable
technologies such as heat pumps will likely
be in the A+ or A++ bands (depending on
flow temperature).
10
What about systems that contain
different products?
In these circumstances, there is a responsibility to In either circumstance, Worcester will provide an
provide a package label when combining a heating online tool that makes calculating the overall
appliance with a temperature control and/or solar package efficiency of a Worcester system effortless.
device, cylinder or a supplementary heating
appliance (for example, a two-boiler cascade with
a combined total output of under 70kW).
The person who puts that package together will

need to produce a package document known as
a fiche (data table) and label that provides the
combined energy efficiency rating rather than
ratings of each individual component.
For example, this could be the merchant’s

responsibility if they supply a complete package
under one part number or the installer if the
items are bought individually under separate
part numbers.
ErP easy as ABC with Worcester
The Energy Labelling obligation under the

Energy Related Products (ErP) Directive
comes into force on the 26th September 2015.
Worcester will have a number of measures in
place to support you including:
An online tool which creates product
and heating system labels
ErP will be covered in all Worcester
training courses
ErP experts – our technical and
customer support teams can answer
all your questions.
ErP Technical Support: 0330 123 3641

Email: ErP-advice@uk.bosch.com
11
Inside story – Greenstar Danesmoor
regular condensing boiler
Flow 1" BSP

Flue gas analyser
test point
Flue connection
Secondary
heat exchanger
Return
22mm (12/18, 18/25)
28mm (25/32)
Demand indicator
Temperature control
Optional digital
plug-in programmer
Lock-out indicator
Flue overheat
Boiler overheat
reset button
reset button
Flue gas analyser
test point
(behind control box)
Burner lead Flue manifold and

secondary heat
exchanger access door
Primary heat
Internal
condensate trap
Primary heat exchanger Oil supply

isolating valve
Burner
12
Technical data
Greenstar Danesmoor Greenstar Danesmoor Greenstar Danesmoor

Boiler
12/18 18/25 25/32
Height 855mm 855mm 855mm
Width 370mm 370mm 370mm
Depth 600mm 600mm 600mm
Weight – lift 104kg 108kg 114kg
2009 SEDBUK efficiency 91.1% 90.9% 90.7%
Solar compatible 9 9 9
Heating flow / return connections 1 inch BSP, 22mm 1 inch BSP, 22mm 1 inch BSP, 28mm
Condensate connection (polypropylene) 21.5mm 21.5mm 21.5mm
Oil connection 10mm 10mm 10mm
Primary water content 20 ltr 21 ltr 22 ltr
Output to central heating 12 - 18kW 18 - 25kW 25 - 32kW
Oil burner Riello RDB 2.2 Riello RDB 2.2 Riello RDB 2.2
Optional plug-in twin channel digital controls 9 9 9

Maximum primary static head 30m 30m 30m
Minimum primary static head 1m 1m 1m
Water side resistance 20ºC 20mbar 30mbar 56mbar
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
Maximum power consumption 143W 160W 160W
Part load power consumption 43W 48W 48W
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 100mm
Flue diameter (RS) 80/125mm 80/125mm 80/125mm
Maximum horizontal flue RS 6,000mm 6,000mm 6,000mm
Maximum vertical flue RS 8,000mm 8,000mm 8,000mm
Maximum hearth temperature <100ºC <100ºC <100ºC
13
Utility regular condensing boiler
Flow 1" BSP Flue gas analyser

test point
Flue connection
Secondary
heat exchanger
Return
22mm (12/18, 18/25)
28mm (25/32)
Temperature
control
Flue overheat
reset button
Boiler overheat
reset button Flue manifold and
secondary heat
Burner lead
Primary heat
Internal
condensate trap
Primary
heat exchanger Oil supply
isolating valve
Burner
14
Technical data

Boiler
Utility 12/18 Utility 18/25 Utility 25/32
Optional plug-in twin channel digital controls N/A N/A N/A

15
External regular condensing boiler
Flow 1" BSP Flue gas analyser

test point
Flue connection
Secondary
Return heat exchanger
22mm (12/18, 18/25)
28mm (25/32)
Temperature control Service mode switch
Flue overheat reset button

Boiler overheat
reset button
Flue gas analyser test point
Flue manifold and
secondary heat
exchanger access
Burner lead
Primary heat exchanger

access door
Internal condensate trap
Oil supply isolating valve

Burner
16
Technical data

Boiler
External 12/18 External 18/25 External 25/32
Oil burner Riello RDB 1 Riello RDB 2.2 Riello RDB 2.2
Balanced flue kit Supplied in boiler case Supplied in boiler case Supplied in boiler case
Flue diameter 80/125mm 80/125mm 80/125mm
Ingress protection rating IP45 IP45 IP45
17
Inside story – Greenstar Utility regular
condensing boiler series
Multi-directional flue
outlet box (RS only)
Air vent to secondary
heat exchanger
Return Flue gas analysis point
Flue gas
overheat thermostat
Service access door to

secondary heat exchanger
Burner combustion
air hose (RS only)
Thermostat pocket
Lock out reset button Flow
Data label
Burner control box
Burner Burner lead
Primary heat
exchanger service
access door
Temperature Overheat thermostat Flue gas

control reset button reset button
Greenstar Utility regular fascia
18
Technical data
Greenstar Greenstar
Boiler
Utility regular 32/50 Utility regular 50/70
Height 1,012mm 1,012mm
Width 520mm 520mm
Depth 815mm 815mm
Weight – lift 271kg 281kg
ErP Seasonal space heating energy efficiency class B / 89% B / 88%
2009 SEDBUK efficiency 90.0% 90.5%
Solar compatible 9 9
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
Maximum power consumption 188W 176W
Part load power consumption 63W 57W
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
19
System condensing boiler series
Pressure relief valve
Flue gas analyser

test point
Flue connection
Flow 1" BSP Secondary
heat exchanger
Return
22mm (12/18, 18/25)
28mm (25/32)
Pressure gauge
Optional digital
Demand indicator plug-in programmer
Temperature control Lock-out indicator
Flue gas analyser

test point
Flue overheat reset button

(under control box)
Boiler overheat reset button
Internal
condensate trap
Primary heat
Expansion vessel
ErP compliant low energy

circulating pump
Expansion vessel bracket
Burner
20
Technical data

Boiler
System 12/18 System 18/25 System 25/32
Heating flow / return connections 22mm 22mm 28mm
Optional plug-in twin channel digital controls 9 9 9

Available pump head 20ºC 5.2 mH2O 4.3 mH2O 4.1 mH2O
Maximum power consumption (including low energy pump) 191W 208W 208W
Part load power consumption* 43W 48W 48W
*Power consumption excluding pump.
21
System Utility condensing boiler series
Flue gas analyser

test point
Flue connection
Flow 1" BSP Secondary
heat exchanger
Return
22mm (12/18, 18/25)
28mm (25/32)
Temperature control
Flue overheat reset button Flue gas analyser

(under control box) test point
System pressure gauge

Boiler overheat reset button
Burner lead
Internal
condensate trap

access door
Expansion
vessel

circulating pump
Expansion
vessel bracket
Burner
22
Technical data

Boiler
System Utility 12/18 System Utility 18/25 System Utility 25/32

23
System External condensing boiler series
Flue gas analyser

test point
Flue connection
Flow 1" BSP
Secondary
Return heat exchanger
22mm (12/18, 18/25)
28mm (25/32)
Temperature Service mode switch

control Pressure gauge
Flue gas analyser

test point
Burner lead
Combustion air inlet tube

access door
Internal condensate trap

circulating pump
Expansion vessel
Burner
24
Technical data

Boiler
System External 12/18 System External 18/25 System External 25/32
Condensate trap 9 9 9
Balanced flue kit Supplied in boiler case Supplied in boiler case Supplied in boiler case
25
Site preparations and guidance
(internal models)
Siting of appliance
Greenstar Danesmoor regular, Danesmoor Utility regular,
Danesmoor System, Danesmoor System Utility and Utility
regular oil-fired appliances are not suitable for external
installation unless a sufficient enclosure is provided. The
floor must be firm and level.
The floor on which the boiler is to be mounted should be

capable of supporting an overall weight of approximately
140kg (Danesmoor) or 300kg (Utility regular). All models
have a hearth temperature of below 100°C removing the Installation of a Greenstar Oilfit RS flue system
need for a constructional hearth.
All materials used on open flue systems must be able to
The appliances should be positioned on a non-combustible sustain the corrosive elements present within the flue
solid base as near to the flue location point as possible. gases from condensing boilers. Worcester’s Oilfit flexible
Care should be taken to ensure that the appliance is level. flue liner is available in a variety of lengths from 8m to 15m
and is suitable for the Greenstar range† (see installation
Siting of appliance (wall mounted models) manual for further details or contact our Technical Support
Wall mounted models are supplied with a wall mounting Department). Guidance on the suitability of appropriate
frame and the primary pipework can be installed prior to materials should be sought from the flue manufacturer, if a
the installation of the appliance. The wall must be capable non-Worcester flue is to be installed. Worcester can supply
of supporting the weight of the appliance, accessories and a flexible flue liner suitable for CF chimney installations.
water content, approximately 135kg. The appliance is not
suitable for external installation unless a suitable enclosure
is provided.
Flue system
The Greenstar Danesmoor regular, Danesmoor Utility
regular, Danesmoor System, Danesmoor System Utility
and Utility regular appliances can be connected to either a
conventional flue system or a multi-directional, room-sealed
balanced flue. In either case, the conventional flue adaptor
or the appropriate RS flue kit needs to be specified.
The Greenstar Oilfit flexible flue liner
26 †Excluding external models

Installation and service clearances
The minimum clearances shown below should be allowed
for installation and servicing.
Greenstar Danesmoor regular, Danesmoor Utility regular,

Danesmoor System and Danesmoor System Utility
Installation clearances Service clearances
1,200mm 570mm 1,200mm 380mm
300mm 10mm or 300mm**
min
min
max
max
DANESM
DANESM OOR
OOR 18/25 !
18/25 !
100mm 5mm*
1,155mm 1,155mm
100mm 5mm*
600mm 600mm
Note:
*Remove the flue ‘knock-out’ panel sections if this clearance is less than 75mm.
**Top: 300mm for maintenance and repair. Top: 10mm for annual service check.
Greenstar Utility regular
Installation clearances Service clearances

720mm 1,415mm 540mm
1,415mm
300mm 300mm
100mm 10mm
1,297mm 1,312mm
100mm 10mm
600mm 600mm
27
Compartment installation
Follow the requirements of BS 5410 and note: Conventional flue† – minimum air vent area (cm2) for
• Minimum clearances must be maintained appliances installed in a compartment
• An access door is required to install, service and Internal ventilation* External ventilation**
maintain the boiler as well as any ancillary equipment, kW High level Low Level High level Low Level
(D) (C) (D) (C)
i.e. condensate trap
12/18 198 297 99 198
• If fitting the boiler into an airing cupboard use a non-
18/25 275 413 138 275
combustible material to separate the boiler from the airing
25/32 330 495 165 330
space. If the material is perforated, the holes must not
32/50 495 743 248 495
exceed 13mm.
50/70 715 1,073 358 715
Compartment ventilation
• Ventilation must be provided for boilers fitted into Room-sealed flue† – minimum air vent area (cm2) for
compartments as described in BS 5410 appliances installed in a compartment
• Referring to the diagram below, a minimum of 2 air Internal ventilation* External ventilation**
vents must be fitted, one at low level (C) and another kW High level Low Level High level Low Level
(D) (C) (D) (C)
at high level (D) onto the same wall using the same
air (E) for circulation 12/18 198 198 99 99
18/25 275 275 138 138
• Free air must not be taken from a room or internal space
25/32 330 330 165 165
containing a bath or shower and must not communicate
32/50 495 495 248 248
with a protected area such as a hall, stairway, landing,
corridor, lobby, shaft, etc. 50/70 715 715 358 358
*Internal air to and from a space/room inside the building.
• Air vents must allow access for clean, free air and **External air to and from directly outside the building.
must be sited to comply with the flue terminal †Due to changes to BS 5410 and modern building design, these figures no
longer incorporate the adventitious ventilation allowance.
position requirements
• Air ducting runs must not exceed 3 metres. Air supply
• Low level air vents must be within 450mm from the floor
Conventional Flue (CF)
• A warning label must be added to the vents with a
An adequate supply of free air must be delivered to the boiler
statement to the effect: “Do not block this vent.
for combustion purposes through a permanent inlet, such as
Do not use for storage”.
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 99cm2
18/25 138cm2
25/32 165cm2
32/50 248cm2
50/70 258cm2
*Due to changes to BS 5410 and modern building design,
these figures no longer incorporate the adventitious
ventilation allowance.
Internal ventilation External ventilation
Compartment ventilation
A Compartment
B Boiler
C Low level vent
D High level vent
E Air supply
28
Important: bathroom locations and clearances Greenstar Danesmoor regular, Danesmoor Utility regular,
• The boiler must not be installed in zones 0, 1 or 2 Danesmoor System and Danesmoor System Utility
• Any switch or appliance control which uses mains Casing dimensions
electricity must not be within reach of a person using
the bath or shower 600mm 370mm
• Electrical switches, fused spurs and socket outlets must

not be situated in the bathroom. min
max
DANES
MOOR
18/25 !
Refer to the latest IEE wiring regulations.

855mm
600mm 600mm
750mm
2 1 1 2 2,250mm
2,250mm Greenstar Utility regular
Casing dimensions
0 815mm 520mm
600mm 1,012mm
750mm
2 1 1 2
2,250mm 2,250mm
600mm radius
Conventional flued boilers must not be fitted in

a bathroom.
29
Pipework connections
The diagrams below show the flue and pipe outlets (mm):
Note: For servicing purposes, keep the condensate and pressure relief discharge
pipes away from components and pipework connections.
Greenstar Danesmoor System &

Greenstar Danesmoor & Danesmoor Utility models Danesmoor System Utility models
Pipework connections Pipework connections TOP VIEW
69
67
35
CF 170
B 23 RS 155
67 D
100
B A G
D D
370
69 67
A A 35 B
48 19 48
A G
825 21.5
747 C C 825 C
50
712 E
TOP VIEW F
40
417 412
321
FRONT VIEW SIDE VIEW

FRONT VIEW
Flue and pipe connections Flue and pipe connections

Key Description 12/18 & 18/25 25/32 Key Description 12/18 & 18/25 25/32
A CH flow 1" dia. BSP 1" dia. BSP A CH flow 22mm dia. 28mm dia.
22mm dia. 28mm dia. 22mm dia. 28mm dia.
B CH return B CH return
plain copper plain copper plain copper plain copper
C Condensate outlet 21.5mm dia. 21.5mm dia. C Condensate outlet 21.5mm dia. 21.5mm dia.
D Flue outlet 80/125mm 80/125mm D Flue outlet 80/125mm 80/125mm
E Oil pipe isolating valve 10mm 10mm
Optional oil line
F 10mm 10mm
return line connection
G Pressure relief pipe 15mm dia. 15mm dia.
Greenstar Utility models

Pipework connections
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 100/150mm
30
Site preparations and guidance
(external models)
Greenstar Danesmoor External and
Siting of appliance
Greenstar Danesmoor System External
The Greenstar Danesmoor External appliances are suitable
Casing dimensions
for external installation only. Appliances should be installed
780mm 565mm at a suitable location onto a fixed, permanent and rigid
surface. There must be sufficient hard-standing around
the appliance to allow for servicing. Appliances must be
installed on a flat, level surface to ensure that condensation
does not enter the primary heat exchanger. Appliances
should not be installed where there is a potential for
950mm
excessive ground water coverage. Tarmac and wood hard-
standings are not recommended.
Flue system
For all external boilers, consideration should be given to
the location of the appliance and its flue outlet in relation
Installation and service clearances to windows, doors and air vents. The Greenstar Danesmoor
The minimum clearances shown below should be allowed regular and Danesmoor System External appliances can
for installation and servicing. It is strongly recommended be connected to the Greenstar Oilfit External flue system
that the flue terminal faces away from walls to reduce the (supplied with the Danesmoor External regular) providing
possibility of “wetting” occurring. Care should be taken to balanced fluing options at low level, high level or vertical
ensure that pipework leaving the appliance and entering outlets (see page 48).
the building should not be exposed. The appliance should
be sited as close to the dwelling as possible.
Side view Bird's eye view 2,500mm*

600mm
600mm 2,500mm
FRONT
85mm Plan 45mm

view
FRONT
600mm min.
BASE
600mm
Bird's eye view 50mm** Bird's eye view 50mm**
2,500mm 10mm 10mm 2,500mm
Plan view Plan view
FRONT FRONT
600mm 600mm
**Rear clearance flue outlet on side *Rear clearance flue outlet on rear 31
Pipework connections Danesmoor External Pipework connections Danesmoor System External
The diagrams below show the flue and pipe outlets (mm): The diagrams below show the flue and pipe outlets (mm):
Note: For servicing purposes, keep the condensate and pressure relief discharge Note: For servicing purposes, keep the condensate and pressure relief discharge
pipes away from components and pipework connections. pipes away from components and pipework connections.
Rear Rear
269 152
Flue Flue Services
Services
Condensate 93 Condensate
784 794
Fire valve &

PRV
330 drain access
91
Pressure
relief valve
105
REAR 171
Fire valve capillary
& drain access
Right side Right side 624.5

Services
491.5
Flue Flue Services
Condensate
715 Condensate
Pressure
relief valve 784 794
704
Fire valve &
PRV drain access
437 559
Oil 224 Oil
105 94
RIGHT HAND SIDE 55
659
Fire valve capillary
& drain access 669
Left side Left side

625
Services
492
Flue
Flue
Services
Condensate
Condensate
715
PRV 784 794
Oil
Pressure 699
relief valve
327
Oil
LEFT HAND SIDE 124 90 55
659
679
Danesmoor External regular flue and pipe connections Danesmoor System External flue and pipe connections
Description 12/18 & 18/25 25/32 Description 12/18 & 18/25 25/32
CH flow/open vent 1" dia. BSP 1" dia. BSP CH flow 22mm 28mm
22mm dia. 28mm dia. 22mm dia. 28mm dia.
CH return CH return
plain copper plain copper plain copper plain copper
Flue outlet 80/125mm dia. 80/125mm dia. Flue outlet 80/125mm dia. 80/125mm dia.
Condensate outlet 21.5mm dia. 21.5mm dia. Condensate outlet 21.5mm dia. 21.5mm dia.
Oil 10mm dia. 10mm dia. Oil 10mm dia. 10mm dia.
PRV Pipe 15mm dia. 15mm dia. PRV Pipe 15mm dia. 15mm dia.
32
Installation requirements
Installation regulations Sealed system installation

The appliance should be installed by a competent person The Greenstar system oil-fired appliances are designed for
who is aware of the Health and Safety at Work Act. They sealed systems, incorporating a pre-plumbed expansion
should take appropriate action to ensure that the regulations vessel, pressure relief valve set to 3bar, automatic air
are adhered to. In order to give optimum efficiency and vent and pressure gauge. The expansion vessel fitted to
trouble-free operation, the appliance must be commissioned the appliance will accommodate differing system volumes
by a qualified OFTEC engineer. depending on initial charge pressure and system pre-
pressurisation. Under certain circumstances the system
In particular, the installation of this appliance must be in volume may be in excess of that catered for by the
accordance with the relevant requirements of the following expansion vessel provided. In this instance, an additional
British Standards and regulations in respect of the safe vessel should be fitted as close as possible to the return
installation of equipment: connection of the appliance. Filling of the system can take
place from a make-up vessel, which should be fitted with
The compliance with a British Standard does not, of itself, a non-return valve above the highest point in the system.
confer immunity from legal obligations. Alternatively, and to comply with the Water Authority
requirements, the system may be filled through a temporary
BS 5410: part 1 & 2: Code of Practice for Oil Fired Boilers. hose connection to the mains water supply, provided that a
double check valve assembly and test point are fitted on the
BS 799: part 5: Specification for Oil Storage Tanks.
system side of the temporary connection. Greenstar regular
boilers can be installed on a sealed system subject to an
BS 7593: Code of Practice for treatment of water in
appropriately sized expansion vessel, a 3bar pressure relief
domestic hot water central heating systems.
valve and a filling link with pressure gauge being added.
BS 5449: part 1: Specification for forced circulation hot
water central heating for domestic premises. Open vented primary systems
The feed and expansion cistern (E) must be positioned
BS 5955: part 8: Specification for the installation of to provide a static head (S) of at least 1 metre above the
thermoplastic pipes and associated fittings for use in highest point in the heating system to the water level in the
domestic hot and cold water services and heating systems. expansion tank (E).
BS 7291: Thermoplastic pipes and associated fittings for

The open vent pipe (H), feed and expansion pipe (F) must
hot and cold water for domestic purposes and heating
rise continuously from the appliance.
installations in buildings.
The open vent pipe (H) must be at least 22mm dia.

BS 7074: part 1: Application, selection and installation
of expansion vessels and ancillary equipment for sealed
E
water systems. S
1,000mm min.
150mm max.
BS 7671: IEE Wiring Regulations, current edition. F H M
R R
T T
Full British Standards requirements can be found on L L
the British Standards website.

A R R
K
The Building Regulations England and Wales, Scotland and T L T L
Northern Ireland. C
J K D D
Typical open vent system

Local water company bye-laws.
A Appliance K Zone valve
C Automatic bypass valve L Lockshield valve
The Control of Pollution (Oil) Regulations. D Drain cock M Hot water cylinder
E Feed and expansion cistern R Radiators
OFTEC Standards F Feed and expansion 15mm dia. min S Static head
H Open vent 22mm dia. min T TRV
J Circulating pump
33
Radiator valves Guarantee
Underfloor heating Worcester oil-fired appliances are offered with *
• Plastic pipework used for underfloor heating must be a 2 year* guarantee on parts and labour from
correctly controlled with a thermostatic blending valve, the date of installation providing the appliance
limiting the temperature of the circuits to approximately is commissioned upon installation and the
50ºC. A 20ºC temperature differential must also be regular service requirements are met. The *
maintained at the appliance. primary heat exchanger comes with a 5 year*

guarantee and the secondary heat exchanger
Primary system/connections/valves is guaranteed for 10 years*.
• Do not use galvanised pipes or radiators.
• All system connections 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
• An automatic bypass valve must be connected between
the heating flow and return where TRVs are used on all
radiators. It should be fitted to give at least a 3 metre
circuit when activated.
• Drain cocks are required at all of the lowest points on
the system
• Air vents are required at all of the high points on
the system.
Oil supply
Fire valve
sensor
300mm
Oil storage tank External

4m max.
min.
wall Isolating
valve
Full base (plastic tanks) Isolating

Isolating Oil strainer
valve & water Oil valve Oil pump
Fire valve
separator supply to BS 5410 Oil filter Oil burner
pipe
Fig. 10 Single pipe system
Fire valve to BS 5410

Fire valve
sensor
Non-return valve
Isolating
Oil storage tank valve Oil burner
3.5m max.
Isolating
valve
Oil
Oil supply pipe Isolating pump
valve
150mm
External Oil filter
Oil strainer & wall
Full base (plastic tanks) water separator
Fig. 11 Two pipe system
34 *Terms and conditions apply.

Fire valve sensor
De-aerator Oil burner
Oil storage tank
3.5m max.
Fire valve
to BS 5410
Isolating
valve Oil strainer Isolating Oil pump
& water valve
separator
External wall
Oil supply pipe
Full base (plastic tanks)
Fig. 12 Single pipe lift system with de-aerator
The oil burner on the Greenstar regular and system from the oil tank. There is usually a non-return valve located
oil-fired appliances is supplied with a single flexible fuel in this connection to prevent oil draining back towards the
line from the oil pump, which is connected to the main oil tank under gravity which can create a vacuum. When
oil supply line (via the oil isolation valve), within the the burner is firing, the whole fuel supply system is under
appliance. This enables the burner to be removed without negative pressure, i.e. suction, therefore it is imperative
the need for disconnection of the fuel line. that all joints on the fuel supply system are correct. Whilst
there may be no obvious signs of an oil leak externally,
The maximum permissible head is 4 metres. If the head is when the burner is firing it may be possible for air to
greater, then a head breaking device must be incorporated be drawn in through a bad joint, reducing the pump’s
into the oil supply line. capabilities, resulting in a lack of fuel to the oil pump and
a nuisance ‘lockout’. This may manifest itself as a very low
The oil pump’s primary job is to pressurise the oil once in level of oil or ‘foaming’ of the oil inside the de-aeration
the pump and force it out of the nozzle at high pressure to device whilst the burner is trying to fire.
atomise the fuel, ensuring clean and efficient combustion.
This same pump can also be converted to ‘draw’ up the Most de-aeration devices are made of plastic and vent
fuel line in cases where the oil tank is lower than the to the atmosphere. For this reason, they must always be
appliance’s burner. This conversion should be undertaken located externally. Metal types do exist which do not emit
by the installing engineer. vapour. These can be located internally or externally.
All oil pumps on Worcester appliances can easily be Top outlet oil tanks should have the non-return valve
converted to work on a two pipe system (details of removed from the end of the oil feed pipe within the
this operation are within the Installation and Servicing tank if installed in conjunction with a de-aeration device.
instructions which come with the appliance).
Supply pipe
More advice on fuel lines can be sought from OFTEC Book The oil supply pipe itself would normally be annealed
Three as well as Technical sheet TI/134. copper tube with a protective plastic coating which is easily
manipulated around bends and usually enables the fuel line
De-aeration devices to be run in a continuous length without joints. If joints
A de-aeration device is a container of oil, about the size of must be used, they must be accessible, even if underground
a pint glass, with an automatic air vent on top as well as (via an access duct) and should be of the manipulative
three connections on the bottom. It removes the need to type. Plastic pipe specifically for oil lines does exist and is
run a return oil pipe back to the tank from the burner as acceptable but must only be used underground.
in Fig. 11. Its function is to provide a reservoir of oil from
which the oil pump draws. It also acts to vent any air in the Galvanised pipe, fittings and soldered joints must not be
oil out to the atmosphere preventing a nuisance ‘lockout’ used in oil lines.
of the burner. Not all the oil drawn is consumed and any
excess is returned to the de-aeration device meaning that More advice on fuel lines can be sought from OFTEC Book
whilst the burner is firing, there is a continuous flow and Three as well as Technical sheet TI/134.
return of oil. The third connection is for the main fuel line
35
Supply pipe sizing Oil tanks
The diameter of the oil supply pipe itself is determined by For further information on oil tank location, please consult
the distance from the oil tank to the appliance and the head the tank supplier.
of oil whether it be positive or negative.
Oil filters
Tables 1 and 2 give the required diameter of supply pipe Oil filters must always be incorporated in the oil supply line.
when cross referenced with the head. Table 3 gives the One should be fitted on the outlet from the oil tank to filter
diameter of the supply pipe when the use of a de-aeration deposits from within the tank or fuel, and one should be
device is made. fitted near the appliance to filter deposits from within the
fuel line itself. They are supplied and fitted by the installing
Maximum allowable pipe run engineer and are not part of the boiler’s components. It
8mm inside dia. pipe 10mm inside dia. pipe should be possible to service them without the need for
Head
(10mm OD copper) (12mm OD copper) draining down the fuel supply line. There must be sufficient
0.5m 12m 30m clearance below the filter to enable servicing operations
1.0m 25m 69m to be carried out easily. Filters must comply to OFTEC
1.5m 37m 91m standard OFS E104.
2.0m 49m 100m

Fire valves
2.5m 62m 100m
A fire valve is an essential part of the oil supply system. It
3.0m 74m 100m must be supplied and fitted by the installing engineer and
3.4m 87m 100m is not part of the boiler’s components. Its purpose is to cut
4.0m 99m 100m off the flow of oil outside the building in the event of fire
Table 1: Single pipe gravity feed system

within the boiler area. The valve should be located on the
fuel line at the point of entry into the building. It must be
Maximum allowable pipe run activated by a remote sensor located over the burner. A clip
8mm inside dia. pipe 10mm inside dia. pipe is provided within the appliance for the sensor. Fire valves
Head
(10mm OD copper) (12mm OD copper) must comply with OFTEC standard OFS E101.
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 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
Table 3: Single pipe suction lift with de-aerator
36
The Worcester
Greenstar System Filter
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, a proven
technology that offers a capacity to collect up to 200g of
magnetite a year. Any non-magnetic debris is caught by the
twin-action cyclonic trap.
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 flakes,
Modern condensing boilers are precision engineered paint particles and other system pollutants.
and designed to run with a clean water heating system.
Over time, dirty system water will damage a boiler and Features Benefits
its components, causing failures as well as potentially Safeguards the boiler against
damage and protects the
shortening the life of the overall system.
Highly effective filter efficiency of the system.
Saves up to 6% a year on
Damaged boiler and energy bills*
system components A warmer home and

Prevent blockages in radiators
quieter system
• Blockages in primary
heat exchanger Proven technology that
High powered internal magnet can capture up to 200g
• Increased wear on pumps of magnetite
• Blocked valves. A circulating pump damaged by system Increased performance –
debris and pollutants Cylindrical design
better installation options
Reduced efficiency
Twin-action – magnetic and Instantly effective against a
• Energy efficiency loss equivalent to a boiler being non-magnetic filtration wide range of system debris
reduced from A rated efficiency to D rated, resulting No electrical wiring
in fuel wastage* No power consumption or connection or supply needed.
moving parts Zero running costs and no
• Blocked radiators can reduce efficiency and failure of components
heating comfort.
Can be installed under the
boiler or away from the Flexibility
A highly effective solution appliance
from the brand you can trust Removes the need to isolate
One-way valve for adding a section of the system when
The Worcester Greenstar system chemicals carrying out servicing and
System Filter has been maintenance
specifically designed to Worcester, Bosch Group Reliability of components
combat the damaging specification and design and filter
effects of system debris *Independent research carried out by GASTEC at CRE
and pollutants, allowing

homeowners to protect their Installation
The Greenstar System Filter is easy to
boiler or heat pump for a The filter can be installed almost anywhere in a heating
install and service
fraction of its cost. The filter system. However, to maximise the effectiveness, it should
is suitable for any 22mm piped heating systems. be placed before the boiler and after the last radiator.
Product info
Part number 7 716 192 609
37
Condensate pipework
Important points to consider when siting a condensate Condensate pump

drainage pipe: Where “gravity discharge” to an internal termination is not
• Where a new or replacement boiler is being installed, physically possible, or where very long internal runs would
access to an internal “gravity discharge” point should be required to reach a suitable discharge point, condensate
be one of the factors considered in determining should be removed using a proprietary condensate pump,
boiler location of a specification recommended by the boiler or condensate
• The condensate pipe must be a minimum of 22mm dia. pump manufacturer.
plastic pipe
• The condensate pipework must fall at least 52mm per The pump outlet pipe should discharge to a suitable
metre towards the outlet and should take the shortest internal foul water discharge point such as an internal soil
practicable route and vent stack, internal kitchen or bathroom waste pipe,
• Ensure there are no blockages in the pipe run. washing machine waste pipe etc. A suitable permanent
connection to the foul waste pipe should be used.
Internal connections (see fig. 3 and 4)
In order to minimise risk of freezing during prolonged cold
spells, the following methods of installing a condensate Visible air break
at plug hole Sink or
drainage pipe should be adopted, in order of priority. Universal basin with
connector 22mm dia. integrated
Condensate
overflow
discharge
Wherever possible, the condensate drainage pipe should be from boiler
routed and terminated so that the condensate drains away
from the boiler under gravity to a suitable internal foul water
75mm
discharge point such as an internal soil and vent stack. min. 75mm sink
waste trap
A suitable permanent connection to the foul waste pipe
Condensate
should be used. (see fig. 1) pump
Condensate
discharge Soil and
from boiler vent stack Fig. 3 Condensate pump disposal (internal models)
Universal
connector
Universal
connector Pipework
Insulate &
transition
Condensate increase pipe
discharge 22mm dia. size to 32mm
22mm dia. Min. 450mm from boiler
and up to
three storeys
25mm min.
Fig. 1 Disposal to soil vent stack (internal and external models).

For external models increase pipe size and insulate pipework.
Alternatively if the first option is not possible, an internal Condensate

pump
kitchen or bathroom waste pipe, washing machine waste
Fig. 4 Condensate pump to external disposal (internal models)
pipe, etc. can be used. (see fig. 2)
Condensate Visible air break

discharge at plug hole
from boiler
Universal Sink or basin with
22mm dia.
connector integrated overflow
For full technical information on pipe size, insulation

75mm and different condensate pipework methods, please
min. 75mm sink
waste trap
see Installation, Commissioning and Servicing
Instruction Manual.
Fig. 2 Disposal to a waste pipe (internal models)
38
External connections
Freezing conditions Condensate
discharge 22mm Pipework
transition
• Pipework length should be kept to a minimum and the from boiler dia. 400mm min.
route should be as vertical as possible
25mm min.
• A Worcester CondenseSure siphon may be used to
500mm min.
reduce the risk of freezing
Insulate &
• Where pipework is subjected to extreme cold or wind increase pipe
Universal size to 32mm
chill, a form of weather-proof insulation should be used. connector
100mm dia.
Condensate waste 100mm
dia. min.
100mm dia.
• Care should be taken when siting a soak away to avoid plastic
pipe
min. plastic
pipe Drainage
obstructing existing services. Limestone holes
Drainage
holes chippings
12mm dia. 300mm
If no other discharge method is possible, then the use of
25mm Bottom of sealed tube
an externally-run condensate drainage pipe terminating at 25mm UNSUITABLE FOR CLAY SOIL TYPES
a suitable foul water discharge point, or purpose-designed 50mm
25mm
soak away, may be considered (see fig. 5).
If this method is chosen, then the following measures Fig. 5 Soak away (internal and external models).
should be adopted: For external models increase pipe size and insulate pipework.
• The external run should be kept as short as possible

and not exceed 3m
• A CondenseSure siphon may be used to reduce the risk Condensate
of freezing discharge
from boiler Universal Insulate & External
• The pipe should be run internally as far as possible connector increase rain water
before going externally and the pipe diameter should be pipe size pipe into
to 32mm foul water
increased to 32mm before it passes through the wall to Pipework
transition
the exterior. The pipe should be insulated using suitable
waterproof and weather resistant insulation External
air break
• The external pipe should take the shortest and least
exposed route to the discharge point, and should “fall” Air gap
22mm dia.
as steeply as possible away from the boiler, without
horizontal runs in which condensate might stand
• The use of fittings, elbows, etc., should be kept to a 43mm 90º PVCu strap
male/female bend on fitting
minimum and any internal “burrs” on cut pipework
should be removed so that the internal pipe section is
Fig. 6 Disposal into a rainwater down pipe (internal and
as smooth as possible.
external models). For external models increase pipe size and
insulate pipework.
Fitting an external air break
• Refer to Fig 6. When a rainwater down pipe (which goes In addition to the condensate discharge options illustrated
directly into a sewer that carries both rain water and on these pages and in the Installation, Commissioning and
foul water) is used to dispose of condensate, an air Servicing Instruction Manual, the Worcester CondenseSure
break must be installed. It should be fitted on the siphon provides an innovative alternative for the prevention
43mm pipework, between the boiler condensate outlet of freezing for externally run discharge condensate (see
and the drainpipe. The installation should take place pages 40-41 for details).
outside the property to avoid flooding during adverse
weather conditions.
39
The Worcester
CondenseSure siphon
With temperatures as low as -20ºC being experienced
in very cold winters, practices such as externally run
condensate discharge pipework are now being questioned.
In these conditions the condensate pipe on a condensing

oil-fired boiler can freeze. This can lead to a blocked
condensate pipe, which will cause condensate to drain
back into the boiler leading to corrosion of mild steel
components and leakage of condensate. This can result
in premature component failure, damage to property and
burner failure.
The Worcester CondenseSure siphon has been designed to

allow a more flexible approach to boiler siting.
The CondenseSure
insulating jacket
Tested to extreme temperatures helps to retain the
The Worcester CondenseSure siphon has been extensively temperature of the
condensate.
tested under simulated extreme weather conditions, proving
its effectiveness in preventing frozen condensate at -15ºC
for a sustained period of 48 hours.
A universal fitting for new and existing installations
CondenseSure principle of operation Although developed specifically for Worcester Greenstar
Most oil-fired condensing boilers have a trap which gas- and oil-fired boilers, the Worcester CondenseSure
releases condensate as it is formed. A typical A-rated can also be fitted to any make of condensing boiler for
condensing boiler will generate up to 2 litres of both new and retrofit installations. The CondenseSure
condensate an hour (dependent on output and can provide a simple solution which eliminates the need
temperature) which is discharged as a continuous for re-siting both the new boiler and the system pipework
trickle. With this frequency of discharge, the condensate when replacing an existing non-condensing appliance.
pipework is never empty of condensate, consequently CondenseSure can easily be fitted to an existing
increasing the potential for freezing of the pipework in condensing boiler to provide peace of mind in extreme
prolonged sub-zero temperatures. weather conditions.
The CondenseSure siphon connects to the boiler Features Benefits

condensate discharge outlet and collects the condensate No electrical wiring
No power consumption connection or supply needed,
into a larger volume before releasing it into the
meaning zero running costs
discharge pipe.
No moving parts No failure of components
Can be installed on new or Suitable for any gas- or

With this expanded siphonic operation, the discharge from
existing installations oil-fired condensing boilers
the CondenseSure increases to every 15 to 20 minutes,
Can be attached to 22mm
resulting in: Uses ‘free’ energy from the
heating flow pipework
pipe to heat the condensate
• Increased velocity and flow rate (gas-fired boiler)
• Only 3 to 4 siphonic actions per hour, meaning the Under boiler or remote
Flexibility
installation
condensate pipework is empty for longer
No electrical connections No electrician needed
• Significantly decreased or even eliminated
freezing potential. Cost saving and aesthetically
No pipe insulation needed
pleasing
40
Ease of installation Fitting
The CondenseSure has been designed for ease of
installation and is suitable for most boiler applications.
Although it can be clipped to a flow pipe under a wall
hung boiler, on floor standing boilers the CondenseSure
4
can be wall-mounted away from the boiler, whilst still
being connected to the condensate discharge pipe. 1
Condensate 3
discharge
from boiler
Universal
connector
External pipework 2
3000mm max.
2.5º fall min.
5
32mm OD pipe
CondenseSure
A typical installation using CondenseSure
1. Foam backing with double-sided tape

CondenseSure installation parameters 2. Siphon mounting screws
The CondenseSure will protect an externally run condensate 3. Siphon body
discharge pipe from freezing for 48 hours at -15°C providing 4. Foam insert (used with regular or system boilers)
the following installation parameters are met: 5. Foam cover
• 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 Additional installation considerations include:
in diameter. • Keeping any external pipework as short as possible
Whilst it is not necessary to insulate the pipework, it may • Minimising the number of bends and connections
be a consideration if longer lengths or lower external • Removal of burrs after cutting any pipe
temperatures are expected. • Removal of surplus solvent from the
interior of the pipe.
There is no Part P requirement as the CondenseSure has

no working parts to break down, does not use any energy
and has no electrical connections.
Product info
Part number 7 716 192 746
41
Horizontal and vertical flue terminal positioning
All measurements in millimetres
Conventional flue
8
750
Velux
dormer w
Window 4
600
2 600
600 3
1 600 1,500
600 7
GREENSTAR DANESMOOR KITCHEN 12/18
Boundary 750 300

5 6
Note
Key to illustration
• All measurements are the minimum clearances required.
• Use suitable brackets and fittings to support the flue 1. 600mm distance to a boundary, unless it will cause a
at approximately one metre intervals and at a change nuisance. BS 5410: Part 1 recommends that care is
of direction. taken when siting terminals in relation to boundaries.
• Terminals must be positioned so as to avoid combustion 2. 600mm below eaves and balconies, this can be reduced
products entering the building.
to 75mm, as long as the flue terminal is extended to
• In spite of the dimensions given here, the terminal must
not be closer than 300mm to combustible material, in clear any overhang.
the case of a thatched roof, double this dimension. 3. 600mm horizontally or vertically to an opening, air brick
• Terminals must be positioned so as to avoid products of or opening window.
combustion accumulating in stagnant pockets around or 4. 1,500mm vertically from a terminal on the same wall.
entering the building.
5. 750mm horizontally from a flue on the same wall.
• Terminals must be at least 1.8m from an oil storage tank 6. 300mm to an internal or external corner.
unless a wall with of at least 30 minutes fire resistance
which extends 300mm wider and higher than the tank is
present between the tank and the terminal.
42
2m
1m
52mm 104mm 11
or
window
750
600 10
Drainpipe
External
14 oil boiler
12 2,500
300
300 13
7. Minimum 600mm straight flue before any bend on a 13. Flue clearance must be at least 300mm above ground
conventional flue. or balcony level. Terminal guards must be fitted if the
8. 750mm between a vertical structure and a flue terminal. flue is less than 2 metres from the ground or if a person
9. 1,000mm below a Velux or dormer window, 300mm could come into contact with the flue terminal.
above or to either side of the Velux or dormer window 14. 2,500mm between terminals facing each other.
or any opening on a sloping roof.
10. 600mm above the highest point of an intersection with
a roof.
11. Any flue must fall back towards the boiler by 3° or
52mm for every metre of flue so that the condensate
drains back to the boiler for disposal.
12. 300mm to any vertical sanitary pipework or drain pipe.
43
Greenstar floor standing boiler range
horizontal fluing options (internal models)
The Greenstar regular and system boiler range has a Greenstar Danesmoor regular and
125mm diameter telescopic horizontal room-sealed flue Danesmoor System components
system including a plume management kit. Part No. Description
125mm diameter
Horizontal room-sealed flue Standard telescopic flue kit
7 716 190 064
(460 - 670mm)
Flue diameter 125mm 150mm
Short telescopic flue kit
Maximum flue length 7 716 190 062
6,000mm N/A (350 - 460mm)
Danesmoor 12/18, 18/25 & 25/32
7 716 190 033 1,000mm flue extension
Utility regular 32/50 N/A 3,000mm
7 716 190 097 600mm short flue extension
7 716 190 034 90º bend
Note: The maximum flue length must be reduced by the 7 716 190 035 45º bends (pair)
following amounts for each bend used. 7 716 190 101 Flue damper
45º bend 90º bend
7 716 190 050 Flue terminal guard
80/125mm flues 500mm 1,000mm
Infill plate for high level
100/150mm flues 500mm 1,000mm 7 716 190 105
horizontal flues (Danesmoor)
Greenstar Utility regular components

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. Part No. Description
All components for the left horizontal and right horizontal outlet come within
the Greenstar Oilfit horizontal flue kit (150mm) for the Greenstar Utility regular 150mm diameter
32/50 and 50/70 models.
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)
The following criteria should be noted when planning

the installation:
• The concentric flue 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
efficiency. Care must be taken when selecting the flue
terminal position
• To achieve a maximum flue length, one of the extension
flue kits will need to be cut so that the permitted
maximum flue length is not exceeded
• Note: The short flue extension (600mm) may be used
as an alternative to the standard 1,000mm extension
on 80/125mm flue installations as required up to the
maximum flue lengths stated (Part No. 7 716 190 097).
44
Horizontal flue options 1-4 illustrate common flue installations. Other configurations of the flue system are possible up
to, and not exceeding, the stated maximum flue lengths.
Option 1: Standard rear flue assembly Option 3: Side flue extension
Components Components
Maximum lengths (mm) & no. of components required Maximum lengths (mm) & no. of components required
Greenstar Danesmoor regular & Danesmoor System series Greenstar Danesmoor regular & Danesmoor System series
Part No. 125mm 7 716 190 064 Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
125mm 670 1 125mm 5,000 1 up to 5 1

Greenstar Utility regular series Greenstar Utility regular series
150mm 880 1 150mm 3,000 1 up to 2 1
Option 2: Extended rear flue assembly Option 4: High level horizontal discharge
Part No. 125mm 7 716 190 064 7 716 190 033 Part No. 125mm 7 716 190 064 7 716 190 033 7 716 190 034
125mm 6,000 1 up to 6 125mm 5,000 1 up to 5 2

Part No. 150mm 7 716 190 043 7 716 190 045 Part No. 150mm 7 716 190 043 7 716 190 045 7 716 190 046
150mm 3,000 1 up to 3 150mm 2,000 1 up to 2 2
Note: The maximum flue length must be reduced by the

following amounts for each bend used.
45º bend 90º bend
80/125mm flues 500mm 1,000mm
100/150mm flues 500mm 1,000mm
45
Greenstar floor standing boiler range
vertical fluing options (internal models)
The Greenstar regular and system boiler range has the Greenstar Danesmoor regular, Danesmoor System
choice of 2 differently sized vertical room-sealed flue & Danesmoor System Utility components
systems, 125mm and 150mm. Both systems have different Part No. Description
maximum lengths. 125mm diameter
Vertical balanced flue kit
Vertical room-sealed flue 7 716 190 103
(Danesmoor regular)
Flue diameter 125mm 150mm 7 716 190 033 1,000mm flue extension
Maximum flue length (inc. terminal) 7 716 190 097 600mm short flue extension
Danesmoor 12/18, 18/25 & 25/32 8,000mm† N/A
7 716 190 034 90º bend
7 716 190 035 45º bends (pair)
7 716 190 101 Flue damper
Flue terminal assembly diameter 138mm 163mm
7 716 191 090 Flashing – flat roof
†Flue damper (Part No 7 716 190 101) required at effective flue lengths >6m
7 716 191 091 Flashing – pitched roof
Note: The maximum flue length must be reduced by the Greenstar Utility regular components
Part No. Description
45º bend 90º bend
80/125mm flues 500mm 1,000mm 150mm diameter
100/150mm flues 500mm 1,000mm Vertical balanced flue kit

7 716 190 044 (Greenstar Utility regular)
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. 7 716 190 045 1,000mm flue extension
All components for the left horizontal and right horizontal outlet come within
the Greenstar Oilfit horizontal flue kit (150mm) for the Greenstar Utility regular 7 716 190 046 90º bend
32/50 and 50/70 models.
7 716 190 047 45º bends (pair)
7 716 191 101 Flashing – flat roof
7 716 191 100 Flashing – pitched roof
The following criteria should be noted when planning

the installation:
• To achieve a maximum flue length, one of the extension
flue kits will need to be cut so that the permitted
maximum flue length is not exceeded
• The concentric flue 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 efficiency, a
white plume of condensation will be emitted from the
terminal. Care must be taken when selecting the flue
terminal position
• Note: The short flue extension (600mm) may be used
as an alternative to the standard 1,000mm extension
on 80/125mm flue installations as required up to the
maximum flue lengths stated (Part No. 7 716 190 097).
46
Vertical flue options 1-2 illustrate common flue installations. Other configurations of the flue system are possible up to,
and not exceeding, the stated maximum flue lengths.
Option 1: Vertical balanced flue system minimum height Option 2: Vertical balanced flue system with two 90º bends
125mm 1,080 1 125mm 6,000† 1 up to 6 2

150mm 1,290 1 150mm 4,000 1 up to 4 2

†Flue damper (Part No 7 716 190 101) required at effective flue lengths >6m
Note: The maximum flue length must be reduced by the

45º bend 90º bend
80/125mm flues 500mm 1,000mm
100/150mm flues 500mm 1,000mm
47
Greenstar floor standing fluing options
(external models)
Greenstar Danesmoor External regular and Danesmoor System External boilers include a low level balanced flue kit.
Greenstar Danesmoor External regular Low-level left

and Danesmoor System External components
Top view
125mm diameter
Included Low level horizontal TOP
with boiler balanced flue kit 175mm VIEW
90º bend (internal)

7 716 190 034
required for fluing to left or right 240mm
FRONT
Components
Maximum lengths (mm) & no. of components required
Greenstar Danesmoor External regular &
Greenstar Danesmoor System External series
Part No. 125mm 7 716 190 034 7 716 190 050
Included
125mm 175 1 1
with boiler
Low-level rear Low-level right

Top view Top view
175mm 240mm
TOP
TOP VIEW 175mm
VIEW
240mm
FRONT FRONT
Greenstar Danesmoor External regular & Greenstar Danesmoor External regular &
Greenstar Danesmoor System External series Greenstar Danesmoor System External series
Part No. 125mm 7 716 190 050 Part No. 125mm 7 716 190 034 7 716 190 050
Included Included
125mm 175 1 125mm 175 1 1
with boiler with boiler
48
Plume management terminal positioning
All measurements in millimetres
±45°
Flue exhaust
outlet
2,500
Air intake
6
7
600 300
2
Balcony
150
100 200 300
600
150 600
600
1
3 Window Window Door Window
Boundary 300 4
150 150 200
25
Drainpipe
5
Note Key to illustration

• All measurements are the minimum clearances required 1. 600 mm distance to a boundary, unless it will cause
• Terminals must be positioned so as to avoid combustion a nuisance. BS 5410: Part 1 recommends that care is
products entering the building taken when siting terminals in relation to boundaries.
• Support the flue at approximately one metre intervals 2. Internal/external corners the air intake can be reduced
and at a change of direction. Use suitable brackets to 150mm providing the flue exhaust outlet has a
and fittings. 300mm clearance.
3. Vertical sanitary pipe: 25mm to the flue air intake and
300mm to the flue 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
flue exhaust outlet has a 600mm clearance. Plume kits
running horizontally must have a 10º fall back to the
boiler for proper disposal of condensate.
For details on specific lengths see relevant boiler
Technical & Specification manual.
7. 2,500mm between air intake and facing terminal.
49
Plume management system options
(internal models)
Greenstar Danesmoor regular At least
& Danesmoor System series 1,500mm

from any
opening in
the building
45°
V
Condensfit II™ plume management ™
system components
Part No. Description Direction of flue products, Opening in the
the angle of the terminal bend building i.e. air
must be more than 45° from brick, window.
80mm diameter the wall or structure
Plume terminal
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)
Re-directing flue discharge from an 80mm dia.

plume management outlet
Standard plume management system Plume management system measuring

The flue terminal outlet has built-in stops to limit rotation Note: All boilers have a maximum permissible
for horizontal fluing to allow condensate to run back into plume management length – see table below.
the boiler for safe disposal. Do not attempt to force beyond
the limit stops.
The first section of plume management flue up to the 500mm

(min) (M)
L (max)
first elbow must rise by at least 173mm per metre (10º)
from the terminal; subsequent sections must rise by 52mm
per metre (3º) to ensure that condensate flows back to
the boiler.
5,000mm
(max) (M)
L (max)
500mm (M)
Flue length Max. number Plume length Max. number

(L) of bends (M) 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 3
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 with extensions and two 45º bends Plume management system with extensions
Components
Greenstar Danesmoor regular, Danesmoor System,
Danesmoor External regular & Danesmoor System External series
Part No. 80mm 7 716 190 092 7 716 190 093
80mm 5,000 1 5
Components
Maximum lengths (mm) & no. of components required Greenstar Danesmoor
External regular & Danesmoor
Part No. 80mm 7 716 190 092 7 716 190 093 7 716 190 094 System External series
80mm 5,000 1 5 1
The plume management kit can be used on the Greenstar
Plume management system with extensions and 45º bend Danesmoor regular and System External models in
conjunction with the external low level horizontal flue kit.
±45°
M
Components
Part No. 80mm 7 716 190 092 7 716 190 093 7 716 190 094
Min. 150mm
80mm 5,000 1 5 1
Plume length (M) Max. number of bends

500 - 5,000mm 2
51
Conventional flue
Open (conventional) flued appliances must not be installed To convert the appliance to a conventional flue system the
in a bedroom, bathroom or bedsitting room. vertical flue adaptor needs to be specified:
• The flue system must be in accordance with BS 5410 and Part No. Description
the current Building Regulations. 100mm diameter
• The flue must be constructed of materials suitable for use 7 716 190 104
Greenstar Danesmoor
with condensing combustion products. (100/103mm) CF flue adaptor kit
• External flue systems must be of the insulated type. 7 716 190 065* 130mm adaptor
*Use in conjunction with 7 716 190 104 (100/103mm) CF flue adaptor kit
• Brick and masonry chimneys must be lined with a
suitable non-combustible material and properly jointed Part No. Description
to withstand the effects of the working temperature
130mm diameter
(minimum rating of material 120°C) of the appliance and
any condensate which may form. 7 716 190 049
CF flue adaptor kit
• All flue joints must be sealed to prevent the leakage of
condensate and combustion products. The flue must be constructed of materials suitable for the
• Ensure that joints are made so that the condensate runs use of condensing combustion products.
away and is not collected within the joint.
NOTE: The flue can be increased in size from the boiler D

E
take off point providing the joint is correctly sealed. Never
reduce the flue diameter from the boiler take-off point.
Conventional flue sizing

Output Diameter
12/18 100/103mm
18/25 100/103mm
25/32 130mm
32/50 130mm
50/70 130mm
• Because the flue operates at a lower temperature on a

condensing boiler compared to that of a conventional
appliance, the flue draught will be lower. Typically
the draught will be between 0.5mmwg and 4.4mmwg,
C
measured with the flue warm but the burner not firing.
The actual figure will vary depending on weather
conditions, flue height and position. B
• The flue should be vertical and contain as few bends as A

possible. A maximum of two 135° bends should be used.
• The flue outlet must be extended beyond the eaves of the

building and, where possible, above the apex.
A Boiler D Anti down-draught terminal
• Fit a suitable anti down-draught terminal where down B Flue E Chimney
draughts are experienced. C Maximum 2 bends at 135º
52
Greenstar Danesmoor regular and
Oilfit flexible flue liner Danesmoor System flexible flue liner components
The Oilfit flexible flue liner allows installation into a position
100mm diameter
where a standard efficiency appliance had previously
been installed. It achieves this by enabling a Greenstar 7 716 190 076 Oilfit flexible flue liner kit (8m)
condensing boiler to be open-flued up a chimney. The 7 716 190 077 Oilfit flexible flue liner kit (12m)
continuous flexible flue is installed from the roof, providing 7 716 190 066 1,000mm extension kit*
a condensate-proof lining for the chimney.
7 716 190 067 500mm extension kit*
7 716 190 068 Telescopic extension*

A roof terminal, extension pieces and a flue adaptor are
all included within the kit. The relevant conventional flue 7 716 190 069 45º bend*
adaptor kit is required to make the connection from the (100/103mm)

7 716 190 104
CF flue adaptor kit
boiler to the flexi-flue kit.
7 716 190 074 Wall cover plate kit
Conventional flexible flue liner kit Greenstar Utility regular flexible flue liner components
100mm dia. Oilfit flexible flue liner kit
Greenstar Danesmoor regular & Danesmoor System
1 x chimney cowl 130mm diameter
1 x terminal 7 716 190 079 Oilfit flexible flue liner kit (8m)
1 x support collar 7 716 190 080 Oilfit flexible flue liner kit (12m)
1 x support bracket assembly
7 716 190 081 Oilfit flexible flue liner kit (15m)
1 x centralising spacer
7 716 190 070 1,000mm extension kit*
1 x flexible to rigid adaptor kit (includes liner & seal)
1 x flexible liner 7 716 190 071 500mm extension kit*
1 x rigid to flexible adaptor kit (includes liner & seal) 7 716 190 072 Telescopic extension*
Part No. 7 716 190 076 (8m) 7 716 190 073 45º bend*
Part No. 7 716 190 077 (12m)
7 716 190 049 Conventional vertical flue kit
7 716 190 075 Wall cover plate kit

130mm dia. Oilfit flexible flue liner kit
*Stainless steel
Greenstar Utility regular 32/50 & 50/70 models
1 x chimney cowl
Model Flue diameter Maximum flue length
1 x terminal
Greenstar Danesmoor regular and
1 x support bracket assembly Danesmoor System series
1 x centralising spacer 12/18 100mm 12,000mm
1 x flexible to rigid adaptor kit (includes liner & seal)
18/25 100mm 12,000mm
1 x flexible liner
25/32 100mm 12,000mm
1 x rigid to flexible adaptor kit (includes liner & seal)
Greenstar Utility regular series
Part No. 7 716 190 079 (8m)
32/50 130mm 15,000mm
Part No. 7 716 190 080 (12m)
50/70* 130mm 15,000mm
Part No. 7 716 190 081 (15m)
*For 70kW adjust the first and second stage pump pressure to 125psi.
53
Typical installations
G
Open (conventional) flued 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 flexible flue pipe is only suitable for lining chimneys F
that conform to the Building Regulations and it should not E

L max
be used as a chimney on its own or outside a masonry or
flueblock chimney.
All the flexible liner and adaptors must be within the

chimney with rigid stainless steel flue pipe connecting to
the boiler.
D
The first 600mm of the stainless steel flue pipe off the
C **
boiler must be vertical with no bends or restrictions.
B
There must be at least a 25mm clearance between the

stainless steel flue pipe and any combustible material.
A
The data label must be secured onto the chimney or

chimney hearth using the plate provided.
A Boiler D Fire stop plate/inspection plate
B Stainless steel vertical section E Centralising spacer
If it is not possible to attach the plate to the chimney, (min. 600mm) F Flexible liner
the plate can be attached, in a visible position, next to C Maximum 2 bends at 45° G Chimney cowl
the electricity consumer unit.

Calculating the length:
Do not attach the data plate or label to the flue system. L maximum = boiler maximum minus 1m*.
(Each 45º bend has a 0.5m equivalent flue length)
The terminal should not be modified and an extra cowl or *If the chimney has an additional offset, then L will be reduced by an extra metre.
cover must not be fitted. The boiler is designed so that **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
any rain that enters the flue will be directed down to the section must be adequately supported.
condensate drain.
54
Greenstar system & regular
oil-fired boiler accessories
Digital plug-in 7 day twin Worcester
channel programmer Greenstar System Filter
CondenseSure siphon
(kitchen models only)
Worcester Part No. Worcester Part No. Worcester Part No.

7 716 192 033 7 716 192 746 7 716 192 609
Greenstar Oilfit internal flue system

Greenstar Danesmoor regular, Greenstar Danesmoor System
& Greenstar Utility regular internal series
Standard telescopic Short telescopic flue kit Standard flue kit Vertical flue kit
flue kit (125mm dia.) (125mm dia.) (150mm dia.) (125mm dia.) – Greenstar
Danesmoor models
Worcester Part No. Worcester Part No. Worcester Part No. Worcester Part No.
7 716 190 064 7 716 190 062 7 716 190 043 7 716 190 103
Vertical flue kit 1,000mm flue extension 600mm flue extension Infill plate kit for
(150mm dia.) – (125mm dia.) (125mm dia.) high level horizontal flues
7 716 190 044 7 716 190 033 7 716 190 097 7 716 190 105
55
Greenstar Oilfit internal
flue system continued
Greenstar Danesmoor regular, Greenstar Danesmoor System
& Greenstar Utility regular internal series
1,000mm flue extension 45º bend 45º bend 90º bend
(150mm dia.) (125mm dia.) (150mm dia.) (125mm dia.)
7 716 190 045 7 716 190 035 7 716 190 047 7 716 190 034
90º bend Conventional vertical Conventional vertical Conventional flue

(150mm dia.) flue kit (130mm dia.) – flue kit (100mm dia.) – 130mm adaptor –
Greenstar Utility Greenstar Danesmoor Greenstar Danesmoor
regular series regular & System regular & System
7 716 190 046 7 716 190 049 7 716 190 104 7 716 190 065
Flat roof flashing kit Pitched roof flashing kit Flat roof flashing kit Pitched roof flashing kit
7 716 191 090 7 716 191 091 7 716 191 101 7 716 191 100
Stainless steel flue Stainless steel flue

terminal guard terminal guard
(125mm dia.) (150mm dia.)
Worcester Part No. Worcester Part No.

7 716 190 050 7 716 190 051
56
Greenstar Oilfit flexible
flue kit accessories
Greenstar Danesmoor regular, Greenstar Danesmoor System &
Greenstar Utility regular internal series
Stainless steel Stainless steel Stainless steel
Oilfit flexible flue kit
1,000mm extension kit 500mm extension kit telescopic extension
Worcester Part No. Worcester Part No. Worcester Part No.

100mm dia. 100mm dia. 100mm dia.
7 716 190 066 7 716 190 067 7 716 190 068
Worcester Part No. 130mm dia. 130mm dia. 130mm dia.
100mm dia. 7 716 190 070 7 716 190 071 7 716 190 072
7 716 190 076 (8m)
7 716 190 077 (12m)
Stainless steel
130mm dia. Wall cover plate kit
45º bend
7 716 190 079 (8m)
7 716 190 080 (12m)
7 716 190 081 (15m)
Worcester Part No. Worcester Part No.

100mm dia. 100mm dia. flue
7 716 190 069 7 716 190 074
130mm dia. 130mm dia. flue
7 716 190 073 7 716 190 075
Greenstar Oilfit low level

external flue system
Greenstar Danesmoor External regular &
Greenstar Danesmoor System External series
Low level horizontal 90º bend* Stainless steel flue
flue kit (125mm dia.) (125mm dia.) terminal guard
Included with Worcester Part No. Worcester Part No.

external boilers 7 716 190 034 7 716 190 050
*Used inside boiler when fluing to
the side
57
Plume management accessories
Greenstar Danesmoor, Greenstar Danesmoor System,
Greenstar Utility internal, Greenstar Danesmoor External
& Greenstar Danesmoor System External series
Plume management kit 1,000mm extension 45º bend 90º bend

7 716 190 092 7 716 190 093 7 716 190 094 7 716 190 095
58
Total training experience
from Land’s End to John O’Groats
Worcester has always been committed to setting the College-linked Learning
industry standard for expert professional training and As well as offering training at our own centres, Worcester
this is reflected in the scope and content of the courses, has established close partnerships with many colleges
venues and options available. around the UK, equipping them with our latest products.
We offer training on our entire range of domestic and Worcester has worked closely with leading colleges and
commercial heating technologies as well as industry-led independent training centres for more than 20 years – a
courses. All tuition is handled by expert heating specialists, successful enterprise which in 2007 was enhanced further
combining classroom theory with, practical hands-on with the launch of the College Links Learning Scheme.
experience. Keep up-to-date with legislation and experience
hands-on-training with our new technologies. Mobile training
We can also bring training to you. We have mobile vehicles
To increase your skills, expertise and value in the fully equipped with operational Greenstar gas-fired boilers,
market place, trust Worcester’s unique and proven dry strip-down models and even a Greensource air to air
total training concept. heat pump. Our 7.5 tonne mobile oil vehicle is also available
for hands-on oil product training and OFTEC assessments.
Training centres throughout the UK
Worcester Call now for more information 0330 123 0166.
Worcester’s award-winning, state-of-the-art Training
Academy is an innovative and spacious high tech training
arena at our headquarters in Worcester. Facilities include
open-plan domestic training areas with life-size single- Training centres
T
storey brick buildings. Here installers can get to grips with College links
training centres
Greenskies solar thermal systems working with Greenstar
gas appliances, clearly demonstrating the importance of
system design and operation.
Elgin
Wakefield
Opened in Summer 2013, the Wakefield Training and Dundee
Assessment Academy boasts a large gas laboratory which
Fife
features our entire range of Greenstar gas-fired appliances,
Johnstone
a flushing area, wet and dry boilers and a light commercial Borders
Ayr
area with a cascade of Worcester GB162 boilers. There is a
solar room with fully working components from our entire Durham
Workington
Greenskies solar range and a pitched roof for practical Belfast
training, as well as a large commercial training room.

Burnley
Dublin Wakefield
W
West Thurrock and Clay Cross
Clay Cross
Further academies are located at West Thurrock in
Wrexham
Essex and Clay Cross in Derbyshire, both of which offer
a comprehensive choice of courses. Worcester Cambridge
Tredegar
West Thurrock
Wiltshire
Camborne Paignton
59
Oil-fired product courses
Worcester’s oil manufacturing heritage stretches back to A requirement of Building Regulations 2001 - Part L
the foundation of the company in 1962. Since then, we (England and Wales) and Part J (Scotland) is that every
have built a strong reputation for not only manufacturing boiler installation must be self-certified by an installer
products at the highest levels of quality and reliability, who is OFTEC registered. Worcester can offer this OFTEC
but also for training installers, commissioning engineers training, with a variety of courses to choose from.
and operatives.
Oil-fired condensing boiler course
Our oil-fired boiler training courses are extensive, covering Greenstar Danesmoor and Heatslave II high efficiency
areas such as dismantling a jet burner, setting oil pump condensing oil-fired boiler training.
pressures, maintaining a condensate trap, the relationship Oil advanced fault-finding.
between air and oil supplies, as well as the detection
of intermittent faults. Our advanced fault-finding course OFTEC training and assessment courses
has been designed for installers and heating engineers OFTEC 50.
who are already knowledgeable on our range of oil-fired OFTEC 101 & 105e, OFTEC 600a and
products. Our expert trainers will further increase your OFTEC 101/105e/600a.
experience, whilst also providing a strong understanding
of fault-finding techniques.
Oil-fired Oil Advanced OFTEC OFTEC OFTEC 101/

OFTEC 50
Course Fault Finding 101 & 105e 600a 105e/600a
Duration 1 Day 1 Day 5 Days 4 Days 1 Day 4 Days
Cost Free* £65 £600 £350 £175 £500
Training course covers
Specification D U A preparatory
course for OFTEC Domestic/light
Installation D U assessment commercial
Oil tank installation Combined OFTEC
Commissioning D D courses.
(Price of course
pressure jet
commissioning,
and associated
controls
101, 105e and
600a courses
Servicing D D includes all
necessary OFTEC
servicing and boiler
installation
Maintenance D D text books).
Course locations
Worcester D D D D D D
Clay Cross D D D D D D
Wakefield D D D D D D
West Thurrock D D D D D D
College Links† D D D D D D
Mobile† D D D D D D
*A holding fee of £65 applies to free courses and is refunded on attendance of the course. If a booking is cancelled more than 10 working days before
the course date, the fee will be fully refunded. The fee is non-refundable if a cancellation is made less than 10 working days before the course date.
†Please contact Worcester Training for specific colleges and mobile dates.
To complement the above courses, Worcester also runs unvented, water treatment, Domestic ACS training and
assessment, IDHEE domestic heating design, MCS Made Easy and Green Deal 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-fired 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.
60
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. Call us on 0330 123 0166 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
Gas-fired condensing boiler courses Worcester commercial product courses

• Greenstar CDi Classic gas-fired condensing • Greenspring CWi47 water heater.
combi boilers. • GB162 overview.
• Greenstar CDi Compact and Greenstar Si Compact • GB162 domestic.
gas-fired condensing combi boilers. • GB162 commercial.
• Greenstar i gas-fired condensing combi boilers. • Greenstar Heat Distribution Unit.
• Greenstar system & regular gas-fired condensing boilers. • Commercial ACS training and assessment – CODNCO1.
• Greenstar Highflow CDi & FS CDi Regular floor standing
gas-fired condensing combi and regular boilers. Bosch commercial product courses
• Greenstar Controls • GB312 & GB402 overview.
(covers MT10, MT10RF, NEW Greenstar Comfort range, • Solar thermal product overview.
NEW Wave internet connected room thermostat, FR10, • GWPL Gas Absorption Heat Pumps overview.
FR110, FW100, and solar controls). • CHP overview.
• Commercial controls overview.
Renewable product courses
• Renewables overview. Industry focused courses
• Greenskies solar. • Hot water systems & safety.
• Greenskies advanced solar. • Chemical water treatment.
• Introduction to heat pumps. • Construction skills F-Gas training/assessment
• Greenstore LECP ground source heat pumps. certification.
• Greensource air to air heat pumps. • IDHEE domestic heating design.
• Domestic ACS training and assessment – reassessment.
CCN1 + 3 appliances.
• QCF Level 3 Award
– Air source and ground source heat pumps.
– Air to water and split air to water heat pumps.
– Solar thermal.
• MCS Made Easy.
• Green Deal.
• LPG Changeover.
• WRAS Water Regulations.
61
A complete after-sales service
As part of the worldwide Bosch Group, Worcester strives to Spares

maintain the highest possible standards of after-sales care. Genuine replacement parts for all supported Worcester
products are readily available from stock, or on a next day
Worcester Contact Centre delivery basis. Visit www.worcester-bosch.co.uk/spares
Should you require support, our award winning Contact to find your local stockist.
Centre team, based at our head office in Worcester, are
ready to take your calls. Whatever your query our contact Customer Technical Support
centre operators along with our nationwide team of The Worcester Technical Helpline is a dedicated phone
engineers are ready to help you. line – committed to providing a comprehensive service to
complement the brand name and quality of our products.
Tel: 0330 123 9559 Our experienced team of technical experts provides
answers to queries of a technical nature across the entire
Opening times Worcester range.
Monday – Friday: 7.00am – 8.00pm
Saturday: 8.00am – 5.00pm Technical Support
Sunday: 9.00am – 12 noon Tel: 0330 123 3366
Bank Holidays: 8.00am – 4.30pm Fax: 01905 752 741
Email: technical-advice@uk.bosch.com
Opening times
Monday – Friday: 7.00am – 8.00pm
Saturday: 8.30am – 4.00pm
Bank Holidays: 8.00am – 4.30pm
ErP Technical Helpline

Tel: 0330 123 3641
Email: ErP-advice@uk.bosch.com
62
Notes
63
Useful numbers Customer Service
Sales Engineer Appointments
Tel: 0330 123 9669 Email: service-appointment@uk.bosch.com
sales.mailbox@uk.bosch.com or telephone 0330 123 9339
Spare Parts Service Enquiries

Tel: 0330 123 9779 Email: service-enquiries@uk.bosch.com
spares.mailbox@uk.bosch.com or telephone 0330 123 9559
Technical Helpline (Pre & Post Sales) Guarantee Registration

Tel: 0330 123 3366 To register your Worcester guarantee,
technical-advice@uk.bosch.com please visit our website
www.worcester-bosch.co.uk/registration,
Renewables Technical Helpline
download our guarantee
Email: renewable-advice@uk.bosch.com
registration app or
or telephone 0330 123 9229
telephone 0330 123 2552
ErP Technical Helpline
Guarantee
Tel: 0330 123 3641 app
ErP-advice@uk.bosch.com
Training
Tel: 0330 123 0166
training@uk.bosch.com
Literature
Email: brochure-request@uk.bosch.com
or download instantly from our website
or telephone 0330 123 9119
Calls to 03 numbers cost no more than a national rate call to an 01 or 02 number and must count towards any inclusive minutes in the same way as 01 and 02 calls.
These rules apply to calls from any type of line, including mobile, BT, other fixed phone line or payphone. 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.
worcester-bosch.co.uk
In partnership with
NG & EN
EATI VIR
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ON
I
TE O OMEST
D H E
MEN
I E
TAL ENG
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ITU
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INS S
1964
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.

This leaflet is accurate at the date of printing, but may be superseded and should be disregarded if specification and/or appearances are changed in the interest
BBT3739
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Greenstar Oil System and Regular Boilers Technical and Specification Information

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Greenstar Oil System and Regular Boilers Technical and Specification Information

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Technical and Specification Information Greenstar Danesmoor regular series

Greenstar Danesmoor System series

Greenstar regular and system

The Greenstar regular and system oil-fired range at a glance

Output kW to Min 12kW 18kW 25kW

Output kW to Min 12kW 18kW 25kW

Output kW to Min 32kW 50kW

Whilst offering many of the features of the internal

Greenstar Oilfit – the easy-fit fluing solution

Greenstar Danesmoor External regular

Greenskies Solar-Lux, Solar-Lifestyle, Solar-Lito

Given the competitive nature of the heating industry, Worcester

At Worcester, we pride ourselves on the hard work that goes on

For example, within the product reliability department, every

We collect information on each individual component when we

Did you know?

8 *Source: Worcester Customer Satisfaction Index 2011

Cleaning the primary heat exchanger is now made easy

Further improvements include an oil line which is run

Finally, the Greenstar Danesmoor boilers retain the

What is Energy Labelling?

The new Energy Labelling Directive will introduce

The person who puts that package together will

For example, this could be the merchant’s

ErP easy as ABC with Worcester

The Energy Labelling obligation under the

ErP Technical Support: 0330 123 3641

Flow 1" BSP

Burner lead Flue manifold and

Primary heat exchanger Oil supply

Greenstar Danesmoor Greenstar Danesmoor Greenstar Danesmoor

Optional plug-in twin channel digital controls 9 9 9

Flow 1" BSP Flue gas analyser

Greenstar Danesmoor Greenstar Danesmoor Greenstar Danesmoor

Optional plug-in twin channel digital controls N/A N/A N/A

Maximum primary static head 30m 30m 30m

Flow 1" BSP Flue gas analyser

Temperature control Service mode switch

Flue overheat reset button

Primary heat exchanger

Oil supply isolating valve

Greenstar Danesmoor Greenstar Danesmoor Greenstar Danesmoor

Return Flue gas analysis point

Service access door to

Lock out reset button Flow

Burner control box

Burner Burner lead

Temperature Overheat thermostat Flue gas

Greenstar Utility regular fascia

Pressure relief valve

Flue gas analyser

Temperature control Lock-out indicator

Flue gas analyser

Flue overheat reset button

Boiler overheat reset button

ErP compliant low energy

Expansion vessel bracket

Greenstar Danesmoor Greenstar Danesmoor Greenstar Danesmoor

Optional plug-in twin channel digital controls 9 9 9

Pressure relief valve

Flue gas analyser

Flue overheat reset button Flue gas analyser

System pressure gauge

Primary heat exchanger

Bird's eye view 50mm Bird's eye view 50mm