INSTRUCTION MANUAL FLUE KIT INSTALLATION 7 716 191 155 7 716 191 086 ROOM SEALED TELESCOPIC FLUE PLUME MANAGEMENT SYSTEM 60/100 HORIZONTAL FLUE FOR USE WITH WORCESTER APPLIANCES: Greenstar FS 30CDi Regular, Greenstar FS 42CDi Regular, Greenstar Highflow 440CDi, Greenstar Highflow 550CDi. DO NOT USE WITH ANY OTHER MODEL OF APPLIANCE. UK/IE 8 718 682 335b (09.
CONTACT INFORMATION WORCESTER, BOSCH GROUP: MAIN RECEPTION: 01905 754624 MAIN FAX: 01905 754619 TECHNICAL SUPPORT: 08705 266241 SERVICE: 08457 256206 SPARES: 01905 752571 LITERATURE: 01905 752556 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: www.worcester-bosch.co.uk INSTALLATION INSTRUCTIONS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. THESE INSTRUCTIONS ARE APPLICABLE ONLY TO THE PRODUCT(S) STATED ON THE FRONT COVER OF THIS MANUAL.
SAFETY & REGULATIONS CONTENTS SAFETY & REGULATIONS 2 INSTALLATION REGULATIONS 2 PRODUCT INFORMATION SAFETY PRECAUTIONS ROOM SEALED TELESCOPIC FLUE: TELESCOPIC FLUE COMPONENTS 3 FLUE EXTENSION COMPONENTS 4 PREINSTALLATION PRODUCT INFORMATION PRE-INSTALLATION TERMINAL OUTLET POSITIONS FLUE LENGTHS FLUE MEASURING & CUTTING 5, 6, 7 8 9, 10 11 EXTENDED FLUE INSTALLATION 12 FLUE TERMINAL PLUME MANAGEMENT 13 COMMISSIONING STANDARD FLUE INSTALLATION INSTALLATION INSTALLATION PLUME MANAGEMENT
SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: Failure to install correctly could lead to prosecution. DON'T SMOKE OR STRIKE MATCHES. DON'T TURN ELECTRICAL SWITCHES ON OR OFF. DO PUT OUT NAKED FLAMES. DO OPEN DOORS AND WINDOWS. DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED. DO TURN OFF THE CONTROL VALVE AT THE METER.
TELESCOPIC FLUE COMPONENTS A Ø60/100mm TELESCOPIC FLUE KIT: Part Number: 7 716 191 155 including: A TELESCOPIC FLUE ASSEMBLY: C FLUE CONNECTOR. D FLUE ADAPTOR. E WALL SEAL INNER. F WALL SEAL OUTER. G ACCESSORY PACK. H INSTALLATION INSTRUCTIONS & CHECK LIST. C PRODUCT INFORMATION B 93° ELBOW. B J ALUMINIUM TAPE. D E F G H J INSTALLATION INSTRUCTIONS 8 718 682 335b (09.
FLUE EXTENSION COMPONENTS A Ø60/100 990mm EXTENSION KIT: Part Number: 7 716 191 083 including: PRODUCT INFORMATION A EXTENSION TUBE ASSEMBLY. E GREASE PACK, CONTAINING 2 No.8. SCREWS & GREASE SACHET. Ø60/100 220mm SHORT FLUE EXTENSION: B Part Number: 7 716 191 133 B E GREASE PACK. Ø60/100 90° BEND: Part Number: 7 716 191 084 including: C 90° BEND ASSEMBLY. E GREASE PACK, CONTAINING 2 No.8. SCREWS & GREASE SACHET. Ø60/100 45° BEND: Part Number: 7 716 191 085 including: D 45° BEND x2.
TERMINAL OUTLET POSITIONS REDIRECTING FLUE DISCHARGE FROM A Ø60/100mm TELESCOPIC FLUE TERMINAL REDIRECTING THE FLUE DISCHARGE: Opening in building Min. 1500mm Direction of flue discharge Plume deflector INSTALLATION INSTRUCTIONS 8 718 682 335b (09.
• The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1. • The flue must not cause an obstruction. • Discharge and any noise from the flue outlet must not cause a nuisance. • Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet. Where this could be a nuisance, for example, near security lighting, an alternate position should be found.
00mm DORMER WINDOW VELUX WINDOW 1500mm between a vertical flue terminal and a window or dormer window PREINSTALLATION 1500mm 400mm 400mm from a pitched roof or in regions with heavy snow fall 500mm 2000mm below a Velux window, 600mm above or to either side of the Velux window The flue cannot be lower than 1000mm from the top of a light well due to the build up of combustion products 1200mm 300mm RAINPIPE 1200mm between terminals facing each other 300mm 300mm to an internal or external corner 150
FLUE LENGTHS 1 L Ø60/100mm HORIZONTAL TELESCOPIC FLUE LENGTHS: The maximum effective straight flue lengths (L) are stated opposite for the relevant appliance and must not be exceeded. 1 Measure the total straight length (L) along the flue route, then add the following to length (L) to check the maximum flue length is not exceeded: 2000mm for each 90° bend.
FLUE MEASURING & CUTTING 1 Flue bends: 1 950mm 1145mm Connecting flue bends increases the effective pipe length and an allowance must be made for the different connectors. The example opposite shows dimensions for two 90° bends connected to a standard flue extension. Adjusting the standard terminal length: 2 530mm Secure with screw provided and seal joint with the aluminium tape supplied.
FLUE MEASURING & CUTTING Y Y FLUE OUTLETS (X or Y): X 1 2 3 Remove seal (B) from flue adaptor (A). Cut square to mark, as shown, deburr and clean. Replace seal (B). 2 X 1 A B INSTALLATION 3 2 Y 1 A B 3 B C CONVERT FROM REAR FLUE OUTLET: E D The boiler is supplied ready to fit a rear flue outlet. To flue from the sides or top of the boiler, follow the procedure below: 1 Remove the required side or top 'knock-out' panel (A) from the outer casing (B).
STANDARD FLUE INSTALLATION 1 NOTE: to ease assembly of the flue components, grease seals lightly with the solvent-free grease supplied. B Check all the seals are seated properly in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products. Installing the standard flue: 2 1 Set the flue terminal (B) to the distance required, secure with screw and seal joint with the aluminium tape supplied.
2m EXTENDED FLUE INSTALLATION 1m 52mm NOTE: to ease assembly of the flue components, grease seals lightly with the solvent-free grease supplied. 104mm Check all the seals are seated properly in the grooves provided and are in good condition. TOP D B C All flue joints must be sealed to prevent leakage of condensate and flue products.
FLUE TERMINAL PLUME MANAGEMENT The flue discharge can be redirected allowing some plume management control, alternatively, a complete plume management system can be fitted to the flue terminal. 2 A Redirecting the flue discharge: Important: should you wish to use the plume deflector please use the additional grease enclosed to ensure that an adequate seal is retained. 1 1 Remove screws (A) and terminal end (B).
A PLUME MANAGEMENT SYSTEM COMPONENTS COMPONENTS Ø60mm PLUME MANAGEMENT KIT: Part Number: 7 716 191 086 including: PRODUCT INFORMATION A TERMINAL BEND B B EXTENSION 500mm C OUTLET ASSEMBLY D CLAMP PACK C D EXTENSION COMPONENTS: Ø60mm EXTENSION: E Part Number: 7 716 191 087 including: E EXTENSION 1000mm F CLAMP PACK F 90° BEND: Part Number: 7 716 191 088 including: G 90° BEND 45° BEND: Part Number: 7 716 191 089 including: H 45° BEND x2 G H 14 PLUME MANAGEMENT SYSTEM COMPONENTS INSTALLATION I
FLUE LENGTHS Ø60/100mm HORIZONTAL TELESCOPIC FLUE LENGTHS with a Plume Management System: The maximum effective straight flue lengths (L) are stated opposite for the relevant appliance together with the length (M) of the Plume Management system connected, these lengths must not be exceeded. A M min. 500mm max.
• The flue must be fitted and terminated in accordance with the recommendations of BS5440 : Part 1. • The flue must not cause an obstruction. • Discharge and any noise from the flue outlet must not cause a nuisance. • Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation will be discharged from the flue outlet. Where this could be a nuisance, for example, near security lighting, an alternate position should be found.
PREINSTALLATION TERMINAL OUTLET POSITIONS The flue cannot be more than 1000mm from the top of a light wall due to build-up of combustion 1,000mm 1200mm 1,200mm between terminals facing each other. The plume kit can flue through a flat roof, providing it is open to the sides or ends & the hole is suitably weatherproofed. Ensure that clearance from openings etc. are maintained. 300mm 300mm 200mm 150mm 300mm 150mm 300mm Clearances less than 200mm from lowest part of balcony or overhang.
PLUME MANAGEMENT OPTIONS & MEASURING C A C A M Min. 500mm B D The diagrams (opposite) show the components required for typical plume management configurations. D B M H IMPORTANT: All plume management sections must rise away from the terminal by a minimum of 173mm per metre (10°) to allow the condensate to drain back to the boiler.
STANDARD PLUME MANAGEMENT INSTALLATION NOTE: to ease assembly of the flue components, grease seals lightly with the solvent-free grease supplied. Check all the seals are seated properly in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products. 4 Fitting the standard plume management system: 3 F 1 Remove screws (C) and discard the complete terminal end (D).
EXTENDED PLUME MANAGEMENT INSTALLATION E NOTE: to ease assembly of the flue components, grease seals lightly with the solvent-free grease supplied. C Check all the seals are seated properly in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products. 2 1 Remove screws (C) and discard the complete terminal end (D). 2 Fit the terminal bend (E) to the terminal outlet and secure reusing screws (C).
SERVICING & SPARE PARTS SERVICING & MAINTENANCE: The plume management kit must be visually inspected - annually. DO NOT paint the plume management kit! SPARE PARTS: Ø60/100mm Telescopic horizontal flue: 1 2 3 1 Flue Connector: Part No. 8 716 114 137 0 2 Flue adaptor: Part No. 8 718 680 382 0 3 Terminal outlet assembly: Part No. 8 716 111 209 0 5 Part No. 8 716 111 211 0 5 Wall seal outer: Part No.
Dedicated to heating comfort Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 22 8 718 682 335b (09.
