Applicable - Worcester Highflow 400 RSF Installation And Servicing Instructions

Withdraw the two securing clips from the pump body.
East the pump forwards about 10mm off the "O" ring seals. It is
not necessary to disconnect the electrical cable. The cable is
sufficient to allow the pump head to rest on top of the appliance.
Do not allow the pump head to be suspended by the cable.
Secure the pump head. See Figs. 18 and 45.
NOTE: INTERNAL FLUE FITTING KIT.
If the Internal Flue Fitting Kit is to be used refer to Section 11.7
following describing the assembly of the flue components and
fitting the Internal Flue Kit.
GENERAL INFORMATION AND GUIDE LINES FOR ALL FLUE
OPTIONS.
Check the contents of the standard flue kit and extension flue kit
or kits against the respective packing list.
Remove ALL packaging from the ducts, flue bend or bends and
flue terminal assemble.
N.B. The size of the Air Duct is 100 mm diameter and Flue Duct
60 mm diameter.
IMPORTANT: The air duct, flue duct and flue bend/bends are
manufactured from aluminium and must be handled with care.
Measure and cut the air and flue ducts to length ensure the cuts
are square and free from burrs. Always check the dimensions
before cutting the duct.
Do not cut the expanded end of the extension air or flue ducts
unless instructed otherwise.
The air and flue ducts supplied with the standard flue kits must
be adjacent to the flue adaptor or first flue bend. See Fig. 22 or 23.
The flue adaptor,supplied with the Standard Horizontal Rear Flue
Kit, must be fitted for Flue Option 1 and 3. See Fig. 5.
Other flue options, that require a horizontal section of flue duct
fitted directly to the rear of the appliance, must be fitted with a
flue adaptor. See Fig. 5 Frame 9.
The flue adaptor is also available as an optional extra. See Fig. 5
Frame 9 and refer to Section 5b Option 9.
Fit the flue adaptor into the flue sealing grommet located on the
rear of the inner casing. Ensure it is located correctly against the
stop. Tighten the clamping screw located on top of the inner
casing. See Fig. 14.
When assembling extension air and flue ducts ensure the ducts
are correctly located in the socketed joints. See Fig. 23.
Measure the length of the air and flue ducts from the end that
will be fixed into the adaptor or flue bend fitted to the appliance.
Before cutting the air or flue ducts ensure the final expanded
section is at least 100 mm clear of the flue terminal end or flue
bends. If it is not reduce the length of the adjacent air and flue
ducts by cutting off from the non-expanded end the amount
necessary to give the minimum clearance. See Fig. 23.
Take care to seal all the flue joints where indicated. See Fig. 23.
To seal the flue joints disengage the joint and apply a smear of
silicone sealant around the duct. See Fig. 23.
If the flue assembly is longer than 1500 mm the flue duct must
be supported within the air duct with a flue spacer available as
an optional extra. See Fig. 23.
On final assembly the air duct must be adequately supported.
Air duct support brackets are available as an optional extra.
See Section 5b for flue spacer and air duct support bracket part
number.
Flue Restrictor Rings are supplied with the hardware pack. A
restrictor ring must be fitted into the flue terminal the size will
depend on the Flue Option chosen. Refer to the following table for
restrictor size. When fixing the flue restrictor ring refer to Fig. 24.
NOTE: For flue options using two or three flue bends the
restrictor rings are NOT required and MUST be discarded.
The optimum route for the flue must be measured and sufficient
extension flue/flues and other components ordered to install the
flue satisfactory.
Flue Flue Length or
Option Total Straight Flue
Length (mm)
1 100 to 1000
2 100 to 1000
3 1000 to 3000
4 1000 to 3000
5 100 to 2300
6 100 to 2300
7 100 to 1000
8 100 to 1000
See Section 5b for parts identification and part numbers.
Because of site conditions it may be necessary to deviate from
the following method of installation. Joints must be sealed and
fixed where applicable.
Now turn to the appropriate section to install the flue system:
Section 11.4 Standard Horizontal Rear Flue Assembly.
Section 11.5 Standard Horizontal Side Flue Assembly including
one 90° Flue Bend.
Section 11.6 Fitting Extension Flues and Extra 90° Flue Bend or
Bends.
11.4 STANDARD HORIZONTAL REAR FLUE.
(FLUE OPTION 1). See Fig.19.
IMPORTANT: (i) A flue restrictor ring MUST be fitted in the flue
terminal. Refer to Section 11.3 for the correct
size and the following instructions for fixing.
See Fig. 24.
(ii) The flue adaptor MUST be fitted to connect the
flue system to the appliance. See Fig. 21. Refer
to Section 11.3 and the following instructions
for fixing.
AIR AND FLUE DUCT PREPARATION.
The standard flue assembly, supplied with the appliance,
accommodates a maximum flue length of 500 mm measured
from the REAR of the appliance casing. See Fig. 19.
HORIZONTAL REAR FLUE ASSEMBLY.
Measure accurately the distance from the rear of the appliance,
previously marked on the floor, to the outside surface of the wall.
Dimension A. See Fig. 19.
Air duct length = A + 188 mm
Flue duct length = A + 228 mm.
Cut air and flue ducts to length. Do not cut the drilled end of the
air duct.
IMPORTANT: Fit the flue restrictor ring marked 72 into the flue
terminal. See Fig. 24.
Assemble the air duct to the flue terminal. Ensure it fits fully into
the flue terminal and the restrictor ring is located firmly between
the end of the air duct and flue terminal. See Fig. 24.
Drill through the holes in the flue terminal into the air duct with
the drill provided. Apply a smear of silicone sealant to the end of
the air duct and fix into the flue terminal using the screws
provided. See Fig. 21.
Fit the flue duct into the extended end of the flue adaptor, ensure
it is located correctly against the stop. Drill two holes through
the holes in the flue adaptor. See Fig. 21.
Fit the air duct over the outside of the flue duct and onto the flue
adaptor.
Ensure it is located correctly against the stop and the flue duct
fits into the flue terminal. Drill two holes through the holes in the
air duct. See Fig. 21.
Disconnect the air and flue ducts from the flue adaptor.
Apply a smear of silicone sealant around the outside of the flue
duct.Fit the flue duct into the flue adaptor and fix with the
screws provided. See Fig. 21.
20
Flue Restrictor
Size mm (dia.)
72
75
75
77
Not required
Not required
Not required
Not required