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FLUE KIT INSTALLATION MANUAL
7 716 191 082 ROOM SEALED TELESCOPIC FLUE
7 716 191 171 ROOM SEALED LONGER TELESCOPIC FLUE
7 716 191 086 PLUME MANAGEMENT SYSTEM
GREENSTAR
60/100 HORIZONTAL FLUE
FOR WORCESTER GREENSTAR CDi WALL HUNG, Si, i JUNIOR, i SYSTEM & Ri SERIES
OF GAS APPLIANCES INCLUDING BRITISH GAS VARIANTS
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Table of Contents
Related Manuals for Bosch WORCESTER Condensfit II GREENSTAR 60/100 HORIZONTAL FLUE
Summary of Contents for Bosch WORCESTER Condensfit II GREENSTAR 60/100 HORIZONTAL FLUE
- Page 1 FLUE KIT INSTALLATION MANUAL 7 716 191 082 ROOM SEALED TELESCOPIC FLUE 7 716 191 171 ROOM SEALED LONGER TELESCOPIC FLUE 7 716 191 086 PLUME MANAGEMENT SYSTEM GREENSTAR 60/100 HORIZONTAL FLUE FOR WORCESTER GREENSTAR CDi WALL HUNG, Si, i JUNIOR, i SYSTEM & Ri SERIES OF GAS APPLIANCES INCLUDING BRITISH GAS VARIANTS...
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Page 2: Table Of Contents
CONTENTS CONTENTS KEY TO SYMBOLS AND SAFETY PRECAUTIONS Explanation of symbols ....3 Safety precautions ....4 PRODUCT INFORMATION . -
Page 3: Key To Symbols And Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS KEY TO SYMBOLS AND SAFETY PRECAUTIONS EXPLANATION OF SYMBOLS WARNING SYMBOLS SYMBOLS Cutting required Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background. Electrical hazards are identified by a lightning symbol surrounded by a warning Cutting not required... -
Page 4: Safety Precautions
KEY TO SYMBOLS AND SAFETY PRECAUTIONS SAFETY PRECAUTIONS Flue systems must not be modified in any way other than as described in the fitting instructions. Any misuse or IF YOU SMELL GAS: unauthorised modifications to the appliance, flue or B CALL NATIONAL GAS EMERGENCY SERVICE ON associated components and systems could invalidate 0800 111 999 the warranty. -
Page 5: Product Information
PRODUCT INFORMATION PRODUCT INFORMATION TELESCOPIC FLUE COMPONENTS FLUE EXTENSION COMPONENTS 60/100mm - 220mm Part No.: 7 716 191 133 60/100 mm TELESCOPIC FLUE KIT: Extension tube assembly plus: grease pack - Part No.: 7 716 191 082 two No. 8 screws & grease sachet 60/100 mm LONGER TELESCOPIC FLUE KIT: 60/100mm - 1000mm Part No.: 7 716 191 083... -
Page 6: Pre-Installation
PRE-INSTALLATION PRE-INSTALLATION FLUE TERMINAL POSITIONS All measurements in millimetres Dormer Window 1,500 Velux Window Drainpipe 1,200 1,500 Boundary Window 6720643895-13.1Wo Fig. 3 Flue terminal positions NOTE: B All measurements are the minimum clearances required. B Terminals must be positioned so to avoid combustion products entering the building. B Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings (Flue bracket part numbers.: 100mm - 7 716 191 092. - Page 7 PRE-INSTALLATION FLUE SYSTEMS IN VOIDS When installing a new flue system consider the following information. CAUTION: Flue systems in ceilings or roof voids. Where a flue system is not going to be accessible, provision for access must be made for service and inspection: B Voids containing concealed flues must have at least one inspection hatch no less than 300mm square.
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Page 8: Flue Measuring And Cutting
PRE-INSTALLATION FLUE MEASURING AND CUTTING NOTE: FLUE LENGTH B Do not exceed the maximum straight length for a horizontal 60/100mm flue or a 60mm plume management system (if used) as stated in the relevant Installation, Commissioning & Servicing Instructions manual or addendum. Cutting the flue to an exact measurement is not normally required as the telescopic flue terminal can allow for some adjustment. -
Page 9: Flue Length Guide
PRE-INSTALLATION 3.3.2 FLUE LENGTH GUIDE 45° BENDS Flue length range (mm) Cut Number of extensions This application can only be used with the 130 - 265 None Si, i Junior and i System boilers. 350 - 570 None Figure 7 shows a possible application for a 45° bend 570 - 790 None that could be used if fluing from the right or left from the... - Page 10 PRE-INSTALLATION REDUCING THE TELESCOPIC FLUE LENGTH From standard telescopic flue Ensure that the TOP label of both sections are aligned before securing the two parts at 265 mm the required length. The flue terminal MUST be fitted with the 'TOP' label uppermost to allow the correct fit and use of the plume management system.
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Page 11: Installation
INSTALLATION INSTALLATION TELESCOPIC FLUE INSTALLATION 4.1.1 INSTALLING THE TELESCOPIC FLUE: B When using a 100 mm diameter flue, a 125mm diameter hole through the wall is required. However, if installing the flue from inside the property and fitting the weather sealing collar before the flue is pushed through the hole, then a 150 mm diameter hole is required. -
Page 12: Flue Terminal Plume Re-Direction
INSTALLATION 1. Referring to figure 16, fit the telescopic flue firmly 4.1.3 FLUE TERMINAL PLUME RE-DIRECTION into the 90° bend. The flue discharge can be re-directed to allow some 2. Fit the 90° bend firmly into the extension piece. plume redirection control. Alternatively, a complete plume management system can be fitted to the flue 3. -
Page 13: Extended Flue Installation
INSTALLATION 4.1.4 EXTENDED FLUE INSTALLATION NOTE: OUTLET POSITIONS NOTE: CONDENSATE DISPOSAL B The flue terminal outlet position must B All horizontal flue sections must rise by at follow those stated in figure 3. least 52mm per metre away from the When redirecting the flue discharge the boiler to ensure that the condensate terminal end must be at least 1500mm... - Page 14 INSTALLATION INSTALLING AN EXTENDED FLUE B Refer to figure 23 and slide the support clamps (1) onto the additional flue extensions (2). The flue terminal MUST be fitted with the 1. Working from the boiler, fit the support clamps (1) “TOP”...
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Page 15: Product Information
PRODUCT INFORMATION PRODUCT INFORMATION PLUME MANAGEMENT SYSTEM COMPONENTS PLUME MANAGEMENT COMPONENTS EXTENSION COMPONENTS Ø 60mm PLUME MANAGEMENT KIT comprising: Ø 60mm EXTENSION comprising: Part No.: 7 716 191 086 Part No.: 7 716 191 087 Terminal bend Extension 1000mm Extension 500mm Clamp pack Outlet assembly 90°... -
Page 16: Pre-Installation
PRE-INSTALLATION PRE-INSTALLATION PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres ±45° Plume management deflector: Flue Exhaust Outlet 180° Air Intake ±80° 1,200 Balcony Window Window Window Door Boundary Drainpipe 6720643895-14.1Wo Fig. 27 Plume terminal positions NOTE: B Refer to figure 3 for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume terminal positions”. -
Page 17: Plume Management Options & Measurement
PRE-INSTALLATION PLUME MANAGEMENT OPTIONS & MEASUREMENT NOTE: PLUME MANAGEMENT B 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. The figure 28 shows the components required for typical plume management configurations. -
Page 18: Determine The Plume Management
PRE-INSTALLATION 6.2.1 DETERMINE THE PLUME MANAGEMENT SYSTEM LENGTH Fig. 32 Effective lengths L and M Maximum Plume Length 8,000 for all boilers 7,000 6,000 27CDi 5,000 Si, i Junior, i System & Ri 4,000 30CDi Regular, System & 3,000 BG430/i 30CDi 2,000 BG532/i... -
Page 19: Measuring For A Plume Management
PRE-INSTALLATION 6.2.2 MEASURING FOR A PLUME MANAGEMENT SYSTEM All boilers have a maximum permissible plume management length, refer to figure 33. 1. Measure the plume management flue (M) from the centre of terminal, along the required route to the centre of the plume outlet. 6720644842-20.1Wo Fig. -
Page 20: System
INSTALLATION INSTALLATION STANDARD PLUME MANAGEMENT INSTALLATION To ease assembly of the flue components, lightly grease the seals with the solvent-free grease supplied. Check all the seals are properly seated in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products. -
Page 21: Extended Plume Management Installation
INSTALLATION EXTENDED PLUME MANAGEMENT Refer to figure 38 and assemble the plume extensions. INSTALLATION 1. Mark the position for the wall clamp that coincides with the extension tube, as shown. To ease assembly of the flue components, Drill a suitable hole and fit the wall plug. lightly grease the seals with the solvent-free Screw the clamp into the wall plug as shown. - Page 22 INSTALLATION INSTALLING A TERMINAL GUARD A Terminal guard must be fitted if the flue is less than two metres from the ground or if a person could come into contact with the flue terminal outlet. NOTE: The terminal end must not be swivelled inside the guard.
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Page 23: Redirecting The Flue Discharge
INSTALLATION REDIRECTING THE FLUE DISCHARGE The plume deflector can be adjusted to redirect the flue discharge. NOTE: FLUE DISCHARGE B The Plume terminal outlet position must follow those stated in figure 27. When redirecting the flue discharge the outlet must be at least 1500mm from and angle at least 45° away from any opening in the direction of the discharge, as shown. -
Page 24: Extended Plume Management Installation For A Balcony / Overhang
INSTALLATION EXTENDED PLUME MANAGEMENT INSTALLATION FOR A BALCONY / OVERHANG To ease assembly of the flue components, lightly grease the seals with the solvent-free grease supplied. Check all the seals are properly seated in the grooves provided and are in good condition. -
Page 25: Service And Spares
SERVICE AND SPARES SERVICE AND SPARES SERVICING AND MAINTENANCE An annual visual check of the plume management kit must be carried out. NOTE: PAINTING B DO NOT paint the plume management kit! SPARE PARTS Ø 60/100mm Telescopic horizontal flue Collar - flue turret: Part Number: 8 716 111 254 0 Air sample point plug - flue turret: Part Number: 8 716 111253 0... - Page 26 NOTES 6 720 644 842b (2010/12)
- Page 27 NOTES 6 720 644 842b (2010/12)
- Page 28 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: worcester-bosch.co.uk Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. 6 720 644 842b (2010/12)