Bosch WORCESTER Condensfit II GREENSTAR 60/100 HORIZONTAL FLUE Installation Manual Download

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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)

WORCESTER, BOSCH GROUP:

TECHNICAL SUPPORT:

0844 892 3366

APPOINTMENTS:

0844 892 3000

SPARES:

01905 752571

LITERATURE:

0844 892 9800

TRAINING:

01905 752526

SALES:

01905 752640

WEBSITE: worcester-bosch.co.uk

Summary of Contents for WORCESTER Condensfit II GREENSTAR 60/100 HORIZONTAL FLUE

Page 1: ...16 191 171 ROOM SEALED LONGER TELESCOPIC FLUE 7 716 191 086 PLUME MANAGEMENT SYSTEM GREENSTAR 60 100 HORIZONTAL FLUE 6720644842 00 1Wo FOR WORCESTER GREENSTAR CDi WALL HUNG Si i JUNIOR i SYSTEM Ri SERIES OF GAS APPLIANCES INCLUDING BRITISH GAS VARIANTS 6 720 644 842b 2010 12 ...

Page 2: ...a high level telescopic flue 10 4 1 3 Flue terminal plume re direction 11 4 1 4 Extended flue installation 12 5 PRODUCT INFORMATION 14 5 1 Plume management system components 14 6 PRE INSTALLATION 15 6 1 Plume management terminal positions 15 6 2 Plume management options measurement 16 6 2 1 Determine the plume management system length 17 6 2 2 Measuring for a plume management system 18 7 INSTALLAT...

Page 3: ...SYMBOLS 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 triangle Notes contain important information in cases where there is no risk of personal injury or material losses and are identified by the symbol shown on the left They are bordered by ho...

Page 4: ...dance with the current Gas Safety Installation and Use Regulations Flue systems must not be modified in any way other than as described in the fitting instructions Any misuse or unauthorised modifications to the appliance flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights SERVICING A...

Page 5: ...se pack two No 8 screws grease sachet 60 100mm 1000mm Part No 7 716 191 083 2 Extension tube assembly plus grease pack two No 8 screws grease sachet 60 100mm 2000mm Part No 7 716 191 172 3 Extension tube assembly plus grease pack two No 8 screws grease sachet 60 100 High level horizontal flue adapter Part No 7 716 191 164 4 Flue connector vertical plus Screw pack 60 100mm 45 bend Part No 7 716 191...

Page 6: ...m from a pitched roof or in regions with heavy snow fall 500mm 9 The flue cannot be lower than 1 000mm from the top of a light well due to the build up of combustion products 10 2 000mm below a Velux window 600mm above or to either side of the Velux window 11 200mm below eaves and 75 mm below gutters pipes and drains 12 1 200mm between terminals facing each other 13 300mm to an internal or externa...

Page 7: ...the flue system is inspected under the annual service the engineer must inspect and confirm that B the flue system is continuous without any breaks B all joints in the flue system are sound and correctly assembled according to the manufacturers instructions B the flue has a fall of 3 52 millimetres per metre back to the boiler CAUTION Flue systems in ceilings or roof voids Where a flue system is n...

Page 8: ...ume 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 The terminal end projects beyond the outside wall by the distance shown in fig 5 Maximum effective flue lengths L max mm Greenstar Si i Junior i Sy...

Page 9: ... with the aluminium tape supplied Flue length range mm Cut Number of extensions 130 265 YES None 350 570 NO None 570 790 NO None 790 1300 YES 1 1300 1520 NO 1 1520 2250 YES 2 2250 2470 NO 2 2470 3200 YES 3 3200 3420 NO 3 3420 4150 YES 4 4150 4370 NO 4 4370 4600 YES 5 Table 9 Flue extension guidance up to 4600mm NOTE EFFECTIVE LENGTH B Each flue bend is rated as a certain straight length of flue re...

Page 10: ...ge the tubes B Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage Fig 11 Further reduction REDUCING EXTENSION FLUE TUBE LENGTH B Mark the extension tube to the required distance measuring from the socket end and cut the tube square taking care not to damage the tubes B Remove any burrs and chamfer the outer edge of the tubes to ease the co...

Page 11: ...heck the boiler flue seal is correctly seated and apply silicone grease 3 Position terminal through the flue opening in the wall to the outside of the building by the distance shown 4 Align the flue turret to the boiler flue outlet with flat facing to the rear of the boiler Push the flue turret straight down into the boiler flue outlet B Fit the screws remove in step 1 to secure flue turret B If f...

Page 12: ...al flue adapter to the boiler with the screws provide in the adapter kit Fig 17 Fitting the high level horizontal flue 4 1 3 FLUE TERMINAL PLUME RE DIRECTION The flue discharge can be re directed to allow some plume redirection control Alternatively a complete plume management system can be fitted to the flue terminal RE DIRECTING THE FLUE DISCHARGE 1 Using a suitable tool unclip the end of the te...

Page 13: ...lue discharge 3 Terminal end 4 Minimum 1500mm from an opening in the building Table 11 Key to figure 19 6720643895 119 1Wo 1 3 4 2 NOTE CONDENSATE DISPOSAL B All horizontal flue sections must rise by at least 52mm per metre away from the boiler to ensure that the condensate flows back into the boiler for safe disposal via the condensate waste pipe To ease assembly of the flue components lightly gr...

Page 14: ...Drill two holes 180 apart through the outer flue tube of each extension take care not to drill into the inner flue tube and secure with the screws provided Fig 23 Extensions 1 Refer to figure 24 and slide the inner wall seal onto the terminal If fitting the flue from inside the building slide the outer wall seal onto the terminal locating the ridge on the seal with the groove on the terminal 2 Pos...

Page 15: ...art No 7 716 191 086 1 Terminal bend 2 Extension 500mm 3 Outlet assembly 4 Clamp pack Table 12 60mm Plume management kit 1 2 3 4 6720644842 14 1Wo EXTENSION COMPONENTS Ø 60mm EXTENSION comprising Part No 7 716 191 087 5 Extension 1000mm 6 Clamp pack 90 BEND comprising Part No 7 716 191 088 7 90 Bend 45 BEND comprising Part No 7 716 191 089 8 45 Bend x 2 Terminal guard Part No 7 716 191 176 9 Termi...

Page 16: ...al of condensate For details on specific lengths see relevant boiler Technical Specification information 8 This feature allows some basic plume re direction options on a standard telescopic horizontal flue terminal 300 mm minimum clearances to a opening e g window However the minimum clearance to an opening in direction that the plume management is facing must be increased to 1 500 mm Where the fl...

Page 17: ...inal by a minimum of 173mm per metre 10 to allow the condensate to drain back to the boiler 1 Terminal bend 2 Extension 500mm 3 Outlet assembly 4 Clamp Table 14 Key to figure 28 5 Extension tube 100mm and Clamp 6 90 Bend 7 45 Bend Table 15 Key to figure 29 1 2 3 4 6720644842 16 1Wo 1 2 3 4 5 6720644842 17 1Wo NOTE PLUME MANAGEMENT LENGTH B Measurement M must be a minimum of 500mm and must not exce...

Page 18: ... that point read down to the horizontal scale to determine the maximum plume length M allowed For the CDi range of boilers the available plume length M is reduced as the flue length L increases Any flue must have a minimum of 500mm plume length 0 500 1 500 2 500 3 500 4 500 0 1 000 2 000 3 000 4 000 5 000 6 000 7 000 8 000 27CDi Maximum Plume Length for all boilers 30CDi BG532 i 37CDi BG537 i 42CD...

Page 19: ...ent length Each bend has an equivalent straight length and must be factored into the overall effective length 90 bend is equivalent to 1500mm 45 bend is equivalent to 750mm Fig 35 Plume management bends EXAMPLE Using two 45 bends will reduce the permissible length by 1500mm A Greenstar 28i junior has a maximum permissible plume management length of 4500mm so using two 45 bends will reduce the stra...

Page 20: ...ws provided 3 Push the outlet assembly fully into the extension tube 4 Rotate the outlet assembly to the required direction 5 Secure the outlet to the extension with the self tapping screw provided Fig 36 Terminal bend installation Fig 37 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 prop...

Page 21: ...ension tubes as before and secure to the wall 5 Push the outlet assembly fully into the extension tube 6 Rotate the outlet assembly to the required direction and secure the outlet to the extension with the self tapping screw provided Fig 38 Plume extensions To ease assembly of the flue components lightly grease the seals with the solvent free grease supplied Check all the seals are properly seated...

Page 22: ...rd B Fold the gates in the order stated below or the gates will not latch properly 1 Fold the single pronged gate in and latch onto the guard frame 2 Fold the two pronged gate in and latch onto the guard frame Fig 39 Terminal guard flue outlet Fig 40 Terminal guard flue inlet NOTE The terminal end must not be swivelled inside the guard The terminal end must be mounted at right angles with respect ...

Page 23: ...n 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 This is to prevent combustion products from entering the building 1 2 3 45 V 6720644842 28 1Wo 4 1 Opening in the building i e air brick window 2 Direction of flue products must be more than 45 from the wall or structure 3 Plume terminal 4 ...

Page 24: ...crews provided B Mount the other extension tubes as before and secure to the wall 4 Remove the screw from the terminal end and remove the grill 5 Drill a hole through the plume outlet end and secure the grill in place Fig 42 Under balcony 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 th...

Page 25: ... management kit Ø 60 100mm Telescopic horizontal flue 1 Collar flue turret Part Number 8 716 111 254 0 2 Air sample point plug flue turret Part Number 8 716 111253 0 3 Flue sample point cap with seal flue turret Part Number 8 716 111 252 0 4 Terminal outlet assembly Part Number 8 716 111 209 0 5 Wall seal Inner Part Number 8 716 111 211 0 6 Wall seal Outer Part Number 8 716 111 212 0 Table 17 Key ...

Page 26: ...6 720 644 842b 2010 12 26 NOTES ...

Page 27: ...6 720 644 842b 2010 12 27 NOTES ...

Page 28: ...cester Bosch Group is a brand name of Bosch Thermotechnology Ltd 6 720 644 842b 2010 12 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0844 892 3366 APPOINTMENTS 0844 892 3000 SPARES 01905 752571 LITERATURE 0844 892 9800 TRAINING 01905 752526 SALES 01905 752640 WEBSITE worcester bosch co uk ...

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