INSTALLATION INSTRUCTIONS 7 716 191 159 ROOM SEALED FLUE 80MM FLEXIBLE FLUE SYSTEM Only for use with Worcester appliances: Greenstar FS 30CDi Regular and Greenstar FS 42CDi Regular 8 716 115 519a (2009/03) UK/IE
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CONTENTS CONTENTS 1 EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 3 1.1 Explanation of symbols . . . . . . . . . . . . . . . 3 1.2 Safety precautions . . . . . . . . . . . . . . . . . . 4 2 INSTALLATION REGULATIONS . . . . . . . . . . . . . . 5 3 PRODUCT INFORMATION . . . . . . . . . . . . . . . . . 6 3.1 Flexible flue components . . . . . . . . . . . . . 6 3.2 Flue extension components . . . . . . . . . . . 7 4 PRE-INSTALLATION . . . . . . . . . . . . . . . .
EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS 1 EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS 1.1 EXPLANATION OF SYMBOLS WARNING 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. Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions.
EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS 1.2 SAFETY PRECAUTIONS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION: These installation instructions are applicable to the Worcester flue kit stated on the front cover of this manual and must not be used with any other make or model. These installation instructions must be read in conjunction with the appliance manual. The instructions apply in the UK/IE only and must be followed except for any statutory obligation.
INSTALLATION REGULATIONS 2 INSTALLATION REGULATIONS Current Gas Safety Regulations (Installation and Use): Failure to install flue systems correctly could lead to prosecution. All flue systems and associated components must be installed by a CORGI registered, competent person in accordance with the following regulations.
PRODUCT INFORMATION 3 PRODUCT INFORMATION 3.1 FLEXIBLE FLUE COMPONENTS No.
PRODUCT INFORMATION 3.2 FLUE EXTENSION COMPONENTS Ø 80/125 1000mm Extension kit (Part No: 7 719 001 892) 1 Extension tube assembly Table 4: Extension kit contents Ø 80/125 90° bend (Part No: 7 719 001 891) 2 90° bend Table 5: 90°bend contents Ø 80/125 45° bends (Part No: 7 719 001 899) 3 45° bend x2 Table 6: 45° bends contents Fig.
PRE-INSTALLATION 4 PRE-INSTALLATION NOTICE: Risk of damage to the appliance or flue. B Read all Pre-Installation sections. B Ensure all requirements are met before using the appliance or flue installation. 4.1 FLEXIBLE FLUE TERMINAL POSITIONS Flue gases have a tendency to plume and in certain weather conditions a white plume of condensation may be discharged from the flue outlet. Where this could cause a nuisance, for example near security lighting, an alternate flue position should be found. Fig.
PRE-INSTALLATION 4.2 INSTALLATION CLEARANCES For information regarding installation clearances please refer to the appliance installation manual. 4.3 REQUIREMENTS FOR THE CHIMNEY CHIMNEY SIZE Before starting with the flue installation: B Ensure the cross section of the chimney complies with table 8 below and figure 3 opposite. cmin cmax Ø dmin Ø dmax 130mm 300mm 146mm 300mm Table 8: Fig.
PRE-INSTALLATION 4.5 CALCULATING THE EFFECTIVE FLUE LENGTH appliance variant max flue length vertical (Lvmax) max flue length horizontal (Lhmax) FS 30CDi 12m 3m FS 42CDi 12m 3m Table 10: Maximum flue length To calculate the effective flue length: B Check the flue path and consider the following: – number of 90° and 45° elbows required outside the chimney – number of bends in the flexible liner B Deduct the effective length of each elbow from the maximum horizontal flue length of 3m.
INSTALLATION 5 INSTALLATION 5.1 CREATING THE CHIMNEY HOLE WARNING: To avoid debris falling into the air inlet duct, do not install the duct with the open end facing up the chimney. The horizontal flue pipe connecting appliance and flexible liner must rise by at least 52mm for every metre of length. This is to ensure the condensate flows back into the appliance. B Ensure the lower edge of the chimney hole is higher than the appliance. As shown in fig. 5, the height h is dependant on the distance d.
INSTALLATION 5.2 INSTALLING THE SUPPORT ELBOW Depending on the depth of the chimney, it may be necessary to cut the support bar. B Cut the support bar to fit the chimney as in fig. 8. B Drill a new hole into the support bar. Ensure it will match with the securing hole in the ledge. Fig. 8 Cutting the support bar Fig. 9 Fitting the elbow onto the elbow support B Measure the depth of the chimney. B Position the elbow centrally on the elbow support as shown in fig. 9. B Secure with the wing nut.
INSTALLATION 5.3 ASSEMBLING THE FLEXIBLE FLUE B Use a hack saw. B Cut the flexible liner off square directly below a set of ridges. B Do not cut between the individual ridges of a set. Fig. 11 Where to cut the flexible liner 1. Remove the liner and seal from the adaptor. 2. Remove the seal (b) from the liner (a). a b Fig. 12 Removing liner and seal from adaptor 3. Use a screwdriver to release the locking tab. 4. Rotate the moveable band anti-clockwise to open the bayonet release. Fig.
INSTALLATION 5. Fit the seal (b) into the first wide recess on the flexible liner (c). Make sure the seal (b) is not twisted and is seated properly. 6. Fit the liner (a) into the flexible liner (c). 7. Grease the seal (b). b c a b Fig. 14 Fitting the seal and liner 8. Push the adaptor onto the flexible liner until it “bottoms out” and the moveable band “clicks” into place.
INSTALLATION The centralising spacer must be shortened to fit the 80mm flexible liner. 10. Snap off the centralising spacer at the perforated section marked 80mm to suit the flue. Fig. 17 Shortening the centralising spacer 11. Secure the centralising spacer around the flexible liner as shown in fig. 18. Fig. 18 Fitting the centralising spacer The centralising spacers must be fitted to the flexible liner in certain positions to ensure the liner is centred within the chimney.
INSTALLATION 5.4 INSTALLING THE FLEXIBLE LINER ASSEMBLY To ease the assembly of the flue components: B Grease all seals lightly with solvent-free grease . B Ensure all seals are seated properly and are in good condition. 1. Feed the flexible liner assembly into the chimney from the top. 2. Insert the adaptor into the support elbow. Fig.
INSTALLATION 3. Fit the support collar onto the flexible liner. Ensure the retaining ring at the top of the collar is seated in a ring of the corrugated section as shown opposite. 4. Assemble the support bracket onto the support collar. In order to install the terminal adaptor, there must be at least three corrugated sections of the flexible liner left above the support bracket assembly. Fig. 21 Fitting support collar and support bracket The flexible flue must be centrally aligned within in the chimney. 5.
INSTALLATION The flexible flue must now be prepared so the terminal adaptor can be fitted. 6. Cut the flexible liner three complete corrugated sections above the support collar. Ensure to cut at the bottom of the wide recess directly above the corrugated section. 7. Grease the seal. 8. Fit the seal into the first wide recess on the flexible liner. Make sure the seal is not twisted and is seated properly. Fig. 23 Cutting flexible liner and fitting seal To reinforce the end of the flexible liner: 9.
INSTALLATION 5.5 INSTALLING THE FLUE TERMINAL To ease the assembly of the flue components: B Grease all seals lightly with solvent-free grease . B Ensure all seals are seated properly and are in good condition. B Fit the terminal into the terminal adaptor. B Check the height is a minimum of 350mm from the top of chimney to the top of terminal. B Remove the terminal from the terminal adaptor. Fig. 26 Checking the height B Fit the self-adhesive weather seal to the base of the chimney cowl.
INSTALLATION 5.6 CONVERTING THE FLUE OUTLET The appliance is supplied ready to have a flue fitted to the rear flue outlet. To convert the flue from the rear to the top of the appliance, follow the procedure below: 1. Remove the “knock-out” panel from the top outer casing. 2. Remove the screws, blanking plate and gasket from the top flue outlet. Refer to the appliance installation manual for information on how to disassemble the casing. Fig. 28 Preparing the appliance 3.
INSTALLATION 5.7 FITTING THE FLUE ADAPTOR To ease the assembly of the flue components: B Grease all seals lightly with solvent-free grease . B Ensure all seals are seated properly and are in good condition. 1. Fit the flue connector to the appliance. 2. Ensure the connector‘s flat section is at the rear edge of the inner casing. Fig. 30 Fitting the flue connector to the appliance 3. Secure the connector from inside the inner casing using three hexagonal bolts. 4.
INSTALLATION 5.8 EXTENSIONS AND ELBOWS Connecting flue bends increases the effective flue length and allowance must be made for the different connectors. The examples opposite show the dimensions for: • a 90° elbow and the tee piece connected together • two 45° elbows connected together To calculate the effective flue length: B Identify the number of 90° and 45° elbows required. B Deduct the effective length of each elbow from the maximum horizontal flue length of 3m.
INSTALLATION To install flue extensions: 1. Slide a bracket onto each additional straight flue extension. Working from the appliance, fit extensions with brackets as required to support the weight of the flue. 2. Drill two holes (180° apart if possible) through the outer collar of each flue tube and use screws to secure the connection. NOTICE: Take care not to drill the inner flue tube. B The appliance might go into lockout due to flue gases mixing with combustion air. 8 716 115 519a (2009/03) Fig.
INSTALLATION 5.9 FITTING THE HORIZONTAL FLUE To ease the assembly of the flue components: B Grease all seals lightly with solvent-free grease . B Ensure all seals are seated properly and are in good condition. 1. Slide the seal from the inspection plate assembly over the flue pipe. Fig. 36 Slide the seal over flue pipe 2. Fit the tee piece to the flue pipe. Secure with two screws in the same manner as described on page 23. 3. Fit the flue pipe to the elbow in the chimney. Fig.
INSTALLATION 5. Align the two inspection plates with the seal. 6. Screw the two plates together with four self tapping screws. 7. Check the rubber gasket is seated properly as shown in fig. 39. Fig. 39 Assembling flue inspection plates 8. Align the inspection plate over the chimney opening, mark and drill four fixing holes. 9. Fix the inspection plate to the chimney with the screws and wall plugs provided. Fig.
SERVICING AND SPARES 6 SERVICING AND SPARES 6.1 SERVICING An annual visual check of the flue system must be performed. To perform the visual check of the flue system: 1. Rotate and remove the end cover from the tee piece. 2. Unscrew and remove the inner flue end cover 3. Remove the screws that secure the inspection plate and slide the inspection plate away from the chimney. Replace all end covers and the inspection plate after visual inspection of the flue system. Fig.
SERVICING AND SPARES 6.2 SPARE PARTS This table contains the available spare parts for the 80mm flexible flue kit. No. Description Part No. 1 Flue connector 8 718 682 378 0 2 Flue adaptor 8 718 682 380 0 Table 16: Spare parts Fig.
CONTACT INFORMATION WORCESTER, BOSCH GROUP: TECHNICAL: 08705 266241 CONTACT CENTRE: 08457 256206 CONTACT CENTRE (IE): 01494 0099 SPARES: 01905 752571 LITERATURE: 01905 752556 TRAINING: 01905 752526 SALES: 01905 752640 WEBSITE: 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. www.worcester-bosch.co.uk 8 716 115 519a www.worcester-bosch.co.
