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1. 222 6720644842 11 1Wo Fig 22 Extended flue turret fitting Refer to figure 23 and slide the support clamps 1 onto the additional flue extensions 2 Working from the boiler fit the support clamps 1 and extensions 2 to take the weight of the flue 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 6720644842 12 1Wo 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 Position the terminal assembly through the opening in the wall to the outside Push the flue into the extension as far as possible 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 If using the telescopic flue slide the assembly until the flue terminal projects out of the wall by 110mm Secure the flue with the screw provide and seal the joint with the tape provided If fitting from outside the building slide the outer wall seal onto the terminal locating the ridge on the seal with the groove on the terminal 6720644842 13 1Wo Fig 24 Extended flue 14 WORCESTER Bosch Grou2. 7 4 REDIRECTING THE FLUE DISCHARGE The plume deflector can be adjusted to redirect the flue discharge 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 This is to prevent combustion products from entering the building f NOTE FLUE DISCHARGE 6720644842 28 1Wo P sr Fig 41 Plume direction conditions 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 At least 1500mm from any opening in the building Table 16 Key to figure 41 WORCESTER 6 720 644 842b 2010 12 T Bosch Group INSTALLATION 7 5 EXTENDED PLUME MANAGEMENT INSTALLATION FOR A BALCONY OVERHANG To ease assembly of the flue components il 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 1 Refer to figure 36 and remove and retain the screws and terminal end 2 Fitthe terminal bend to the terminal outlet and secure with the screws removed earlier 3 If required rotate the terminal bend for angled fluin
3. 6 Rotate the outlet assembly to the required direction and secure the outlet to the extension with the self tapping screw provided WORCESTER 6 720 644 842b 2010 12 Bosch Group 21 INSTALLATION 7 3 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 The terminal end must be mounted at right angles with respect to the wall The terminal guard does not have to be fitted over the flue inlet but is recommended to protect the flue from third party damage Fit the terminal guard centrally over the flue inlet or outlet Mount the terminal guard to the wall utilising the three mounting points attached to the guard 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 SS 6720646219 31 1Wo Fig 39 Terminal guard flue outlet 6720646219 32 1Wo r Fig 40 Terminal guard flue inlet 22 6 720 644 842b 2010 12 WORCESTER Bosch Group INSTALLATION
4. two No 8 screws amp grease sachet 60 100mm Support Part No 7 716 191 092 bracket kit 7 Wall bracket swivel bracket clamp fixing screws and wall plugs 6 in kit Table 5 Flue extension components 6720644842 02 2Wo S Fig 2 extension components WORCESTER 6 720 644 842b 2010 12 Bosch Group PRE INSTALLATION 3 3 1 Fig 3 PRE INSTALLATION FLUE TERMINAL POSITIONS All measurements in millimetres Boundary 600 zl Flue terminal positions Dormer Window 1 500 Velux Window E MIT 400 6720643895 13 1Wo 1 NOTE All measurements are the minimum clearances required Terminals must be positioned so to avoid combustion products entering the building 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 Key to illustration 1 Flue clearance must be at least 300mm from the 8 400mm from a pitched roof or in regions with heavy ground Terminal guards must be fitted if the flue is snow fall 500mm less than 2 metres from the ground or if a person 9 Theflue cannot be lower than 1 000mm from the top could come into contact with the flue terminal of a light well due to the buil
5. 60 100mm Telescopic horizontal flue 1 Collar flue turret Part Number 8 716 1112540 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 2520 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 to figure 43 6720644842 27 1Wo Fig 43 Spare parts WORCESTER 6 720 644 842b 2010 12 Bosch Group 25 5 26 6 720 644 842b 2010 12 WORCESTER Bosch Group 5 WORCESTER 6 720 644 842b 2010 12 Bosch Group 27 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 Worcester Bosch Group or Cotswold Way Warndon Worcester WRA 9SW Tel 0844 892 9900 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd Bosch Group 6 720 644 842b 2010 12
6. 790 1300 1 1300 1520 1 1520 2250 2 2250 2470 2 2470 3200 3 3200 3420 3 3420 4150 4 4150 4370 4 4370 4600 5 Table9 Flue extension guidance up to 4600mm FLUE BENDS NOTE EFFECTIVE LENGTH N Each flue bend is rated as a certain straight length of flue refer to table 10 below The effective length of each bend is added to the straight length of flue Adding bends to the flue system reduces the actual flue length available The effective length of the flue must not exceed that stated in the relevant appliance Installation commissioning and service manual Effective length in metres Si i junior Bend i System amp Ri CDi 90 2 1 5 45 1 0 75 Table 10 90 BENDS Figure 6 shows the actual length added by a 90 bend when used in either orientation 45 BENDS This application can only be used with the Si i Junior and i System boilers Figure 7 shows a possible application for a 45 bend that could be used if fluing from the right or left from the boiler In this application the flue would be 100mm closer to the wall 6720644842 06 1Wo Fig 7 45 Bend offset dimensions ADJUSTING THE TELESCOPIC FLUE LENGTH STANDARD OR LONGER VERSION 6720643895 30 1Wo Fig 8 Standard telescopic flue Extend tube 1 by withdrawing from tube 2 to achieve the flue length required
7. between 350 570mm If using the longer telescopic flue extend tube 1 by withdrawing from tube 2 to achieve the flue length required between 570 790mm 6720644842 04 1Wo Fig 6 90 Bend offset dimensions 6720644842 34 1Wo Fig 9 Longer telescopic flue Secure with screw provided and seal joint with the aluminium tape supplied WORCESTER 6 720 644 842b 2010 12 Bosch Group PRE INSTALLATION REDUCING THE TELESCOPIC FLUE LENGTH Ensure that the TOP label of both sections il are aligned before securing the two parts at the required length The flue terminal MUST be fitted with the label uppermost to allow the correct fit and use of the plume management system Remove securing screws 3 to detach the terminal assembly from the turret Slide terminal section 2 from the terminal assembly and discard Touse terminal 1 without cutting remove the location lug 4 on the inner flue tube 5 and remove any burrs 3 Fig 10 Reducing the telescopic terminal 2 1 6720643895 31 1Wo To reduce the telescopic flue length further Markthe length required for the terminal as shown in figure 11 min 130mm and cut square taking care not to damage the tubes Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage The aluminium tape is not required when reducing the terminal From st
8. INSTALLATION 3 2 FLUE SYSTEMS VOIDS When installing a new flue system consider the following information CAUTION Flue systems in ceilings or roof N voids Where a flue system is not going to be x accessible provision for access must be dl made for service and inspection 1 SC 1 HN Voids containing concealed flues must x have at least one inspection hatch no less than 300mm square Flue joints within the void must not be 5 more than 1 5m from the edge of the inspection hatch d 7 Inspection hatches should be located at obe changes of flue direction a 4 CI 1 gt If this is not possible bends should be viewable from both directions FLUE SYSTEMS IN CEILINGS OR ROOF VOIDS When installing a flue system in a ceiling or roof void the following points must be observed Boiler 1 Access points for inspection of the flue system must TEE sufficiently sized for visual inspection particularly at any joint in the flue system Fig 4 Flues in voids 2 The flue system must not pass through a neighbouring property as access may not be possible at the time of X This dimension must not be more than 1 5 inspection metres 3 Any access must not contravene any other building 1 Inspection hatch regulations or fire regulations Refer to Building Regulations Approved Docu
9. is risk of personal injury or material losses and are identified by the symbol shown on the left They are bordered by horizontal lines above and below the text ADDITIONAL SYMBOLS Symbol Meaning gt a step in an action sequence gt reference to a related part in the document or to other related documents a list entry a list entry second level Table 1 Documentation symbols ABBREVIATIONS 2 Diameter RS Room Sealed Table2 Abbreviations Table3 Symbols WORCESTER 6 720 644 842b 2010 12 Bosch Group KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1 2 SAFETY PRECAUTIONS IF YOU SMELL GAS CALL NATIONAL GAS EMERGENCY SERVICE 0800 111 999 gt DO NOT TURN ELECTRICAL SWITCHES ON OR OFF DO NOT STRIKE MATCHES OR SMOKE v KEEP PEOPLE AWAY FROM THE AFFECTED AREA PUT OUT NAKED FLAMES OPEN DOORS AND WINDOWS TURN OFF THE CONTROL VALVE AT THE METER vv v 4 Denchmar LICENSED INSTALLER FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Buildin
10. just below the top fitting Refer to figure 37 point 2 Drill a hole to suit the wall plug and fit the wall plug 4 Screw the clamp into the wall plug to the distance shown in figure 36 NOTE DO NOT ROTATE THE COMPLETE N FLUE TERMINAL ASSEMBLY The flue terminal outlet has built in stops to limit rotation for horizontal fluing to allow condensate to run back to the boiler for safe disposal Do not attempt to force beyond the limit stops Refer to figure 37 plume management installation 1 Push the extension tube fully into the terminal bend then withdraw the tube by approximately 10mm to allow for expansion 2 Secure the extension to the wall with the clamp and screws 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 um CH N CN 6720644842 23 1Wo Fig 37 Plume management installation 20 WORCESTER Bosch Group 6 720 644 842b 2010 12 INSTALLATION 7 2 EXTENDED PLUME MANAGEMENT INSTALLATION D 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
11. positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings Key to illustration 1 600 mm distance to a boundary or surface facing a boundary unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to boundaries Internal external corners The air intake clearance can be reduced to 150 mm providing the flue exhaust outlet has a 300 mm clearance The flue cannot be lower than 1 000 mm from the top of the light well due to the build up of combustion products 1 200 mm between air intake and facing terminal Clearance no less than 200 mm from the lowest point of the balcony or overhang Installations in car ports are not recommended 6 1 200 mm from an opening in a car port on the same wall i e door or window leading into dwelling 7 Using a Plume Management Kit the air intake measurement can be reduced to 150 mm providing the flue exhaust outlet has a 300 mm clearance Plume kits running horizontally must have a 10 fall back to the boiler for proper disposal of condensate For details on specific lengths see relevant boiler Technical amp 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 windo
12. FLUE KIT INSTALLATION MANUAL Condensfit IT 7 716 191 082 ROOM SEALED TELESCOPIC FLUE 7 716 191 171 ROOM SEALED LONGER TELESCOPIC FLUE 7 716 191 086 PLUME MANAGEMENT SYSTEM IZONTAL FLUE i WALL HUNG Si i JUNIOR i SYSTEM amp Ri SERIES RITISH GAS VARIANTS WORCESTER Bosch Group 6 720 644 842b 2010 12 5 5 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 3 1 1 Explanation of symbols 3 12 Safety precautions 4 2 PRODUCT INFORMATION 5 2 1 Telescopic flue components 5 2 2 Flue extension components 5 PREINSTALLATION 6 3 1 terminal positions 6 3 2 Flue measuring and cutting 7 3 2 1 Flue extension example 7 3 2 2 Flue length 8 4 INSTALLATION 10 4 1 Telescopic flue installation 10 4 1 1 Installing the telescopic flue 10 4 1 2 Installing 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 amp measurement 16 6 2 1 Determine the plume managemen
13. RVICING Advise the user to have the system serviced annually by a competent qualified Gas Safe registered engineer Approved spares must be used to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Record on the Benchmark Checklist after each service INSTALLATION REGULATIONS Current Gas Safety Installation amp Use Regulations All gas appliances must be installed by a competent person in accordance with the above regulations Failure to install appliances correctly could lead to prosecution The appliance must be installed in accordance with and comply to the current Gas Safety Regulations IEE Regulations Building Regulations Building Standards Scotland Consolidation Building Regulations Northern Ireland local water by laws Health amp Safety Document 635 The Electricity at Work Regulations 1989 and any other local requirements British Standards The relevant British Standards should be followed including BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Flues BS5440 2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Air Supply BS6798 Installation of gas fired boilers of rated input up to 70kW net Where no specific instruction is given reference should be made to the relevant British Standard codes of Practice Timber framed b
14. agement lengths PLUME LENGTH The minimum plume length for all boilers stated on the front page of this manual is 500mm 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 Refer to figure 33 to determine the appropriate plume length versus the flue length L The flue length is the effective length L which includes the effective length of any bends plus the straight flue lengths Once the length L is know find that value on the vertical scale of the graph and read that across to the line that represents the installed boiler From that point read down to the horizontal scale to determine the maximum plume length M allowed The Si i System i Junior and Ri can use up il to 4 500mm of plume management regardless of flue length 18 6 720 644 842b 2010 12 WORCESTER Bosch Group 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 4 en 6720644842 20 1Wo Fig 34 Plume management length M ADDITIONAL BENDS 2 Adding bends to the plume management system reduces the actual plume management length Each bend has an equival
15. andard telescopic flue 1 From longer telescopic flue 1 5 6720644842 35 1Wo Fig 11 Further reduction REDUCING EXTENSION FLUE TUBE LENGTH il A 220mm short extension is available 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 Remove any burrs and chamfer the outer edge of the tubes to ease the connection and prevent damage to the seals 6720644842 07 1Wo Fig 12 Cutting an extension tube 10 WORCESTER Bosch Group 6 720 644 842b 2010 12 INSTALLATION 4 INSTALLATION 4 1 TELESCOPIC FLUE INSTALLATION 4 1 1 INSTALLING THE TELESCOPIC FLUE 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 The flue turret of the 100 mm flue has an in built 3 angle If extensions are to be added then the complete flue must rise at an angle of 3 or 52mm for every metre of flue length Drill the hole using a suitable core drill 1 Referring to figure 13 set the flue length to the distance required secure with screws 2 Seal the joint with the aluminium tape 3 Slide the inner wall seal onto the terminal 4 If fitting from inside the building slide the oute
16. condition All flue joints must be sealed to prevent leakage of condensate and flue products NOTE PLUME MANAGEMENT N 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 FITTING THE EXTENDED PLUME MANAGEMENT 1 Refer to figure 36 and remove and retain the screws securing the terminal end and discard the terminal end Fit the terminal bend to the terminal outlet and secure with the screws retained earlier If required rotate the terminal bend for angled fluing NOTE DO NOT ROTATE THE COMPLETE N FLUE TERMINAL ASSEMBLY Theflue terminal outlet has built in stops to limit rotation for horizontal fluing to allow condensate to run back to the boiler for safe disposal Do not attempt to force beyond the limit stops Refer to figure 38 and assemble the plume extensions 1 Mark the position for the wall clamp that coincides with the extension tube as shown Drill a suitable hole and fit the wall plug Screw the clamp into the wall plug as shown Push the extension tube fully into the terminal bend then withdraw the tube by approximately 10mm to allow for expansion Secure the extension to the wall with the clamp and screws provided Mountthe other extension tubes as before and secure to the wall 5 Push the outlet assembly fully into the extension tube
17. d up of combustion 2 600mm distance to a boundary unless it will cause products nuisance BS 5440 Part 1 recommends that care is 10 2 000mm below a Velux window 600mm above or taken when siting terminals in relation to to either side of the Velux window boundaries 11 200mm below eaves and 75 mm below gutters 3 600mm minimum clearance from a skylight to a pipes and drains vertical flue 12 1 200mm between terminals facing each other 4 Vertical flue clearance 500mm to non combustible 13 300mm to an internal or external corner building material and 1 500mm clearance to combustible building material Installations in car ports are not 5 The dimension below eaves gutters pipes and recommended drains can be reduced to 25mm as long as the flue terminal is extended to clear any overhang An AME y 8 y 14 The dimension below eaves balconies and car ports external flue joints must be sealed with a suitable P can be reduced to 25 mm as long as the flue silicon sealant terminal is extended to clear any overhang 6 500mm clearance to any vertical structure on a roof Any external flue joints must be sealed with suitable 600mm to room sealed flue or 1 500mm to an open Silicon sesl nt flue 15 300mm above below and either side of an opening T 1 500mm between a vertical flue terminal and a door air vent or opening window window or dormer window 6 6 720 644 842b 2010 12 WORCESTER Bosch Group PRE
18. elescopic flue WORCESTER 6 720 644 842b 2010 12 Bosch Group 11 INSTALLATION 1 Referring to figure 16 fit the telescopic flue firmly into the 90 bend 2 Fit the 90 bend firmly into the extension piece 3 Fit the vertical flue adapter to the end of the extension 6720644842 33 1Wo Fig 16 Assembling the extensions 1 Referring to figure 17 remove and discard the three screws securing the flue outlet in the boiler 2 Check 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 vertical flue adapter to the boiler flue outlet with flat facing to the rear of the boiler Push the adapter straight down into the boiler flue outlet 5 Secure the telescopic flue bends and extensions with the screws provided 6 Secure the vertical flue adapter to the boiler with the screws provide in the adapter kit 6720644842 32 1Wo 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 NOTE DO NOT ROTATE THE COMPLETE N FLUE TERMINAL ASSEMBLY Theflue terminal outlet has built in stops to limit rotation for ho
19. ent straight length and must be factored into the overall effective length 90 bend is equivalent to 1500mm 45 bend is equivalent to 750mm 6720644842 21 1Wo 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 straight length to 3000mm WORCESTER 6 720 644 842b 2010 12 Bosch Group 19 INSTALLATION 7 INSTALLATION 7 1 STANDARD PLUME MANAGEMENT INSTALLATION To ease assembly of the flue components il 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 NOTE PLUME MANAGEMENT N 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 FITTING THE STANDARD PLUME MANAGEMENT SYSTEM Refer to figure 36 for terminal bend installation 1 Remove and retain the screws and discard the terminal end 2 Fit the new terminal bend to the terminal outlet and secure with the screws removed previously 3 Mark the position for the wall clamp so that it coincides with the extension tube
20. g NOTE DO NOT ROTATE THE COMPLETE N FLUE TERMINAL ASSEMBLY Theflue terminal outlet has built in stops to limit rotation for horizontal fluing to allow condensate to run back to the boiler for safe disposal Do not attempt to force beyond the limit stops 1 Refer to figure 42 and mark the position for the wall clamp that coincides with the extension tube just below the top fitting Drill a suitable hole and fit the wall plug Screw the clamp into the wall plug as shown 2 Push the extension tube fully into the terminal bend then withdraw the tube by approximately 10mm to allow for expansion 3 Secure the extension to the wall with the clamp and screws provided Mountthe other extension tubes as before and secure to the wall Ensure that the plume outlet projects at il least 100mmpassed the balcony overhang 4 Remove the screw from the terminal end and remove the grill 5 Drill a hole through the plume outlet end and secure Fig 42 Under balcony installation the grill in place 6720644842 26 1Wo 24 6 720 644 842b 2010 12 WORCESTER Bosch Group SERVICE AND SPARES 8 SERVICE AND SPARES 8 1 SERVICING AND MAINTENANCE An annual visual check of the plume management kit must be carried out NOTE PAINTING N DO NOT paint the plume management kit 8 2 SPARE PARTS
21. g Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme Visit centralheating co uk for more information HEALTH AND SAFETY The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations Control of Substances Hazardous to Health Regulations 1988 COMBUSTION AND CORROSIVE MATERIALS Do not store or use any combustible materials paper thinners paints etc inside or within the vicinity of the appliance Chemically aggressive substances can corrode the appliance and invalidate any warranty FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance 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 SE
22. h bend 0 173mm Fig 31 1m ot 2m d 6720644842 19 1Wo Plume management with straight extension IN NOTE PLUME MANAGEMENT LENGTH Measurement M must be a minimum of 500mm and must not exceed the maximum straight length for a horizontal 60 100mm flue or a 60mm plume management system as stated in the relevant appliance Installation commissioning and service manual or addendum WORCESTER 6 720 644 842b 2010 12 Bosch Group 17 PRE INSTALLATION 6 2 1 DETERMINE THE PLUME MANAGEMENT SYSTEM LENGTH a Fig 32 Effective lengths L and M 6720644842 29 1Wo Maximum Plume Length 8 000 for all boilers E 7 000 i 6 000 5 9 5 000 27CDi Si Junior System amp 2 4 000 r 30CDi Regular System amp 3 000 BG430 i 30CDi 2 000 BG532 i 37CDi amp BG537 i 1 000 42CDi 40CDi Regular amp BG542 i 0 0 500 1 500 2 500 Plume management length allowed M mm 3 500 4 500 6720644842 30 2Wo Fig 33 Effective flue lengths versus plume man
23. he distance shown in fig 5 nd Measure the flue length L from the centre line of the flue turret along the route of the flue system to the face of the outside wall 2 Select the required number of extensions and bends to achieve the require flue run 3 If the flue requires cutting Set the telescopic flue length to 400mm Secure the joint with the screw and tape provided Subtract 400mm from the measured flue length L to determine the amount to be cut of an extension Maximum effective flue lengths L max mm Greenstar Si i Junior i System amp Ri 4600 Series Greenstar 30CDi System amp Regular 7900 Greenstar 40CDi Regular 6000 Greenstar 27CDi 10000 Greenstar 30CDi 7000 Greenstar 37CDi 6500 Greenstar 42CDi 6000 British Gas 430i 7900 British Gas 532i 7000 British Gas 537i 6500 British Gas 542 6000 Table 7 Maximum flue lengths 50 e Fig 5 length determination L Effective length of the flue system R Actual length of the flue sections L 50 R Extension flue length Telescopic flue length Table 8 Key to figure 5 6720644842 03 1Wo 6 720 644 842b 2010 12 WORCESTER Bosch Group PRE INSTALLATION 3 3 2 FLUE LENGTH GUIDE Flue length range mm Number of extensions 130 265 None 350 570 None 570 790
24. ments B L and E Flue terminal 4 The access panels must be no less than 300mm Concealed flue connection External wall whole flue system needs to be viewed 5 The flue system must be adequately supported at Internal wall 2 3 square Larger access panels can be considered if the 5 6 regular interval approximately every 1 5 metres Any intervening joints must be visible within 1 5 metres of the inspection hatch 7 Accessible flue connection Table 6 ANNUAL INSPECTION When the flue system is inspected under the annual service the engineer must inspect and confirm that the flue system is continuous without any breaks all joints in the flue system are sound and correctly assembled according to the manufacturers instructions the flue has a fall of 3 52 millimetres per metre back to the boiler WORCESTER 6 720 644 842b 2010 12 e Bosch Group PRE INSTALLATION 3 3 FLUE MEASURING AND CUTTING NOTE FLUE LENGTH N 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 amp Servicing Instructions manual or addendum il Cutting the flue to an exact measurement is not normally required as the telescopic flue terminal can allow for some adjustment 3 3 1 FLUE EXTENSION EXAMPLE The terminal end projects beyond the il outside wall by t
25. p 6 720 644 842b 2010 12 PRODUCT INFORMATION 5 PRODUCT INFORMATION 5 1 PLUME MANAGEMENT SYSTEM COMPONENTS PLUME MANAGEMENT COMPONENTS 0 60mm PLUME MANAGEMENT KIT comprising EXTENSION COMPONENTS 60mm EXTENSION comprising Part No 7 716 191 086 Part No 7 716 191 087 1 Terminal bend 5 Extension 1000mm 2 Extension 500mm 6 Clamp pack 3 Outlet assembly 90 BEND comprising 4 Clamp pack Part No 7 716 191 088 Table 12 60mm Plume management kit 7 90 Bend 45 BEND comprising Part No 7 716 191 089 1 8 45 Bend x 2 Terminal guard 2 Part No 7 716 191 176 9 Terminal guard Table 13 60mm Extension 3 5 4 6 6720644842 14 1Wo Fig 25 Plume management kit components f 8 9 6720644842 15 2Wo Fig 26 Plume management extension components WORCESTER 6 720 644 842b 2010 12 Bosch Group 15 PRE INSTALLATION 6 6 1 Fig PRE INSTALLATION PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres Plume management deflector Balcony Drainpipe 27 Plume terminal positions A Flue Exhaust Outlet Air Intake 6720643895 14 1Wo NOTE N Refer to figure for all concentric flue terminal positions unless the flue position is specified on the figure above Plume terminal positions All measurements are the minimum clearances required Terminals must be
26. r wall seal onto the terminal locating the ridge on the seal with the groove on the terminal 6720644842 08 1Wo Fig 13 Telescopic flue 1 Referring to figure 14 remove the three screws securing the flue outlet to the boiler 2 Check 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 Fit the screws remove in step 1 to secure flue turret gt If fitting the outer seal from outside the building slide the outer wall seal onto the terminal as shown locating the ridge on the seal with the groove on the terminal 6720643895 33 1Wo Fig 14 flue Lu 4 1 2 INSTALLING A HIGH LEVEL TELESCOPIC FLUE 1 Referring to figure 15 remove and retain the screws securing the telescopic flue to the turret Disconnect the flue from the turret and discard the turret 2 Slide the inner wall seal on to the terminal 3 Set the telescopic flue to the required length and secure with the screws provided 4 Seal the joint with the aluminium tape supplied 5 If fitting the flue from inside the property slide on the outer wall seal locating the ridge on the seal with the groove on the terminal 6720644842 31 1Wo Fig 15 Preparing the t
27. rizontal fluing This allows condensate to run back to the boiler for safe disposal Do not attempt to force beyond the limit stops 1 Using a suitable tool unclip the end of the terminal 2 Rotate the end by 180 and refit the terminal end ensuring to engage the clips to secure 3 Loosen the screws securing the entire outlet assembly and rotate by 80 to the desired position and re secure the assembly vn 6720643895 34 1Wo Fig 18 Plume redirection 12 WORCESTER Bosch Group 6 720 644 842b 2010 12 INSTALLATION NOTE OUTLET POSITIONS A The flue terminal outlet position must follow those stated in figure 3 When redirecting the flue discharge the terminal end must be at least 1500mm from any opening in the direction of the discharge to prevent combustion products from entering the building as shown 4 1 4 EXTENDED FLUE INSTALLATION NOTE CONDENSATE DISPOSAL N 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 6720643895 119 1 Fig 19 Plume distance to opening il Opening in building 2m gt Sa 52mm 104mm 6720644842 10 1W0 Fig 20 Slope for condensate disposal To ease assembly of the flue components lightly grease the seals with the solvent free grease
28. 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 Flue discharge Terminal end m Minimum 1500mm from an opening in the building Table 11 Key to figure 19 WORCESTER 6 720 644 842b 2010 12 Bosch Group 13 INSTALLATION INSTALLING AN EXTENDED FLUE The flue terminal MUST be fitted with the upper most to allow the correct fit and use of the plume management system il 1 Remove the screws retaining the flue to the turret 2 Disconnect the flue 1 from the turret 2 3 Slide the support clamp optional item 3 onto the flue extension as shown 4 Push fit the extension 4 as far as possible into the flue turret 5 Drill through the turret screw holes into the flue outer tube take care not to drill into the inner tube Secure the extension to the turret with the screws removed earlier 6720644842 09 1Wo Fig 21 Flue extensions 1 Remove the three screws from around the flue outlet on the boiler and retain For CDi models the screw pack is in the boiler 2 Ensure that the boiler flue seal is seated correctly and apply silicone grease to the seal 3 Fit the flue turret to the boiler flue outlet and rotate to the direction required ensuring the flat on the clamp ring is facing the rear of the boiler
29. t system length 17 6 2 2 Measuring for a plume management System zu ar een x bode aes 18 7 INSTALLATION 19 7 1 Standard plume management installation 19 7 2 Extended plume management installation 20 7 3 Redirecting the flue discharge 21 7 4 X Extended plume management installation fora balcony overhang 22 8 SERVICE AND SPARES 23 8 1 Servicing and maintenance 23 8 2 Spare parts 23 2 6 720 644 842b 2010 12 WORCESTER Bosch Group KEY SYMBOLS AND SAFETY PRECAUTIONS 1 SYMBOLS AND SAFETY PRECAUTIONS 1 1 EXPLANATION SYMBOLS WARNING SYMBOLS SYMBOLS Safety instructions in this document are N framed and identified by a warning triangle which is printed on a grey background Electrical hazards are identified by a N 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 NOTICE indicates possible damage to property or equipment but where there is no risk of injury CAUTION indicates possible injury WARNING indicates possible severe injury DANGER indicates possible risk to life IMPORTANT INFORMATION Cutting required Cutting not required Notes contain important information in H cases where there
30. uilding Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440 Part 1 and IGE Gas Installations in Timber Frame Buildings should be followed WORCESTER Bosch Group 6 720 644 842b 2010 12 PRODUCT INFORMATION 2 PRODUCT INFORMATION 2 1 TELESCOPIC FLUE COMPONENTS 2 2 FLUE EXTENSION COMPONENTS 60 100 mm TELESCOPIC FLUE KIT Part No 7 716 191 082 60 100mm 220mm Part No 7 716 191 133 60 100 mm LONGER TELESCOPIC FLUE KIT Part No 7 716 191 171 1 Extension tube assembly plus grease pack two No 8 screws amp grease sachet 60 100mm 1000mm Part No 7 716 191 083 TELESCOPIC FLUE ASSEMBLY 2 Extension tube assembly plus grease pack two No 8 screws amp grease sachet 60 100mm 2000mm Part No 7 716 191 172 2 WALL INNER SEAL 3 WALL OUTER SEAL 4 INSTALLATION MANUAL 5 ALUMINIUM TAPE 6 ACCESSORY PACK 3 Extension tube assembly plus grease pack two No 8 screws amp grease sachet 60 100 High level Part No 7 716 191 164 horizontal flue adapter Table 4 Telescopic flue components 6720644842 01 2Wo Fig 1 Telescopic flue components 4 Flue connector vertical plus Screw pack 60 100mm 45 bend Part No 7 716 191 085 5 45 bend x 2 plus grease pack two No 8 screws amp grease sachet 60 100mm 90 bend Part No 7 716 191 084 6 90 bend assembly plus grease pack
31. w However the minimum clearance to an opening in direction that the plume management is facing must be increased to 1 500 mm Where the flue is less than 150 mm to a drain pipe and plume re direction is used the deflector should not be directed towards the drainpipe 16 6 720 644 842b 2010 12 WORCESTER Bosch Group PRE INSTALLATION 6 2 PLUME MANAGEMENT OPTIONS amp MEASUREMENT NOTE PLUME MANAGEMENT N 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 PLUME MANAGEMENT KIT d e e 6720644842 16 1Wo Fig 28 Plume management components 1 Terminal bend 2 Extension 500mm 3 Outlet assembly 4 Clamp Table 14 Key to figure 28 PLUME MANAGEMENT OPTIONAL KIT ot ET g M 5 ee 6720644842 17 1Wo Fig 29 Optional components 5 Extension tube 100mm and Clamp 6 90 Bend 7 45 Bend Table 15 Key to figure 29 Fig 30 6720644842 18 1Wo Plume management wit
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