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Flue InstallationHigh Effi ciencyCondensing Boilers
Table of conTenTs
- 3 -
InTRoDUcTIon
1 Instructionguidance...........................................................................................................................41.1 Productdocumentation...........................................................................................41.2 Explanationofsymbols..........................................................................................41.3 ImportantNotes.....................................................................................................4
InsTallaTIon
2 TelescopicDirectRearFlueKitØ60/100-Pt.No.A2043500...........................................................72.1 FlueLengthandTerminalPosition.........................................................................72.2 ExternalFlueInstallation........................................................................................82.3 InternalFlueInstallation........................................................................................8
3 TopHorizontalTelescopicFlueKitØ60/100-Pt.No.A2043600.....................................................93.1 FlueLengthandTerminalPosition.........................................................................9
4 TopHorizontalStandardFlueKitØ60/100-Pt.No.A2043400...................................................... 114.1 FlueLengthandTerminalPosition....................................................................... 114.2 FlueCutting.......................................................................................................... 114.3 FlueFitting............................................................................................................12
5 VerticalConcentricFlueSystemØ60/100-Pt.No.A2043400.......................................................135.1 FlueLengthandTerminalPosition.......................................................................135.2 FlueInstallation....................................................................................................135.3 FlueTerminal........................................................................................................145.4 RidgeTileTerminal...............................................................................................155.5 FlueTerminalCutting............................................................................................155.6 FlueExtensionCompletion...................................................................................15
6 Accessories......................................................................................................................................166.1 DeflectorFlueTerminalKitØ60/100.....................................................................166.2 Installation............................................................................................................166.3 BlackTerminalKitØ60/100..................................................................................176.4 Installation............................................................................................................176.5 PlumeManagementKitØ60/100.........................................................................186.6 TerminalSiting......................................................................................................196.7 Installation............................................................................................................206.8 Terminationaboveeaves......................................................................................226.9 Termination...........................................................................................................226.10 FixingInstructions.................................................................................................22
7 FlueSystemsandComponents.......................................................................................................237.1 TopHorizontalStandardFlueØ80/125................................................................247.2 FlueLengthandTerminalPosition.......................................................................247.3 ExtensionCutting.................................................................................................247.4 InstallingtheSlidingSleeve.................................................................................247.5 FittingElbows.......................................................................................................257.6 FlueTerminalAssemblyFitting.............................................................................257.7 HorizontalFlueRoofTermination.........................................................................257.8 VerticalConcentricFlueØ80/125.........................................................................267.9 FlueLengthandTerminalPosition.......................................................................267.10 PitchedRoofTerminalInstallation........................................................................267.11 FlatRoofTerminalInstallation..............................................................................277.12 FlueTerminalCutting............................................................................................277.13 FittingAir/FlueDuctExtensions............................................................................277.14 FittingElbows.......................................................................................................27
0020095198_02-06/11-Glow-worm
INTRODUCTION
- 4 -
InTRoDUcTIon
1 Instructions guidance
1.1 Product documentation
Theinstructionsareanintegralpartoftheapplianceandmustbehandedtotheuseroncompletionoftheinstallationinordertocomplywiththecurrentregulation.
• Carefullyreadthemanual,tounderstandalltheinformationtoenablesafeinstallation,useandservicing.Noliabilitycanbeacceptedintheeventofdamagefornotcomplyingwiththeguidanceinthisinstructionmanual.
1.2 explanation of symbols
a DANGER: Risk of injuries.
e DANGER: Risk of electric shock.
ATTENTION: Risk of damage to the appliance or to its surroundings.
IMPORTANT: Important information.
1.3 Important notes
Read the following before installing your flue system!
flue options - 60/100
Therearevariousfluesystemsasillustratedindiagramopposite.
1.Directreartelescopicflue
2.Tophorizontaltelescopicflue.
3.Tophorizontalstandardflue.
4.Verticalconcentricflueflue.
Thesesystemsarecomplimentedwithvariousaccessories.
flue systems concealed in Voids
InaccordancewithBuildingRegulationsPartJ:2010andtheGasSafeRegisterTechnicalBulletinTB008:ForBoilerfluesystemsinstalledwithinanyconcealedenclosure(suchasaceilingspace,floorvoid,orapurposebuiltenclosure),theentirefluesystemshouldbeaccessible.Thisistoallowproperinspectionofthefluetodeterminethatitiscontinuousandfullysupportedthroughoutitslengthandalljointsarecorrectlyassembled.
Themaximumequivalentfluelengthsarestatedintheinstructionsprovidedwitheachappliance.Thesevaluesmustneverbeexceeded.
Multiple boiler chimney flue - 60/100 (flue category c43 natural draught)
Verticalconcentricmultipleflueissuitableforusewith:-
Tophorizontaltelescopicflue,
Topstandardhorizontalflue,
Refertoyourapplianceinstallationinstructionsforinformationrelatingtofluelengthandinstallation.
flue options - 80/125
Thetwofluesystemsavailableare:
1.Topstandardhorizontalflue
2.Verticalconcentric.
flue systems
ThefluelengthsavailablearedescribedintheappropriatesectionoftheInstallationInstructionssuppliedwithyourappliance.
• Thefluesealsaresensitivetomineraloilbasedlubricants.Donotgreasetheseals.Ifthesealsdoneedtobelubricateduseonlywater.
• Duringtheinstallationofthefluesystem,ensurethatdebrissuchasmortar,filingsorswarfareclearedfromthefluesystembeforecompletion.
• Inspectthefluepipesbeforefittinganddonotinstalldamagedordentedfluecomponents.
• Whenassemblingthefluesystem,ensurethattheinnersealsarenotdamaged,donotinstallafluecomponentwithadamagedseal.
• Thefluecanbeinstalledfrominsidethebuilding,whenaccesstotheoutsidewallfaceisnotpracticable.
• Whenextensionpipesareusedthefluesystemmustbedesignedtohaveacontinuousfalltotheapplianceofatleast2.5°44mm/metretoallowcondensatetorunbackintotheapplianceandoutviathecondensatedrain.
• Longlengthsoffluesmustbesecuredtothewallsorceilingstheyrunagainst.Useatleastonefixingbracketforeveryflueextensionthatisused.
• Aftercuttinginnerfluepipeensurethatyoude-burrandchamferthemaletubeendtopreventdamage.
• Inspectthefluepipesbeforefittinganddonotinstalldamagedordentedfluecomponents.
• Whenassemblingthefluesystem,ensurethattheinnersealsarenotdamaged,donotinstallafluecomponentwithadamagedseal.
• Whenfittingflueelbowsensurethattheyarefittedatthecorrectangletoavoidstrain,thiswillensurethatthesealfitscorrectlypreventingleakage.
0020095198_02-06/11-Glow-worm
INTRODUCTION
- 5 -
flue clearances
Thefluesshouldbepositionedsothatatleasttheminimumoperationalandservicingclearancesareprovided,refertotheappropriatesectionoftheinstallationliteraturesuppliedwithyourappliance.Additionalclearancesmaybebeneficialforinstallationandservicing.
Forflueinstallationswhereexternalaccessisnotpracticable,considerationshouldbegivenforthespacerequiredtoinserttheflueinternally,whichmaynecessitateclearancelargerthanthosespecified.
Timber frame buildings
IftheflueistobeinstalledinatimberframebuildingitshouldbefittedinaccordancewiththeInstituteofGasEngineersdocumentIGE/UP/7/1998.
IfindoubtseekadvicefromGlow-wormortheadvicelineforregisteredgasinstallersprovidedbythebodyapprovedatthetimebytheHealthandSafetyExecutive.
combustible Material
Theflueissuitableforinstallationontoandthroughcombustiblematerialsprovidedthataminimum5mmclearanceismaintainedaroundthecircumferenceoftheflue(airintake).
1.3.1 local regulations
Benchmarkplacesresponsibilitiesonbothmanufacturersandinstallers.Thepurposeistoensurethatcustomersareprovidedwiththecorrectequipmentfortheirneeds,thatitisinstalled,commissionedandservicedinaccordancewiththemanufacturer’sinstructionsbyacompetentpersonapprovedatthetimebytheHealthandSafetyExecutiveandthatitmeetstherequirementsoftheappropriateBuildingRegulations.TheBenchmarkChecklistcanbeusedtodemonstratecompliancewithBuildingRegulationsandshouldbeprovidedtothecustomerforfuturereference.
Installersarerequiredtocarryoutinstallation,commissioningandservicingworkinaccordancewiththeBenchmarkCodeofPracticewhichisavailablefromtheHeatingandHotwaterIndustryCouncilwhomanageandpromotetheScheme.
• Visitwww.centralheating.co.ukformoreinformation.
0020095198_02-06/11-Glow-worm
INTRODUCTION
- 6 -
Top HorizontalTelescopic Flue
A2043600
Ridge Tile Terminal
A2043800
Flue AdaptorA2024600
Top HorizontalStandard Flue
A2043400
Direct RearTelescopic Flue
A2043500
Pitched RoofWeather Collar2000460479
Flat RoofWeather Collar2000460478
Special ordercontact: Tower Flue
ComponentsMorley Road
TonbridgeKent TN9 1RA
Vertical Concentric
Flue 2000460480
Vertical Concentric Flue 60/100
Flue Systems
flue componentsØ60/100 Direct Toptelescopic Topstandard
Vertical
0.5mPtNo.20004604811mPtNo.20004604822mPtNo.2000460483incl.securingcollar
45° elbowPtNo.2000460485(packof2) 87° elbowPtNo.2000460484 Verticalflueadaptor
PtNo.A2024600
SlidingsleevePtNo.2000460487 - - TelescopicextensionPtNo.2036900incl.securingcollar - - FixingbracketPtNo.2000460486100Ø
Refer to section 2. Refer to section 3. Refer to section 1.
Refer to section 4.
15703
0020095198_02-06/11-Glow-worm
INSTALLATION
- 7 -
InsTallaTIon
All the drawings dimensions are shown in mm.
2 Telescopic Direct Rear flue Kit Ø60/100 - Pt. no. a2043500
Direct rear flues are only possible with certain boilers, check the instructions provided with your boiler.
Checkthecontentsofyourkit.
SEALINGTAPE
SEALINGCOLLAR
FLUESECURINGSCREWS(3OFF)
CLAMPINGBAND
2.1 flue length and Terminal position
RefertoyourInstallationinstructionssuppliedwiththeappliancetoconfirmthefluelengthavailableandlocationoftheflueterminal,thenproceedasfollows:
• Measurethedistancefromtheexternalwalltotheappliancemountingface”Y”,seediagrambelow.
• Setthefluetotherequiredlength‘Y’plus24mmminto28mmmax.
*Y+24to28
INSIDEWALLFACE
OUTSIDEWALLFACE
*noTe:Iffittingsealingcollaranadditional12mmisrequired
noTe:Iffittingthesealingcollar,addafurther12mmtotheoveralllength.
noTe:DONOTcutthetelescopicflue,ifthefluelengthcannotbeachieved,thestandardflueorextensionsshouldbeused.Howeverifnecessarythefluecanprojecttoamaximumof600mm.beyondtheoutsidewallface.
• Aligntheairductseams.
• Markanddrilla3mmholeintheairduct,takingcarenottopiercetheinnerflueduct.
• Securethejointwiththescrewsandtapeprovided.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 8 -
Alignairductseams
Ø3mm
2.2 external flue Installation
• Ifrequired,fitthesealingcollarontothelocatingringoftheflueterminal.
• Pushthetelescopicflueassemblyintothewallandthroughthegrips.
• Pulltheflueassemblyforwardtotherequireddepthshownindiagram,thensecureusingoneofthedescribedmethodsopposite.
2.3 Internal flue Installation
• Ifrequired,fittheinternalsealingcollarontothelocatingringoftheflueterminal.
• Pushthetelescopicflueassemblythroughthegripsandwall,untilthesealingcollarhasexitedthehole.
• Pulltheflueassemblyforwardtotherequireddepthshownindiagramopposite,thensecureusingoneofthedescribedmethodsopposite:
Method 1. securing screws (3)Therearesixholesprovidedinthegrips,threeoftheseshouldbeusedtosecuretheflue.Markanddrill3mmholesintheairductthensecuretothegripswiththescrewsprovided.
Method 2. clamping bandSecurethetelescopicterminalassemblyusingtheclampingbandsupplied.Theclampingbandsecuringscrewmustbefittedinthecorrectorientation.
MeTHoD 1
Secure clamping band grips at three positions with screws provided
Ø3mm
MeTHoD 2
Secure clamping band in position
Check that the flue air duct has been securely retained by the clamping band and grips before fitting the appliance.
Oncompletionofflueinstallation,continuewiththeapplianceinstallation,referringtotheappropriatesectionoftheapplianceinstallationinstructionssupplied.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 9 -
3 Top Horizontal Telescopic flue Kit Ø60/100 - Pt. no. a2043600
Checkthecontentsofyourkit.
3.1 flue length and Terminal position
RefertoyourInstallationinstructionssuppliedwiththeappliancetoconfirmthefluelengthavailableandlocationoftheflueterminal,thenproceedasfollows:
• Withtheflueelbowtemporarilyfitted,measurethedistancefromtheexternalwalltotheelbow.
noTe:*Iffittingthesealingcollar,addafurther12mmtotheoveralllength‘Y’,seediagramsbelow.
• Settheflueductstotherequiredlength‘Y’.Ifthemeasurement‘Y’exceedsthetelescopicfluelength,thentheappropriatelengthofextensionpipewillberequired.
15610
ReaR flUe
* ‘Y’
15611
sIDe flUe
* ‘Y’
DO NOT cut the telescopic flue, if the flue length cannot be achieved, the standard flue or extensions should be used.
Ifdesirablethefluecanprojecttoamaximumof600mmbeyondtheoutsidewallface.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 10 -
• Aligntheairductseams.
• Markanddrilla3mmholeintheairduct,takingcarenottopiercetheinnerflueduct.
• Securethejointwiththescrewsandtapeprovided.
• Ifrequired,fitthesealingcollarontothelocatingringoftheflueterminal.
• Removetheflueelbow.
• Pushtheflueassemblyintothewall,untiltheendoftheassemblyprotrudesashortwayfromtheinsidefaceofthewall.Thiswillenabletheinternaltrimring(ifrequired)tobepositionedandallowtheflueassemblytobedrawnbackuptotheflueelbow.
• Securetheflueelbowinpositionontopoftheappliancewithfourscrewssupplied.
• Fittheflueassemblytotheelbow.
• Fitthesecuringcollarintoposition.
• Ensuringcorrectalignmentoftheairductseam,markthroughtwoofthepredrilledholesinthesecuringcollar.
• Removesecuringcollaranddrilltwo3mmdiameterholesoneintheelbowandoneintheairduct,takecarenottopiercetheinnerflueduct.Securecollarandairductwithscrewsprovided.
• Slidetheinternaltrimringbackagainstthewall,securinginplacewithasmallamountofsealantifrequired.
• Checkthattheouterrubbersealingcollarmakesaneffectivesealagainstthewallface.
Oncompletionofflueinstallation,continuewiththeapplianceinstallation,referringtotheappropriatesectionoftheapplianceinstallationinstructionssupplied.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 11 -
4 Top Horizontal standard flue Kit Ø60/100 - Pt. no. a2043400
Checkthecontentsofyourkit.
4.1 flue length and Terminal position
RefertoyourInstallationinstructionssuppliedwiththeappliancetoconfirmthefluelengthavailableandlocationoftheflueterminal,thenproceedasfollows:
• Withtheflueelbowtemporarilyfitted,measurethedistancefromtheexternalwalltotheelbow.
noTe:*Iffittingthesealingcollar,addafurther12mmtotheoveralllength‘Y’,seediagramsbelow.
• Settheflueductstotherequiredlength‘Y’.Ifthemeasurement‘Y’exceedsthetelescopicfluelength,thentheappropriatelengthofextensionpipewillberequired.
15610
ReaR flUe
* ‘Y’
15611
sIDe flUe
* ‘Y’
4.2 flue cutting• Separatetheflueductfromtheterminalbytwistingto
releasetheterminalcatch.
Theflueductcuttinglengthis(L+11mm),seediagram.
noTe:Iffittingthesealingcollar,addafurther12mmtotheoveralllength.Howeverifdesirablethefluecanprojecttoamaximumof600mmbeyondtheoutsidewallface.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 12 -
Theairductshouldbecutattheoppositeendtotheterminal
andtheplasticflueductMUSTbecutattheoppositeendtotheterminalcatch.
TheplasticflueductextensionsMUSTbecutattheoppositeendtoseal.
• Inserttheflueductintotheairductterminalassembly,rememberingtoengagethecatchwithintheterminal.
*noTe:Iffittingsealingcollaranadditional12mmisrequired
4.3 flue fitting• Fitthesealingcollarontothelocatingringontheflue
terminal,seediagram5.
• Withtheflueterminalremoved,pushtheflueassemblyintothewall,externallyorinternally,untiltheendoftheassemblyprotrudesashortwayfromtheinsidefaceofthewall.Thiswillenabletheinternaltrimring(ifrequired)tobepositionedandallowtheflueassemblytobedrawnbackintotheflueelbow.
• Securetheflueelbowinpositionontopoftheappliancewithfourscrewssupplied.
• Fittheflueassemblytotheflueelbow.
• Fitthesecuringcollarintoposition.
• Ensuringcorrectalignmentoftheflue,markthroughtwoofthepredrilledholesinthesecuringcollar.
• Removesecuringcollaranddrilltwo3mmdiameterholesoneintheelbowandoneintheairduct,takecarenottopiercetheinnerflueduct,securecollarwithscrewsprovided.
• Slidetheinternaltrimringbackagainstthewall,securinginplacewithasmallamountofsealantifrequired.
• Checkthattheouterrubbersealingcollarmakesaneffectivesealagainstthewallface.
noTe:Iftheairandflueductshavebeencorrectlycuttotheinstructionsthesealingcollarshouldfitflushwiththeoutsidewall.Oncompletionofflueinstallation,continuewiththeapplianceinstallation,referringtotheappropriatesectionoftheapplianceinstallationinstructionssupplied.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 13 -
5 Vertical concentric flue systemØ60/100 - Pt. no. 2000460480
Comprisesofcomponentsselectedtosuityoursiterequirements,refertoFluecomponentstable.
Makesureyouhaveallthenecessarycomponentsbeforeproceedingwiththeinstallation.
X X X
TerminalTerminal
Terminal
PITcHeD Roof
flaT Roof RIDGe TeRMInal
Themaximumlength“X”plusterminalassy,refertoinstallationinstructions.Foreach87.5ºor45ºX2bendsfitted,themaximumlengthmustbereducedby1metre.
5.1 flue length and Terminal Position
Themaximumfluelengthandterminalpositionaredescribedinyourinstallationinstructionssuppliedwithyourappliance.
5.2 flue Installation
Securetheflueadapterinpositionontopoftheappliancewithfourscrewssupplied.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 14 -
Make sure the nib fits into the locating slot in the appliance casing to ensure correct orientation.
Withtheflueadapterfitted,measurethefluelengthrequired.
The use of a sliding sleeve will allow the appliance to be easily removed and replaced without dismantling the flue.
Ensure that at least one fixing bracket supports each extension pipe used.
DO NOT connect the final extension until the flue terminal has been positioned.
• Securetheextensionpipetotheflueadapterwiththesecuringcollarsupplied,bypositioningthecollarcentrallyoverthejointthentighteningthetwoscrewsonthesecuringcollar.
• Fitadditionalextensionpipesasrequiredusingthecollarandscrewssuppliedwitheachextensionpipe.
• Tofit,positionthecollarcentrallyoverthejointandtightenthetwoscrewsonthesecuringcollar.
• Usingtheholesprovidedinthesecuringcollardrillandinsertthetwoselftappingscrewssupplied,seediagram6.Therubber‘O’ringsofeachsectionshouldbelubricatedpriortoassembly.
• Projecttheriseofthefluetorooflevel.Theflueterminalwillrequirea150mmhole.
5.3 flue Terminal Installation
Pitched Roof
Fittherequiredpitchedroofweathercollaroverthe150mmholeintheroof.Makegoodthetilingorslatingaroundthecollarincorporatingtheflashingoftheweathercollar.Positiontheanglecapovertheweathercollarinthecorrectorientationtoattainthecorrectangleforyourroof.
flat Roof
Fitthealuminiumweathercollaroverthe150mmholeintheroofensuringaweathertightseal.
Fromabovecarefullyplacetheflueterminalthroughtheweathercollar.
5.4 Ridge Tile Terminal
Aridgetileterminalisavailable-partno.A2043800,seeFlueSystemsatthefrontofthisliterature.Theinstallationofaridgetilewillberequired.Asuitableridgetileismanufacturedby:-AspectEastAngliaLimitedTheOldMillEastHarlingNORWICHNR162QWWebsite:www.aspectroofing.co.ukContact:ChrisHaythorpeGeneralManager-TileDivisionTel:01953717777Fax:01953717164
0020095198_02-06/11-Glow-worm
INSTALLATION
- 15 -
FLAT ROOF
1.
TERMINAL
2.
3.
5.
10
0-11
05 SECURING
COLLAR
SECURINGSCREW
SECURINGSCREW
6.
DO NOTSECURE
4.
TERMINAL
PITCHED ROOF
10
0-11
05
SECURINGCOLLAR
1.
2.
3.
4.
5.
SECURINGSCREW
SECURINGSCREW
6.
DO NOTSECURE
5.5 flue Terminal cutting
Shouldtheclearancesabovetheappliancetotheflueterminalnotallowforextensions,itispermittedtocuttheflueterminalensuringtherelationshipofflueandairductlengthsareretained.
5.6 flue extension completion
Withtheflueterminalpositionedintheroof,measurethelengthofthepiperequiredtocompletetheconnectionbetweenterminalandextension.Ifatelescopiclengthcannotbeused,thenanextensionpipecanbecuttothecorrectlength.Cutthefluetothedesiredlengthmeasuringfromthe‘O’ringendanddiscardtheplainendofthetube.Thecutsmustbesquareandmadefreeofburrstoallowcorrectassembly.
noTe:Thefluepipeis10mmlongerthantheairpipe.
Carefullypushtheterminalassemblyupwardstoallowroomforfittingthefinalfluepiece.Fitafixingbrackettotheterminalassembly.Pulltheterminalassemblydownandjointothefluesystem.Ensurethattheterminalismakingaweathertightsealontheweathercollar.Securethefixingbracketfittedtotheterminaltotheroofingstrutsorapurposemadebatton.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 16 -
6 accessories
6.1 Deflector flue Terminal Kit Ø60/100
Checkthecontentsofyourkit.
Part no. 0020060582 - blackPart no. 0020060583 - White
Installation Instructions
www.glow-worm.co.uk
Deflector flue terminal kit
Part No. A200*****
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
00
20
06
82
79
-02
0
4 .
08
General/Sales enquiries:
Tel: (01773) 828100 Fax: (01773) 828070
Installation refer to diagram 2.
The terminal kit fits onto the telescopic and standard
horizontal flue, see diagram 1 for contents.
NOTE: The deflector terminal kit can be fitted after the boiler
and flue have been installed.
Remove the rubber collar (a).
Use a 8mm. flat screwdriver to bend catches inwards (b).
Remove the flue terminal and flue duct (c).
Remove the flue pipe from the flue terminal by twisting them
against each other (d).
Push the flue duct into the deflector flue terminal.
NOTE: the catch on top (inside) the terminal must lock firmly
into the notch on top of the flue duct (e).
Fit the rubber collar supplied with the kit (f).
Push the flue duct and terminal into the air duct make sure
the seals fit tightly.The deflector part of the deflector flue terminal can be
rotated 45o to the left or right if required (g).
NOTE: Do not fit the deflector flue terminal with the deflector
positioned downwards.
If the boiler has not been fitted, continue as described in the
installation, servicing and user instructions supplied with the
boiler.To remove the deflector flue terminal from the air duct pull
the locking strap down (h), this will release the two side
locking positions (f).
14697
14696
Diagram 1
Diagram 2
For Use WithGlow-worm High Efficiency
Condensing CombinationBoilers
(a)
(b)
(c)
(d)
(e)
(g)
(h)
(f)
TheDeflectorFlueTerminalkitwillfiteitherthetelescopicorstandardhorizontalfluesystemsandisdesignedtoberotated45ºfromthetopcentre,directingtheplumeawayfromopenings,people,cars,windowsetc.
Itcanbefittedaftertheapplianceandfluehavebeeninstalled.
Shouldthedeflectorterminalbepositionedunderasoffitorhorizontalsurface,itisallowedtoprojecttheflue600mmfromthewall,toallowthedischargeoffluegasesproducedintofreeair.
Do not fit the deflector flue terminal with the deflector positioned downwards.
6.2 Installation
(a)Ifpreviouslyfitted,removetherubbercollar.
(b)Usinga8mm.flatscrewdrivertoreleasethecatch.
(c)Withdrawtheflueterminalandpipefromtheduct.
(d)Removethefluepipefromtheterminal,twistandpull,discardtheterminal.
(e)Locatethe“notch”onthepipe,alignwiththe“catch”onthedeflectorterminalandpushthepipeintoposition,ensuringthattheengagementissecure.
(f)Fittherubbercollar
(g)Rotatethedeflectortosuityourrequirements.
(h)ReleasingStrap.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Pushthefluepipeandterminalintotheairduct,makesurethesealsfittightly.Toremovedeflectorflueterminalfromtheairductpulllockingstrapdown(h),thiswillreleasebothsidelockingpositions(f).
0020095198_02-06/11-Glow-worm
INSTALLATION
- 17 -
6.3 blacK Terminal Kit Ø60/100
Checkthecontentsofyourkit.
Part no. a2043700
TheBlackTerminalkitwillfiteitherthetelescopicorstandardhorizontalfluesystemsandcanbefittedafter
theapplianceandfluehavebeeninstalled.
6.4 Installation
(a)Usinga8mmflatscrewdrivertoreleasethecatch.
(b)Withdrawtheflueterminalandpipefromtheduct.
(c)Removethefluepipefromtheterminal,twistandpull,discardtheterminal.
(d)Locatethe“notch”onthepipe,alignwiththe“catch”ontheBlackterminalandpushthepipeintoposition,ensuringthattheengagementissecure.
(e)Fittherubbercollar.
Pushtheflueductandterminalintotheairductmakesurethesealsfittightly.noTe:theseamoftheairductmustbeatthetop.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 18 -
flue length-Theconcentricandplumepipecanvary,butthemaximumfluelength,mustnotbeexceeded.
TheplumemanagementkitfitsontotheconcentrichorizontalflueterminaloftheGlow-wormhighefficiencyappliancesandenablestheflueproductstoberoutedfurtherawayfromtheapplianceflueterminal,therebyreducingthevisualimpactofpluming.Itshouldnotbeusedtoovercometerminalpositionswhichdonotcomplywithstandardsormanufacturersinstructions.
Theflueoutletsuppliedterminatesat87obutcan,ifrequired,terminateverticallyorat45°bysimplyusingtheappropriateaccessory.
Sitingcaneitherbeonawallfacewiththeterminalexhaustingatrightanglestothewallorabovetheeavesofabuilding.Werecommendthatterminalsexhaustingverticallyabovetheeavesaresecured.
Theterminationoftheplumemanagementkit,shouldnotbelessthan2metresabovegroundlevel.
6.5 Plume Management Kit Ø60/100
Forusewithconcentricfluesystems60/100,partno.A2043400andpartno.A2043600.Checkthecontentsofyourkit.
Wallconnector
Pipe fixingbracket (3 off) 1M Pipe
(2 off)
87° bendwith birdprotection
contents of KitWhitekit:A2044100,Blackkit:A2044000
*noTe:Foreveryelbowthefluepipelengthshouldbereducedbythefollowingamounts:
1x90°=1metre
2x90°=2metres
1x45°=0.5metres
2x45°=1metre
Thetotalfluelength(plumemanagementkit+concentric)mustnotexceedthemaximumtotalfluelengthoftheappliance.
Example:Ultracom,“a”=4.0m+“b”=6.0m=10.0mmax.
Plume and Concentric Flue Length
a = flUe PIPe lenGTH (metres) a+bMaximum
combinedfluelength0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
b =
flU
e le
nG
TH
ULTRACOM2 9.5 9.0 8.5 8.0 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 10.0ULTRACOM235STORE 9.5 9.0 8.5 8.0 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 10.0
ULTRACOM 9.5 9.0 8.5 8.0 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 10.0FLEXICOM 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 8.0ULTRAPOWER 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 8.0BETACOMa 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 - - 6.0
0020095198_02-06/11-Glow-worm
INSTALLATION
- 19 -
6.6 Terminal siting
Refer to the diagram below and the appropriate clearances for the flue outlet terminal in relation to openings, air inlet etc., these must be adhered to.
Theminimumsitingdimensionsfortheterminalpositions,A,B,Cstatedinthediagram,canbeappliedwhenaplumemanagementkitisfitted.
MInIMUM sITInG foR HoRIZonTal flUe aIR InleT MM
A)DIRECTLYBELOWANOPENINGWINDOW 50 DIRECTLYBELOWANOPENING,AIRBRICK 25
B)DIRECTLYABOVEANOPENINGWINDOW 50 DIRECTLYABOVEANOPENING,AIRBRICK 25C) HORIZONTALLYTOANOPENINGWINDOW 50
HORIZONTALLYTOANOPENING,AIRBRICK 25
MInIMUM sITInG DIMensIons foR fanneD flUe TeRMInals PosITIon
MInIMUM sITInG foR PlUMe ManaGeMenT KIT flUe oUTleT MM
D)DIRECTLYBELOWANOPENING,AIRBRICK, OPENINGWINDOWS(HorizontalDischarge) 300
E)DIRECTLYABOVEANOPENING,AIRBRICK, OPENINGWINDOWS(HorizontalDischarge) 300
F) HORIZONTALLYTOANOPENING,AIRBRICK, OPENINGWINDOWS 300
G) ABOVEROOFLINE 300
ForfurtherguidanceonsitingrequirementsconsultBS5440-1:TableC.1
a
a
b
c
G
D,e
f15572
Theminimumlengthis500mm,threeexamplesareshowninthediagramsbelow.
Additionalelbows,bendsand1Mextensionscanbeusedasrequired.
1MExtension(white) A2044300 87°bend(white) A2044700 2x45°elbows(white) A2044500 1MExtension(black) A2044200 87°bend(black) A2044600 2x45°elbows(black) A2044400
21/2°
Horizontal Left or Right
IMPORTANT:Flue must always slope at least(44mm / m) towards the boiler
500
min
. dis
tanc
e
0020095198_02-06/11-Glow-worm
INSTALLATION
- 20 -
AIRINLET
FLUEOUTLET
6.7 Installation
Theplumemanagementkitcanbefittedwhentheapplianceandfluearebeingfitted,oraftertheapplianceandfluehavebeeninstalled.
Usea8mm.flatscrewdrivertobendcatchesinwards.
8mmScrewdriver
Horizontal Flue
FlueTerminalAir
Duct
FlueDuct
Removetheflueterminalandflueduct.
Removethefluepipefromtheflueterminalbytwistingthemagainsteachother.
45° Left or Right
Minimum installationlength 500mm from air inletto top of vertical, horizontaland 45° outlet terminal.
500
min.
dist
ance
Vertical
Minimum installationlength 500mm from air inletto top of vertical, horizontaland 45° outlet terminal.
500
min
. dis
tanc
e
AIRINLET
FLUEOUTLET
0020095198_02-06/11-Glow-worm
INSTALLATION
- 21 -
Pushthewallconnectorontotheflueduct.
noTe:thecatchontop(inside)ofthewallconnectormustlockfirmlyintothenotchontopoftheflueduct.
Fittherubbercollar.
Pushtheflueductandwallconnectorintotheairductmakesurethesealsfittightly.
Catch
Wall Connector
noTe:Theseamoftheairductmustbeatthetop.
Iftheappliancehasnotbeenfitted,continueasdescribedintheinstallation,instructionssuppliedwiththeappliance.
Usingthe1Mpipes,pipefixingclipsand87°bendwithbirdprotectionbuildthe(Allpushfit)plumemanagementkitfromthefittedwallconnectortotheselectedlocationfortheflueexit.Ensuringthejointsaretotallysealed.Thefluepipeswillexpandwhenheatedleave1cmexpansiongapineachconnection.
The flue should always have a fall of at least 21/2° (44mm/metre) towards the appliance.
Whencutting1Mpipestodesiredlength,cuttheoppositeendtothesealandremoveallburrs.
The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water.
Take care when inserting not to push out the seals.
Additionalpipe,87°bendsand45°elbowsmaybeusedasnecessary.
Usingthepipefixingbracketssupplied,securethestraightpipetothewall.
The first bracket must be positioned as close to the Wall Connector as possible.
PIPEFIXINGBRACKETS
Thestraightpipemustbesecuredeverymetreandateachchangeofdirectionsomorebracketsmayberequired(3supplied).
55
LockingPosition Collar
0020095198_02-06/11-Glow-worm
INSTALLATION
- 22 -
6.8 Termination above eaves
TheHorizontalterminationshouldbeterminated100mmabovetheeaves.Theverticalflueoutletshouldbeaminimumdistanceof300mmabovetheeaves.
Exposedsiteconditionsmayrequirethatthefluebesecuredasdescribedindiagram.
6.9 Termination
Theterminationcanbechangedfrom87°horizontalto45°orvertical.
Toachievethisremovethewirebirdprotectionguardfromthe87°Bend.RemovetheO-ringsealfromthe1MPipeor45°elbowandfitthewirebirdprotectionguardintothe1MPipeor45°elbowwheretheO-ringsealwasfitted.
Itisnotnecessarytofitaterminalguardovertheappliancemainflueoutlet.Howevershouldtheplumemanagementkitterminaldischargeinaplacewhereitrequiresprotection,aguardshouldbefitted.
VerticalTerminal
45°Terminal
Wall plate
Stud bolt
Pipe fixing bracket
IMPORTANT:Remove the seal and fit the bird protection wire from the 87° bird protection bend
Bird protection wire
Seal
MinimumClearanceVertical 300mm900 or 450 100mm
90°Terminal (supplied)
WERECOMMENDTHATTERMINALSABOVEEAVESARESECURED
6.10 fixing Instructions
TheseinstructionsaresuppliedtoenablethefluepipefromthePlumeManagementAssemblytobesecurelyfixedeitherattheeavesoronthegableendofabuildingwhentheflueterminalistobeterminatedabovetheroof.
Thestudboltandwallplatefixingscanbeobtainedfromkitpt.no.A2043900andusedwiththepipefixingbracketsupplied.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 23 -
flue systems and components
7 flue systems and components
SECURINGCOLLAR
STANDARDTERMINALASSEMBLY
TRIMPLATE
TRIM RING
SECURINGCOLLAR
87BEND
SCREW x 2
SCREW x 2 SCREWx 2
SCREW x 2
º
0.5m Pt No. 00201045531m Pt No. 00201045542m Pt No. 0020104555(incl. securing collar)
45° Pt No. 0020104557(pack of 2 incl.2 securing collars)
87° Pt No. 0020104556(incl. securing collar)
Vertical flueadaptorPt No. 0020104550(incl. securing collar)
SlidingsleevePt No. 0020104558
Refer to page 28
Refer to page 31
Fixing bracket (5)Pt No. 0020104559
Flue components Ø80/125
Flue accessories Ø80/125
Flat RoofWeather CollarPt No. 2000460478
Pitched RoofWeather CollarPt No. 2000460479
Top horizontal standard flue terminal Pt No. 0020104551
Vertical concentric flue Pt No. 0020104552
0020095198_02-06/11-Glow-worm
INSTALLATION
- 24 -
25 mm15 mm
5 mm
CUT THISEND ONLY
AIR DUCT
TWIST
INNERSECURINGCATCH
FLUEDUCT
5 mm
noTe:Forassemblyreasonsdonotshortenanyairducttoalengthoflessthan100mm.Ifnecessaryshortentwoadjacentextensionstoachievetheoverallrequiredlength. noTe:Forinstallationswherethereisinsufficientmovementtoallowfittingoftheflueintoflueoutlet,aslidingsleeveisavailablePartNo.0020104558.Whenusingtheslidingsleeveboththeairandflueductsofthelastextensionmustbeshortenedbyafurther85mm.
7.4 Installing the sliding sleeve
Pushtheslidingsleeve(1)overthecutendoftheflueduct(2).Pullbacktheslidingsleevesothatitengagesintothesocket(3)oftheboiler(4).Ensurethattheslidingsleevepenetratesthesocketsuchthatthereisatleast20mmengagementatbothendsoftheslidingsleeve.Fittheairductclamp(7)overtheairducts(5and6)oftheextension/terminalandboileroutlet.Closethesnapclamp.
Drilltwoholes3mmdiameterthroughtheairductclamp(7)(thecentreoftheholesshouldbe6mmfromtheedgeoftheclamp).Ensurethatthedrilldoesnotpenetratetheinnerflueduct.Screwtheairductclamptotheairductofthesleeveusingthescrewsprovided.
Completetheinstallationoftheflueasdetailedintheseinstructions.
7.1 Top Horizontal standard flue Ø80/125
Refertodiagram1andcheckthecontentsofyourkit.
Makesureyouhaveallthenecessarycomponentsbeforeproceedingwiththeinstallation.
7.2 flue length and Terminal Position
RefertoyourInstallationinstructionssuppliedwiththeappliancetoconfirmthefluelengthavailableandlocationoftheflueterminal,thenproceedasfollows:
• Securetheflueadapterinpositionontopoftheappliancewithfourscrewssupplied.
noTe:Makesurethenibfitsintothelocatingslotintheappliancecasingtoensurecorrectorientation.
• Withtheflueelbowtemporarilyfitted,measurethedistancefromtheexternalwalltotheelbow.
SIDE FLUE
* ‘Y’
• Ifthemeasurement‘Y’exceedstheachievablefluelength,960mm.thentheappropriatelengthofextensionpipeisrequired.
7.3 extension cutting
• Separatetheflueductfromtheterminalbytwistingtoreleasefromthesecuringcatchinsidetheair/flueduct
• Whencutting,cutequalamountsofftheairductandflueduct.
• Whenjoiningextensionsleaveagapof5mmbetweeneachairductthiswillleaveacorrectflueductconnectionof30mm.
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INSTALLATION
- 25 -
1. 2.
3. 4.
5. 7. 6.
7.5 fitting elbows
The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage.
• Theelbowfittedtothetopoftheboiler(1)shouldbetwistedby3°toensurethatthesecond87°elbow(2)exitsthewallperpendicular.
7.6 flue Terminal assembly fitting
• Pushtheflueterminalassemblyintothewall,externallyorinternally,untiltheendoftheassemblyprotrudesashortwayfromtheinsidefaceofthewall.Thiswillenabletheassemblytobedrawnbackintotheflueelbowontopoftheflueadapter.
• Fittheinternaltrimplate.
• Securetheflueelbowwiththesecuringcollarinpositionontopoftheverticalflueadapter.
• Ensuringcorrectalignmentoftheflueterminalassemblytotheflueelbowandsecurewiththesecuringcollar.
• Markthroughtwoofthepredrilledholesinthesecuringcollars.
• Drill3mmdiameterholes,takecarenottopiercetheinnerflueduct.
• Securethesecuringcollarstotheairduct,seeinset1.
• Makegoodtheexternalwallfaceandfittheexternaltrimring.
noTe:Theairinletmustprotrudecompletelybeyondthefaceoftheexternalwallandtheexternaltrimring.
Oncompletionofflueinstallation,continuewiththeapplianceinstallation,referringtotheappropriatesectionoftheapplianceinstallationinstructionssupplied.
SECURINGCOLLAR
SECURINGCOLLAR
TERMINALASSEMBLY
MAXIMUM220mm
SECURINGSCREW(4 OFF)
SECURINGSCREW(2 OFF)
INSET 1.
VERTICALFLUEADAPTER
INSET 2.
EXTERNAL TRIM RING
INTERNAL TRIM PLATE
AIR INLET
7.7 Horizontal flue Roof Termination
OrdertheflueflashingfromfromUbbink,Northants,Telephone01280700211.
• Followthepreviousinstructionsandthediagrambelow,topreparetheflueandfollowtheinstructionssuppliedwiththeflashing.
82 - 90
0020095198_02-06/11-Glow-worm
INSTALLATION
- 26 -
TERMINAL
x x
PITCHED ROOF FLAT ROOF
TERMINAL
The maximum length X plusterminal, refer to installationinstructions.For every 87º or 2 x 45º bendsfitted, the maximum lengthmust be reduced by 1 metre.
7.8 Vertical concentric flue Ø80/125
Checkthecontentsofyourkit.
Makesureyouhaveallthenecessarycomponentsbeforeproceedingwiththeinstallation.
7.9 flue length and Terminal Position
Determineyourmaximumfluelengthandterminalpositionrequired,asdescribedinyourinstallationinstructionssuppliedwithyourappliance,thenproceedasfollows:
• Securetheflueadapterinpositionontopoftheappliancewithfourscrewssupplied.
noTe:Makesurethenibfitsintothelocatingslotintheappliancecasingtoensurecorrectorientation.
• Fittheflueterminalsasdescribedinthefollowingparagraphs,pitchedorflatroof.
• Measurethefluelengthsrequired.Incaseofinstallationdirectlytotheboilerwithoutelbows,itisessentialthattherooftile/collarisverticallyalignedwiththeair/flueductoftheboiler.
7.10 Pitched Roof Terminal Installation
• Determinethepointwheretheverticalair/flueductandterminalassemblywillexittheroof.
• Fittheflexiblepitchedroofweathercollar(2).overthe125mm.holeintheroof.Makegoodthetilingorslatingaroundthecollarincorporatingtheflashingoftheweathercollar.
• Positiontheanglecapovertheweathercollarinthecorrectorientationtoattainthecorrectangleforyourroof.
• Workingfromabove,inserttheverticalroofduct(1)throughtherooftileandpushitfirmlyintoplace.
• Verticallyaligntheroofductandattachittotheroofstructurewiththefixingbracket(3)supplied.
• Fittheboilerhangingbracketandinstalltheappliancewithreferencetotheinstallationandservicinginstructionssuppliedwiththeappliance.
0020095198_02-06/11-Glow-worm
INSTALLATION
- 27 -
7.11 flat Roof Terminal Installation
Determinethepointwheretheverticalair/flueductandterminalassemblywillexittheroof.
• Fitthealuminiumweathercollar(2).
• Sticktheflatroofpenetrationcollarfirmlyintoplacewithadhesiveinaccordancewiththecodesofpracticeforflatroofs(CP144)toensureawatertightseal.
• Workingfromabove,inserttheverticalroofduct(1)throughtheflatroofcollarandpushitfirmlyintoplace.
• Verticallyaligntheroofductandattachittotheroofstructurewiththefixingbracket(3)supplied.
• Fittheboilerhangingbracketandinstalltheappliancewithreferencetotheinstallationandservicinginstructionssuppliedwiththeappliance.
7.12 flue Terminal cutting
DONOTCUTTHEFLUETERMINALshouldtheclearancesabovetheappliancetotheflueterminalnotallowforextensions.
7.13 fitting air/flue Duct extensions
Withtheflueterminalpositionedintheroof,completetheconnectionbetweenterminalandadapter.
• Separatetheflueductfromtheterminalbytwistingtoreleasefromthesecuringcatchinsidetheair/flueduct
• Whencutting,cutequalamountsofftheairductandflueduct.
• Whenjoiningextensionsleaveagapof5mm.betweeneachairductthiswillleaveacorrectflueductconnectionof30mm.
noTe: Forassemblyreasonsdonotshortenanyairducttoalengthoflessthan80mm.Ifnecessaryshortentwoadjacentextensionstoachievetheoverallrequiredlength.
noTe:SeeFittingair/flueductextensions/Fittingelbowsforfurtherdetailsontheinstallationofextensionsandelbows.
• Pushtheslidingsleeve(6)firmlyintoplaceontheextension.
• Jointheverticalroofduct(1)totheextension(4).
• Jointheslidingsleeve(6)totheverticalflueadapter(5).
Using the sliding sleeve allows the appliance to be easily removed and replaced without dismantling the flue.
• Drilltwoholes3mmØthroughtheairductoftheflue/boilerclampatthemostconvienientholesontheairductsecuringclamp.(Ensurethatthedrilldoesnotpenetratetheinnerflueduct).Screwtheairductsecuringclamptotheairductsoftheflueassemblyandtheverticalflueadapterusingthescrewssupplied.
• Ensurethatanyairductsecuringclampsusedarepositionedcentrallyandfixedtotheairductusingtheselftappingscrewssupplied.
The air duct securing clamp MUST NOT be screwed to the bottom of the vertical air/flue duct and terminal accessory, this will allow for any slight movement in the roof structure.
• Ensurethatatleastonefixingbracketsupportstheair/flueductateachextensionfitted.
7.14 fitting elbows
The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage.
• Theelbowfittedtothetopoftheboiler(1)shouldbetwistedby3°toensurethatthesecond87°elbow(2)exitsthewallperpendicular.
TERMINAL
PITCHED ROOF
82
- 90
5
SECURINGCOLLAR
1.
2.
3.
4.
5.
SECURINGSCREW
SECURINGSCREW
6.
DO NOTSECURE
FLAT ROOF
1.
TERMINAL
2.
3.
5.
82
- 90
5 SECURINGCOLLAR
SECURINGSCREW
SECURINGSCREW
6.
DO NOTSECURE
GLOW-WORM
Nottingham Road, Belper, Derbyshire. DE56 1JT
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
www.glow-worm.co.uk
Subjecttoengineeringchanges
0020095198_02-06/11