flue installation - glow-worm · on completion of flue installation, continue with the appliance...

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

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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.

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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.

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INTRODUCTION

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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.

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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.

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INSTALLATION

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3 Top Horizontal Telescopic flue Kit Ø60/100 - Pt. no. a2043600




• 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.

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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.


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INSTALLATION

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4 Top Horizontal standard flue Kit Ø60/100 - Pt. no. a2043400





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.

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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.

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INSTALLATION

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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.

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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

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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.

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INSTALLATION

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6 accessories

6.1 Deflector flue Terminal Kit Ø60/100


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).

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INSTALLATION

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6.3 blacK Terminal Kit Ø60/100


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.

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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.




• Securetheflueadapterinpositionontopoftheappliancewithfourscrewssupplied.

noTe:Makesurethenibfitsintothelocatingslotintheappliancecasingtoensurecorrectorientation.


SIDE FLUE

* ‘Y’

• Ifthemeasurement‘Y’exceedstheachievablefluelength,960mm.thentheappropriatelengthofextensionpipeisrequired.

7.3 extension cutting

• Separatetheflueductfromtheterminalbytwistingtoreleasefromthesecuringcatchinsidetheair/flueduct

• Whencutting,cutequalamountsofftheairductandflueduct.

• Whenjoiningextensionsleaveagapof5mmbetweeneachairductthiswillleaveacorrectflueductconnectionof30mm.

0020095198_02-06/11-Glow-worm

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.


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




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

flue installation - glow-worm · on completion of flue installation, continue with the appliance...

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