DOWNDRAFT INSTALLATION INSTRUCTIONS DHD Models YOUR LF8 OUR INSP RATION. SAFETY INSTR[ Read All Instructions Before Using the Appliance. READ AND SAVE THESE INSTRUCTIONS WARNING WARNING TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS, OBSERVE THE FOLLOWING: A. CAUTION: For general ventilating use only. Do not use to exhaust hazardous or explosive materi= als and vapors. Installation work and electrical wiring must be done by qualified person(s)in accordance with all appli= cable codes and standards, including fire-related construction. To reduce risk of fire and to properly exhaust air, be sure to duct air outside. Do not vent exhaust air into spaces within walls, ceilings, attics, crawl spaces or garages. B. Sufficient air is needed for proper combustion and exhausting of gases through the flue (chimney) of fuel burning equipment to prevent backdrafting. Follow the heating equipment manufacturer's guideline and safety standards such as those published by the National Fire Protection Association (NFPA), and the American Society for Heating, Refrigeration and Air Conditioning Engineers (ASHRAE), and the local code authorities. C When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden utilities. D. Ducted fans must always be vented to the outdoors. TO REDUCE THE RISK OF FIRE, USE ONLY METAL DUCT WORK. To reduce the risk of fire, electric shock and injury to persons, ventilator assemblies, All DHD models must be installed with integral blower, model DHG601DUC or remote blower models DHG6003UC or DHG 1003UC. Other ventilator blowers cannot be substituted. E. Always unplug or disconnect the downdraft from the power supply before servicing. R To reduce the risk of fire or electric shock, do not use the fan with any solid-state speed control device. This unit is designed for indoor use only. Use this unit only in the manner intended by the manufacturer. This appliance has been found to be in compli= ance with UL507 Standard for Electric Fans and CAN/CSA-22.2 No. 113 Canadian Standard doe Fans and Ventilators. It is the responsibility of the owner and the installer to determine if additional requirement or standards apply in specific installations. This unit is manufactured for indoor use only. Do not use this unit outdoors. Parts Needed Blower (Remote or Integral) • Tape Measure • Phillips Head Screwdriver • Duct Tape • Ductwork (configuration varies depending on location; See pages 4-7 for further information) • Additional Sheetmetal screws (as necessary for ductwork installation) • Transition(s) (style varies depending on ductwork) Parts Supplied Transition box for remote blower installations is available as an accessory. • Saw (or equivalent for cutting countertop) • #8 x 1 1/4" Wood Screws (4) . Downdraft assembly (1) • #8 Sheetmetal Screws (8) • Blower Cord Traction Relief (1) • Hardware for brackets on vent (2) • Remote Blower Pigtail Page1 Top Cap internal Btower (Not Included) Strain Relief :igure 1 iNTRODUCTiON GENERAL Step 1 PLAN THE INSTALLATION DESCRIPTION Carefully follow the planning procedures listed below (See Figure 2). The complete downdraft system consists of the ventilator, the intake and the blower (See Fig. 1 ). The blower can be either integral (mounted on the vent intake in the cabinet under the cool<top) or a remote (mounted on the roof or outside wall. When a remote blower is used, a duct transition is mounted on the ventilator intal<e in place of the integral blower to connect the intake to the ductworL The duct transition must be purchased separately. The integral blower or duct transition can be mounted in different positions on the intake to route ductworl< to avoid cabinet, building framing, utilities, etc. The downdraft system is available in 30dnch and 36dnch models, it is intended for use with all brands and models of residential 30dnch or 36qnch gas or electric cool<tops except professional style cooktops. A. Determine whether a remote or integral blower will be used. Remote blower Bnstammationrequires 4 wires plus a ground wire to run from the downdraft to the blower. B. Make sure that adequate cabinet and counter space has been provided and that the intake will be accessible if service is required. C. Consider that cross drafts created by adjacent open windows, doors, air conditioning, old heating vents, recessed ceiling lights, and traffic patterns may affect performance. D. For gas cool<top installations make sure that a minimum 10 square inch opening is provided in the toe_l<icl< or other cabinet area. Inadequate ventilation of the cabinet below the cool<top may result in flame outage when operating the vent system. E. Provide for air supply or "mal<e_up air" to the room where unit will be installed. If "mal<e_up air" is not provided, then problems, such as fireplace chimney downdrafts, could result. Page 2 i/8" Min. Be certain to avoid interference electric supply to cooktop. ° Shelving with gas and and drawer depths are dependent upon cooktop depth and setback. Cooktop i_ 25" Cutout SB (see Fig. 7,8) Depth Cooktop Drawer tk_rFor integral ventilator installations discharged through left side of cabinet, this dimension is 32-1/8". Shelving must This installation requires a nonstandard cabinet for clearance. 1- Dimensions discharge are dependent on direction. tntegral A B be removable 9-13/16" 13" Remote 8-1/16" 15" Figure 2 investigate potential ductwork routes and choose the shortest possible route from the unit to an outside walJ or to the roof via an inside walJ and attic. For guidance, typical ducting instalJations are shown in figures 3 through 6. Installation in island locations will require under floor ducting. Peninsula locations usualJy require ducting laterally through cabinets or under cabinet toespaces. Consider potential interferences to ductwork from building framing (floor joists, wall studs, etc.) and utilities (electrical wiring, water, gas, or sewer lines, etc.). e. Determine whether the chosen route of ducting wiJl meet vent system performance requirements. To do this, measure the duct lengths needed and determine specific fittings required. Enter this data in the spaces provided in Table 1 (See Page 5). For duct runs greater than 100 feet please contact customer service for performance estimates. In addition, the duct installation guidelines in Table 2 (See Page 7) should be folJowed in developing the ductwork plan. H. Purchase the necessary ductwork in accordance with the listing developed in G above. Page 3 Figures 3 through 6 are examples of possible Remote Integral Blower Blower Through Wall Installations Roof Mount Installation Remote Blower Duct Transition Box Wall Cap 12" Min. I Ground Figure 3 Integral Figure 4 Remote Blower Blower Through Walt Installation Through Wall Installation 3-1/4" x 10" or 8" Duct End Must Be Closed and Sealed "N Remote Btower BLOWER ROTATED 90 o FOR SIDE CONNECTION Figure 5 Figure 6 Page4 TABLE Uo VENTULATOR PERFORMANCE CALCULATION TOTAL DUCT PIECES EQUIVALENT iQUANTITYEQUIVALENT SiZE LENGTH USED LENGTH 6" BOUND _HT __ 8" SiZE EQUBVALENT QUANTITY TOTAL USED EQUIVALENT LENGTH LENGTH DUCTPIECES U.2' 3=U4"× 0.95' 0.7' 10" CENTER REVERSE ELBOW LEFT 0°6' 3oU4"X r-A -_ STRAIGHT 3-114" × 10" 3-I/4" × 14" STRAIGHT REVERSE ELBOW CENTER BIGHT 0°T 9°° ELBOW 7" 6" 8' U2' BOUND 8" 6' 4S° ELBOW 7" 6" 4' 5' BOUND 8" 3' BIGHT REVERSE 3-1/4"X m0" ELBOW N/_ 5' LEFT NL_ REVERSE 3=m14"x m0" ELBOW _\WALL CAP BOUND ROOF i 5' 25' i 5' 6" Hodem #we8 Model#WClO N/,A ';'5' N/,_ BOUND NIA m5' mO" U' , N/A 2_ 8'_' 1O" 7" 2_ CAP 8" -m/4-xmsFLAT N/A _3 ELBOW _ 20' 20' ROUND TO 6" l ' l/4"Xl0" 7" i' 3-//4"xmo" 6" 5' "t '_ 3' 2' -I!4"×i0" Flex Model #BD i 3-1/4"xlO" to Bound 2w ROUND _BOUND TO 3oml4"Xi 0" _- ° ELBOW 7" 3"il4''xi0'' TO BOUND 6" 10' Backdraft Damper 7" In-Line _9 8' mO' _ 8° ELBOW T' 5' Roof Jack & -ml4"xmo" Shutter, Model # Bj310 _w TOTAL (of both columns)= MUST be LESS than: Integral Blower - 85 ft. Remote Blower - 70 ft. Page 5 TABLE DUCTWORK INSTALLATION For safety reasons, ducting should vent directly outdoors (not into an attic, underneath the house, into the garage or into any enclosed space). GUIDELINES • Where local codes permit, plastic pipe (PVC-schedule 40 pipe orABS pipe 7" or 8" diameter) can be used in areas of high ground moisture and in slab floors to eliminate future rusting. • Use only duct work constructed of materials that are acceptable by the applicable codes. All duct should be 26 gauge or heavier to minimize flex due to air flow. • The remote blowers requires a 10" or 8" diameter round duct (depending on model) to match the inlet ring. A transition is necessary from other duct sizes. • Use sheet metal screws as required to support the duct weight, and seal all joints with duct tape. • Be certain that the duct work does not interfere with floor joists or wall studs. • Do not exhaust more than one vent into a single duct Keep duct runs as short and straight as possible. Duct fittings (elbows and transitions) reduce air flow efficiency. Back to back elbows and "S" turns give very poor delivery and are not recommended. A short straight length of duct at the inlet of the remote blower gives the best delivery. Transition to round duct from the integral blower or remote duct transition as close to the downdraft as is possible, in order of preference, use 1st. 10" round duct 2nd. 8" round duct run. 3rd. 3-1/4" x 14" duct • Thermal breaks, such as a short section of nonmetallic duct, should be used in areas of extreme cold. • Always use an appropriate roof or waGcap with damper. Laundry type wall caps should never be used. 4th. 7" round duct 5th. 3-1/4" x I0" duct 6th. 6" round duct The use of flexible metal round duct should only be used when no other duct fitting exists. Limit use to short lengths and do not crush when making corners. Step 2: Prepare Countertop Cutout For installation with a Bosch cooktop, refer to Part A and Figure 7 (Page 7)). For installation with another brand of cooktop, refer to Part B (Page 8). For overhead cabinet and cooktop side clearances consult cooktop Installation instructions. A. For all installations verify that all cutouts will clear the inside of the front countertop support rail, and that the cooktop and vent will be centered left to right within the cutout. Also, make certain that the front and rear cutouts are straight and parallel to the front edge of countertop and the rear backsplash and/or wall. Assure that the side cutouts are square to the front and rear cutouts. All illustrations and dimensions are based on standard 24" deep by 36" high American style base cabinets with 25" countertops. When installing laminated or solid surface countertops such as Surell T_,and Corian ®, be sure to follow the countertop manufacturer's instructions regarding minimum corner radii, reinforcement of corners, etc. Page 6 For installation with a Bosch cooktop (Figure 7 and Table 2) Provide an opening in the countertop as specified in Table 3 (Page 8). Make sure that the distance from the front of the countertop to the front of the cutout is not less than dimension "SB". Verify that the available fiat countertop is greater than dimensions "OW" by "OD". Make certain that the backsplash thickness does not exceed dimension "BT". ITABLE 2: INSTALLATION 1 [ DIMEN_R DHD WITH BOS-C-R-C-O_ (in.) Cooktop 1 CW CD OW OD SB BT, Max++ Model No. 1 Width Cutout Depth Cutout Width Overall Depth Overall Set Back Minimum Thickness Backsplash 30" Cooktops: Installed NGT, NGP NEM, NES 28-15/16 28-3/4 36"Cooktops" Installed NGT, NGP** NEM, NES 34-15/16 34-3/4 with DHDS008UC 22=1/8 22=1/8 31 31 with 23-3/4 23-7/8 1=1/2 2-1/2 3/4 3/4 DHD9605UC 22-1/8 22-1/4 37 37 1 23-3/4 23-7/8 1=1/2 2-1/2 3/4 3/4 Table 2 Notes * Dimension "SB" is the minimum distance from the leading edge of the counter to the leading edge of the cutout. ++Dimension "BT" is the thickness of backsplash that provides 1/4" clearance between vent and backsplash. Any backsplash with a curved radius where it meets the counter will require additional clearance. Thicker backsplashes may be used by increasing the counter and cabinet depths. Alt dimensions are in inches and are based upon a standard ** NGT and NGP: width in table is at the widest INSTALLATION WITH BOSCH 1 24" deep base cabinet with point (center). COOKTOPS ................ WHEN SPECIFIED 2 1/4" Figure 7 Page 7 25" countertop. INSTALLATION WITH OTHER COOKTOPS WHERE SPECIFIED Figure 8 B. FOR INSTALLATION WITH ANOTHER Have the following cooktop measurements available before proceeding All cooktop dimensions should be verified through measurement prior to cutting the countertop: CCW = Cooktop Cutout Width CCD = Cooktop Cutout Depth COW = Cooktop Overall Width COD = Cooktop Overall Depth BRAND 2. Find the cutout width, if CCW is smaller (CW): CW DHD8005UC 283/8 DHD9605UC 34s/s Calculate the cutout depth, CD: Determine the cooktop overhang (CO) CD = COD - CO+lz7/s '' 3. Determine setback (SB} distance from front of countertop to front of cutout. SB is specified in the installation instructions shipped with the cooktop. 4. Backsp_ash thickness calculated below: than the UCV cutout width then: Installation (Figure 8) CO = (COD-CCD)/2 (Assumes front and rear cooktop overhangs are equal) Calculate the cutout depth, (CD): with the above dimensions confirmed, determine the cutout size as follows: 1. OF COOKTOP must not exceed BT as BT = 24 7/s" z OD-SB+CO (Provides 1/s"clearance between vent and backsplash.) A negative value for BT means countertop is too small for the installation. 5. if CCW is Jarger than the UCV cutout width then: Verify that the available flat countertop has a width greater than OW and a depth greater than OD. OW depends CW = CCW on the installation: DHD8005UC: OW equals the greater of COW or 30". See Figure 8 for UCV cutout widths and dimension definitions. DHD96005UC: OW equals the greater of COW or 36". OD is determined by: OD=COD+21/s '' 6. Page 8 Cut countertop using dims: CD, CW and SB as defined in Figure 8. Point "P" (Center of Rear Cut-line) -..., J Countertop Surface l G Right Side Cabinet Back Left Side F Plumb line to intersection A-A SS-B ! __ N ular Duct Shown -]- \ Receptac+e Location Cabinet BottomShelf 8 Figure 9: Cabinet Cutout for Ductwork Cabinet Cutout 6 3/8" Dimensions for B+ower: 14 1/2" 1 7/8" 15 1/2" 9 3/4" Table 4: Cabinet Cutout Dimensions STEP 3: Prepare Duct Cutouts in Cabinet A. Refer to Figure 9. Drop a plumb-line from Point "P" at the rear center of the countertop cutout. Mark this point on the bottom of the cabinet below. Construct two reference lines through this point: one should be parallel to the cabinet front and directly below the rear countertop cutout (Line A-A), and the other (Line B-B) should be at right angles to A-A. B. Using these reference lines as a base for the measurements shown in Table 4+ layout the necessary cabinet cutouts needed to implement the planned ductwork route. Where a range of measurements is noted, choose a measurement that allows best clearance from wall studs, floor joists, utilities, or other obstructions. C. Temporarily set intake and cooktop in place and attach integral blower (or duct transition fitting if a remote blower is installed). Refer to steps 6 and 7. Verify that the duct cutouts as marked will match the hardware installation. Adjust the duct cutout as necessary to match hardware installation. D. Remove temporarily placed hardware and make cutouts in cabinet to accommodate ductwork installation. E. Make all other cabinet modifications needed to provide proper clearances for drawers or removable shelving. Page 9 Step 4: Install Ductwork (Remote Blower, If Used) A. B. install the ductwork and remote blower (if used) in accordance with the ductwork routing plan developed in Step 1. Make sure that the installation complies with all installa z tion guidelines in Table 2. Also check that the opening where duct passes through outside wall or roof has been properly flashed and sealed to prevent leakage. C. If using Integral Blower, DHG601DUC, proceed to Step 5. D. if using Remote Blower Model DHG6003UC or DHGI003UC, refer to installation instructions with that model. Step 5: Install Electrical Step 6: Mount Vent and Cooktop A. Remove grease filters and any packing materials from inside the intake. B. Set the vent intake into rear of countertop opening. Carefully lower it into position so that the flanges on the rear sides and edges fully support the unit hanging from the countertop. C Hold the unit against the rear of the countertop opening, and slide the leg brackets down to meet the bottom of cabinet. Check and adjust for plumb, then fasten leg brackets to cabinet with hardware provided. D. Place the cooktop in countertop opening with the rear edge of cooktop overlapping the front edge of the vent. Make sure rear edge of cooktop does not bind against front of snorkel. Follow the manufacturer's installation instructions for installing gasket strips, protective heat tape (if required), securing the cooktop to the countertop and making the cooktop electrical and/or gas connections. Service Check your local building codes for proper method of installation. In the U.S., if there are no applicable local codes, this unit should be installed in accordance with the National Electric CodeANSI/NFPA No. 70, Current Issue. (In Canada, installation must be in accordance with the CAN 1 B149.1 and .2 _ Installation Codes for Gas Burning Appliances and/or local codes). The appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This appliance is equipped with a cord having a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded. WARNING _ Improper grounding can result in a risk of electric shock. Consult a qualified electrician if the grounding instructions are not completely understood, or if doubt exists as to whether the appliance is properly grounded. Do not use an extension cord. if the power supply cord is too short, have a qualified electrician install an outlet near the appliance. The receptacle should be located under the countertop so that the 30 inch long power cord from the vent will reach it. See Figure 9. The cord should be routed beneath the appliance and away from heat generated by the cooktop. Access should not be obstructed by blower, cabinet work, ductwork or electricaJ/gas utiJities for the cooktop. All power for the vent system (including the remote blower, if used) is supplied via the cord to the intake unit. The outlet can usually be extended from another kitchen outlet or have its own circuit from the main service panel. Do not plug vent cord into receptacle until Step 8. Page10 Step 7: Mount Integral Blower or Outlet Duct Transition for Remote Blower _ntegra_ B_ower DHG601DUC Figure 10 - Internal Blower (See Figures 10 and 12 for further detail): A. Attach blower in front of round exhaust outlet with 4-6 (depending on configuration) #8 sheetmetal screws B. Feed cord from blower through strain relief. C. Secure strain relief with screws. D. Attach strain relief to downdraft near junction box. 6 Pin Connector E. Connect cord to downdraft at 6 pin connector F. Connect blower toductwork. Remote Blower DHG6003UC or DHG1003UC (See Figures 11 and 12 for further Internal B!ower detail): A. J Strain Remove junction box cover and connect conduit with 5 wires from remote blower. Hook up wires per Wiring Diagram, J Relief Fig. 10. Replace junction box cover. Figure B. Attach duct transition at mounting holes with sheetmetal screws. C. Feed remote blower pigtail through strain relief. D. 11 - Remote Blower Attach strain relief to downdraft near junction box. E. Connect pigtail to downdraft at 6 pin connector. F. Run pigtail wires to junction box. 6 Pin Connector Junction G. inside junction box, connect conduit with five wires from remote blower. Use a conduit connector to secure. Note: Blower and duct transition box may be installed with duct outlet left, down or right. Install blower or duct transition in such a way that access panels can be removed for service. Transition DHZDHR6 J Strain Relief Remote Blower Pigtail Page 11 Conduit Remote To Blower Box Figure 12 - Wiring Diagram [WAR_IIIG: POWER UUST BE DISCCNNECTED BEFORE 8JERVIC_HGTHIS APPLIANCE 1 STEP DOWN SWITOH O01TROL O_OE L@N_N UNIT 8W_TCH POS|T|¢H SHOWN WITH DOWND_FT mN LOWEreD P¢SiTmCN ¢ = COMMON [ _ UPPE[_ UNIT POWER WiRE 8iNGLE PHASE IIHz Lt: 12IV _: GROI_DED WHITE WiRE G_D: G_OI_DI_G GREEN WiRE J_TiNG: _2IV=_IA _E __ LT,eLe_ NO-_@RMALLYOPEN N¢ _ _¢RUALLY CL@8_ Step 8: Install Coordinating Topcap (if app/cable) Topc_p / The downdraft is shipped from the factory with a stainless steel topcap. Color coordinating topcaps in white and black are available as accessory parts. A. Remove filters and set aside. Remove 4 screws from below topcap and two screws (one on each side) from endcaps. Discard topcap and endcaps. Set screws aside. B. Instal new endcaps and topcap as seen in Figure 13 (insert endcaps first). Replace screws. Endcaps Figure 13 - Topcap installation Page 12 Step 9 Verify Installation, Cooktop Alignment Operation and Before performing this procedure, verify that all packing materials were removed from inside the snorkel and that the grease filters and front panel have been properly installed. Refer to the Care and Use Manual for instructions regarding filter and front panel installation. Plug the vent power cord into a proper electrical receptacle and ensure that the circuit is energized. A. Raise the snorkel to its fully extended position by pressing the control button once (Figure 12). Do not hold the push-button. The elevating motor will stop when the snorkel reaches its full height. (Note: the blower will not operate unless the snorkel is fully raised). B. Remove protective tape from top cap. C. Turn the blower ON by selecting in turn each of the 3 speeds. Let the blower run several minutes at each speed to evaluate its operation. D. With the blower running, lower the snorkel to its fully retracted position by pressing the control button once. The blower will immediately turn off. E. With the blower on HIGH, close the windows and doors to the area to ensure that fan does not cause back drafting in any outlet vent for another appliance. F. Raise and lower the vent again, and check to make sure that the top cap on the snorkel does not catch on the back edge of the cooktop when it is lowered. If interference occurs, adjust the position of the cooktop by moving it against the front edge of the countertop cutout, then re-secure the cooktop to the countertop. Failure to eliminate interference may result in permanent damage to the vent. Also, ensure that the vent support legs have been properly secured to the cabinet base using the screws provided. If the vent system does not operate satisfactorily during any of the above procedures, review all steps in these Installation Instructions to ensure that nothing has been omitted or overlooked. Also, refer to the Care & Use Manual for additional information or call Bosch Customer Support 1-800994-2904. YOUR LIFE. OUR INSPIRATION. 5551 McFadden Avenue, 9000065051 Huntington • 10019 RevA Beach CA, 92649 • 800-994-2904 • 02/05 © 2005 BSH Home Appliances • www.boschappliances.com Corporation • Litho in U.S.A.