Powermax HE Installation Instructions - Flue Systems 85, 115 & 150 Litre

Powermax HE Installation Instructions - Flue Systems 85, 115 & 150 Litre
Installation Instructions Flue Systems
Powermax HE
85, 115 & 150 Litre
Condensing Boilers with
Integrated Hot Water Storage
These instructions cover the installation of the following kits and their options:
Concentric Flue - Horizontal Terminal, Page 5
Twin Flue - Vertical Terminal, Page 10
Twin Flue - Pitched Roof Terminal, Page 12
Twin Flue - Mini Horizontal Terminal, Page 13
Contents
General Flue Guidance, Pages 1 to 4
Concentric Kit, Page 4
Twin Flue Guidance, Pages 6 to 7
Twin Flue Kits, Pages 8 & 9
Twin Flue
Pitched Roof
& Mini
Terminal
Twin Flue
Vertical
Terminal
Twin Flue
Double
Pitched Roof
Terminals
Flue Air
Flue Air
Flue Air
Rear Concentric
Terminal
Not to Scale
Side Concentric
Terminal
MAX0047B
Twin Flue Mini
Terminals
Fig. 1
Flueing
Guidance notes for Flue Installation
This is a “room sealed” condensing appliance. Flue
systems are supplied in kits, or components can be
ordered individually from Potterton. Only Powermax flue
components (which are designed for condensing
operation) can be used.
Read these Installation Instructions before installing
the boiler. Before starting an installation, check that the
correct flue kit has been supplied with the boiler.
Flue Systems
All appliances are supplied to accept the Powermax 60
mm dia. twin flue system, however several flue system
options are available.
Each system is room sealed and offers a choice of flue
type and termination method, see Fig. 2.
•
•
•
•
a) The flue system must be constructed using only
Powermax approved components.
b) It is important that the position of the terminal allows
free passage of air across it at all times.
c) It is ESSENTIAL TO ENSURE that products of
combustion discharging from the terminal cannot reenter the building, or any other adjacent building,
through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation / air
conditioning.
Concentric balanced flue with horizontal terminal
Twin flue with vertical terminal *
Twin flue with pitched roof terminal *
Twin flue with horizontal mini terminal
Flue kits are available for each of the above options and
each kit contains all of the components needed for
connection to the appliance and terminal. Flue
extension lengths and bends should be purchased
separately, as required.
d) The minimum acceptable dimensions from the flue
terminal to obstructions and ventilation openings are
specified in Figs. 3 & 4 on Page 4 of these instructions.
* These terminals must be ordered/specified separately.
e) If the flue terminal discharges into a pathway or
passageway check that combustion products will not
cause nuisance and that the terminal will not obstruct
the passageway.
Flue Protection
When using an extended flue system it is essential to fit
protective ducting (such as that supplied in the extended
flue kits) in order to prevent direct contact with the hot
flue pipe, See Page 7.
General Requirements
Terminations
for
Horizontal
Flue
Detailed recommendations for flueing are given in
BS5440: Part 1. The following notes give general
guidance. The horizontal balanced flue terminal must be
installed so that it is exposed to external air, preferably
on a clear expanse of wall. Acceptable positions are
indicated in Fig. 3. Avoid positions where the terminal is
adjacent to projections; particularly immediately under a
balcony, inside a re-entrant position, or immediately
adjacent to a drain pipe. If the appliance is fitted under
a ventilator or opening window, the terminal must be at
least 300 mm from any part of the window or ventilator
and in accordance with BS5440: Part 1.
The flue pipe must not be closer than 25 mm to
combustible material. Additional clearance must be
provided when passing the flue through timber walls.
Advice on gas installations in timber framed buildings is
contained in IGE technical publication IGE/UP/7
available from the Institution of Gas Engineers, 21
Portland Place, London W1N 3AF.
2
Detailed recommendations for flue installations are given
in BS 5440:1: 2000. The following notes are for general
guidance only.
Flueing
f) Where terminals are fitted within 850 mm of a plastic
or painted gutter, or 450 mm of painted eaves, an
aluminium shield at least 750 mm long must be fitted
to the underside of the plastic or painted surface.
g) Where installation will be in an unusual location,
special procedures may be necessary. BS 6798 gives
detailed guidance on this aspect.
h) As the Powermax is a condensing appliance the flue
duct must have a generous fall back to the boiler of
nominally 2°.
j) The efficient condensing operation of the Powermax
HE will naturally give rise to condensation in the flue
gases and pluming will occur in all but the most
favourable atmospheric conditions. Some
condensate may also be discharged from the terminal.
The terminal must, therefore, be sited to avoid
nuisance from either phenomenon.
k) Where the lowest part of the terminal is less than 2 m
above the level of any ground, balcony, flat roof or
place to which people have access, the terminal must
be protected by a guard of durable material. A Terminal
Guard, Part No. P210 is available from Potterton. The
guard requires a flat wall surface of approximately 330
mm diameter, concentric with the terminal assembly.
Publication No. 5106227
Concentric Flue Horiz. Term. (System 1)
Twin Flue Vertical Term. (System 2)
300mm min
to
2.5m max
Vertical
Terminal
Pitched
Roof
Flashing
Flat Roof
Flashing
360˚
Air
Flue
Roof
Reducer
(Ø80 to Ø60)
Concentric
Elbow
135˚
Bend
1.5m max
Adaptor
Box Assy.
Flue
Air
Extension
1m min
to
12m max
Flue Pipe Ø60
Flue
Concentric
Terminal
Air
Extension
Flue Duct
Concentric
Elbow
Twin Flue Pitched Roof Term. (System 3)
600 mm
min
apart
Twin Pitched Roof Terminals
can be fitted
Pitched Roof
Terminal
(135˚ elbow fitted)
Flue Air
Air Pipe Ø60
Twin Flue Mini Horiz. Term. (System 4)
Mini Terminal
360 mm
min
apart
92˚ Bend
Extension
Mini Terminal (sited in loft)
92˚ Bend
Extension
1.5m min
to
12m max
135˚ Bend
1m min
to
12m max
92˚ Bend
Air Pipe
Flue Pipe
Flue Pipe
Air Pipe
Warning
Flue Duct
Flue Duct
Flue
Flue
Air
Air
MAX0012B
Note that the length
of the Air Inlet Pipe
MUST be at least
0.75 x length
of the Flue Pipe
Extension
Fig. 2
Publication No. 5106227
Flueing
3
Mini Terminal Assembly
Horizontal Terminal Position with Minimum Distance (mm)
300 min.
300 min.
Air
Flue
Fanned Draught Balanced Flue
A
Directly below an opening, air brick,
opening window etc.
B Above an opening, air brick, opening window, etc.
C Horizontally to an opening, air brick,
opening window etc.
D Below a gutter, or sanitary pipework
E Below the eaves
F Below a balcony or carport roof
G Above ground, roof or balcony level
H From vertical drain/soil pipe work
J From an internal or external corner
K From a surface facing a terminal
L Vertically from a terminal on the same wall
M Horizontally from a terminal on the same wall
N From a terminal facing the terminal
P From an opening in a carport (e.g. door, windows)
into the building
Q From adjacent wall to flue (vertical only)
R From internal corner to flue (vertical only)
S Below eaves or balcony (vertical only)
Property
Boundary
Line
High Level
Side Twin Flue
Concentric
Terminal
Assembly
Top View
300 min.
300 min.
MAX0027A
Top
View
Top View
Rear
Concentric
Flue
Fig. 3
300
300
75
200
200
300
150
300
600
1500
300
1200
1200
210
230
600
Note: The distance from a fanned draught appliance terminal installed
parallel to a boundary may not be less than 300 mm in accordance with
the diagram opposite.
Side Concentric
Flue
Property
Boundary Line
K,N
M
Q
L
R
300
G
D
E
C
S
A
G
G
G
Concentric Horizontal Terminal Flue Kit
F
P
A
A
H
J
F
K,N
Part No. 5106273
Concentric Elbow
Concentric Terminal
J
G
Wall
Plugs
(2 off)
Elbow to Terminal
Securing Screw
Likely flue positions requiring
a flue terminal guard
Position for Rear Flue Hole
2˚
215
Wall
Plate
Flue
Wall Plate
Screws (2 off)
Flue Stub Pipe
Adaptor to Case
Securing
Screws (4 off)
Air
Foam Seal
(included as part of assy)
Adaptor
Box Assy.
165 Approx.
Options for Concentric Flue
1.0 m Concentric Extension
Maximum Flue Length 2.5 m
Part No. 5106272
0.5 m Concentric Extension
-
+
CH
HW
H.W. TEMP
POWER
MAINS ON
BURNER
LOCK OUT
RESET
C.H. ADVANCE
SEL
+
SEL
PROG
-
PROG
1110 (85 Litre)
Part No. 5106271
0.25 m Concentric Extension
Part No. 5106270
1270 (115 Litre)
1470 (150 Litre)
Part No. 5106158 (1 max.)
Concentric Elbow 135˚
Part No. 5107645 (2 max.)
(additional to Adaptor Box Elbow)
Elbow
Securing
Screw
Part No. 5106217
MAX0028B
Terminal
Guard
Concentric Elbow 90˚
Fig. 4
4
Flueing
Publication No. 5106227
Concentric Balanced Flue System
105mm Minimum
Dimensions in mm
with rear
C/L
facing
Concentric
Rear Flue
Concentric
Flue
(300 min.)
Flue
The concentric balanced flue system is
recommended for use with appliances sited near
an outside wall. The Concentric Flue Kit (Part
No. 5106273) includes all the components
necessary for connection to the appliance and
termination on an outside wall and is suitable for
a wall thickness from 200 mm to 450 mm.
Outer Wall
Inner Wall
Side Flue
A maximum flue length of up to 2.5 m may be
used if required and the flue system may also
include either 1 x 90° (p/n 5106158) or 2 x 135°
bends (p/n 5107645) in addition to standard
appliance elbow.
40
Clearance
Ø100 Air Tube & 65
Ø60 Flue Tube
Top View
All additional flue lengths, flue bends and other
kits should be purchased separately as required.
See Pages 8 and 9.
2˚ Angle within terminal
215
Read the ‘Guidance Notes’ on Page 2 in
conjunction with the following notes prior to
installation.
165 Approx.
Front View
Fig. 5
Optional Terminal
Guard
Outer Wall
Inner Wall
Wall
Plate
Elbow Securing
Screw
b. Insert stub flue pipe into flue outlet on top of
boiler.
c. The 90° appliance elbow can now be fitted
into the adaptor and the appropriate length of
flue pipe calculated by measuring between
the outside wall face and the appliance bend
allowing 45 mm to 55 mm to engage into the
bend.
Concentric
Elbow
450
maximum
Top of Boiler
Concentric
Terminal
Note: Powermax HE is a condensing boiler
and the flue system must have a generous
fall back to the boiler of nominally 2°.
Side View
40
Clearance
d. Fit outer wall seal to terminal and engage
inner wall plate as shown.
e. All flue components contain rubber lip seals
to ensure both ease of assembly and
excellent sealing. Refer to Page 6 before
cutting.
Adaptor Box Assy.
105
Flue C/L
Concentric
Elbow
Rear
Concentric
Flue
Dimensions in mm
1.5m max
Adaptor
Box Assy.
Extension
Concentric
Terminal
Concentric
Elbow
View with Extension
& 90˚ Elbow
MAX0026B
a. Remove protective strip from gasket
underneath the twin concentric adaptor and
carefully locate adaptor on top of the
appliance. Ensure a good seal over the flue
and air connections before securely fixing
with the four M4 screws provided.
Fig. 6
Publication No. 5106227
Concentric Balanced Flue
5
Guidance Notes on Twin Flue Installations
Twin Flue Pitched Roof Terminal
The air pipe MUST NOT BE LESS than 3/4 of the length of the
flue pipe. See Fig. 7.
Warning
Cutting Extensions
Note that the length of the
Air Inlet Pipe MUST not be
less than 0.75 x length
of the Flue Pipe
All flue components contain rubber lip seals to ensure both ease
of assembly and excellent sealing.
Loft
Space
Living
Space
Care must therefore be taken to remove all burrs and sharp
edges from pipes which have been cut to non-standard lengths.
Example
Flue
Example
Air
Length
Length
4m
2m
Expansion Allowance
When cutting and fitting flue pipes on extended flue systems,
allow approx. 5 mm clearance at the bottom of each joint - see
Fig. 7.
Flue Air
Twin Flue Pitched Roof
& Mini Terminal
Badly
Cut
Flue Pipe
Do Not Damage Internal Seals
with badly cut extensions
Twin Flue
Pitched Roof
& Mini
Terminal
Clean
Cut
Flue Pipe
Leave 5mm
clearance at
bottom of
each joint
Ø60
Flue Air
Example
Flue
Example
Air
Length
Length
4m
3m
50mm
depth
Seal
Flue Air
Twin Flue
Double
Pitched Roof
Terminals
Twin Flue Extension/
Bend Connection
300mm max.
Minimum Void Depth (320mm shown)
25mm min.
Flue Brackets
1950mm
2˚ Angle
Void required for long flues
1950mm
Void Length
(5.5m shown)
1.5m
Reqd.
MAX0037A
Twin Flue Mini Terminals (7m Flue Kit shown)
Schematic of 7m Mini Terminal flue system showing flue
rising vertically from boiler & rising towards the terminal.
Use Flue Brackets from kit 5106257 as shown to
secure Air/Flue pipes with a fall of 35mm in one metre.
Flue Kit
Void
Minimum
Length Void Depth
5m
3m
180mm
5m
3.5m
250mm
7m
5.5m
320mm
10m
8.5m
425mm
Fig. 7
6
Guidance Notes on Twin Flue Installations
Publication No. 5106227
Flue Duct
This kit covers pipe lengths from 0.5 m to 1.45 m
Fixing
Rail
Wall
1. Measure length of flue/air pipes to be
covered. Set the short and long covers to the
required length and secure through the
relevant holes using four of the self tapping
screws provided.
2. Attach the pipe clip brackets to the top and
bottom of the covers using the remaining four
self tapping screws provided.
3. Push the assembly onto the pipes until the
clips locate around the pipes.
Kit Contents
A - Pipe Clamp Brackets
2 off
B - Flue Pipe Cover Short
1 off
C - Flue Pipe Cover Long
1 off
D - Fixings Pack
1 off (not shown)
A
Flue Bracket Pack
Part No. 5106207
Wood Screw
Wall
Plug
Cut Threaded Rod
to required length
Pipe
Clamps
Ø60
Locking Nuts
Tee-Bolt
1.5m Flue Pipe Ø60
1.47m Air Pipe Ø60
Ceiling
0.5/1.45m flue
duct set to correct
height and clipped
to air/flue pipes
Support Bracket
Assembly
C
B
Air/Flue Pipe Support
It is recommended that the air/flue pipes should
be clipped or otherwise supported at not more
than 2 m intervals.
Twin Flue
Vertical
Terminal
2m maximum between
Support Brackets
2m
Extension
Ensure that vertical lengths of flue are
adequately supported so that the joints cannot
“creep” in use.
Ensure that air/flue pipes are clamped within
300 mm of every bend. Obtain extra Flue
Bracket Packs (Part No. 5106207) as required.
Twin Flue
Vertical
Terminal
Flue Air
300mm maximum between
Support Brackets & Bends
300mm
maximum
Flue
Condensate
must not be
allowed
to sit in the
bottom of the
Flue Pipes
2˚ Angle
Support
Brackets
Air
2˚ Angle
Flue Air
Twin Flue Mini
Terminals
Flue Air
Flue Air
MAX0045B
Condensate
Fig. 8
Publication No. 5106227
Guidance Notes on Twin Flue Installations
7
Twin Flue Pitched Roof Kit
Twin Flue Vertical Terminal Kit
Vertical Concentric
Terminal
Pitched Roof
Flashing
Part No.5106213
Part No.
15-25˚= P231
25-45˚= P232
35-55˚= P233
Pitched Roof Terminal (25˚- 45˚)
Part No.5106164
Pitched Roof
Terminal
Terminal
Stabilising
Bracket
4.5m Twin Flue Pipe Kit (for Pitched Roof Term)
Part No.5106259
Concentric
to Twin
Adaptor
Flat Roof Flashing
500mm
Part No.
P236
4
Extensions
(1m x Ø60)
3
Fixing
Rails
(0.5m)
Ø80
Air
Ø80
Flue
Mini Terminal
2
Reducers
(Ø80-Ø60)
3 Threaded Rods
(1m x M8)
2.5m Twin Flue Pipe Kit (for Vertical Terminal)
Part No.5106260
1 x Flue Bracket
Pack
4 Locking Nuts - 2 Slide Nuts
2 Wood Screws - 2 Wall Plugs
2 Pipe Clamps Ø60
6 Pipe
Clamps
Ø60
3 x Flue Bracket
Packs
12 Locking Nuts - 6 Slide Nuts
6 Wood Screws - 6 Wall Plugs
Flue Pipe
(1.5m x Ø60)
Flue Pipe
(1.5m x Ø60)
Flue Duct
Flue Duct
4 Extensions
(0.5m x Ø60)
4 Extensions
(0.5m x Ø60)
4 135˚
Bends
Air Pipe
(1.47m x Ø60)
4 135˚
Bends
Air Pipe
(1.47m x Ø60)
MAX0029B
1 Fixing Rail (0.5m)
1 Threaded Rod (1m x M8)
Fig. 9
8
Flue Kits and Options
Publication No. 5106227
Twin Flue Mini Terminal Kits
Pitched Roof Terminal (25˚- 45˚)
Part No.5106164
2 Mini
Terminals
Mini Terminals Part No.
Matt Black = 5106261 (standard finish)
Stone =
5106262
Light Brick = 5106263
Red Brick = 5106264
500mm
Slate =
5106265
White =
5106266
2 Wall Liners
Pitched Roof Terminal
Twin Flue Options
135˚ Bend
92˚ Bend
Part No. 5106162
Part No. 5106161
2 Wall Plates
& Clamps
3m Twin Flue Pipe Kit (for Mini Terminals, other
pipe kits available 5m, 7m & 10m, see table below)
Part No.5106255
150˚ Bend
165˚ Bend
Part No. 5106276
Part No. 5106277
150˚
Bend
2 Extensions
(1m x Ø60)
2 Extensions (0.5m x Ø60)
2 92˚
Bends
1 Fixing Rail (0.5m)
Flue Bracket
Pack
Part No. 5106207
2 Pipe Clamps Ø60
2 x Flue Bracket
Packs
8 Locking Nuts - 4 Slide Nuts
4 Wood Screws - 4 Wall Plugs
1 Threaded Rod
(1m x M8)
Ø60 Twin Pipe
Extension (Flue/Air Pipe)
Part No.
0.25m
0.5m
1.0m
1.5m
2.0m
3.0m
4.25m
=
=
=
=
=
=
=
5106154
5106184
5106185
5106186
5106187
5106188
5107101
Slip Coupling
Part No. 5106807
0.25m
shown
Flue Pipe
(1.5m x Ø60)
Flue Duct
4 Pipe
Clamps
Ø60
2 Threaded
Rods
2 Fixing
Rails (0.5m) (1m x M8)
Air Pipe
(1.47m x Ø60)
Twin Flue Pipe Kits (for Mini Terminals)
3m
5m
7m
10m
Part Number (3m illustrated above)
Air/flue pipe 3.0m
Air/flue pipe 2.0m
Air/flue pipe 1.5m
Air pipe 1.47m
Flue Duct Telescopic 0.5/1.45m
Air/flue pipe 1.0m
Air/flue pipe 0.5m
92˚ Bend
150˚ Bend
Flue Bracket Pack
M8 x 1m Thread rod
Installation Instructions
5106255
0
0
1
1
1
2
2
2
1
2
2
1
5106256
0
2
1
1
1
2
2
4
1
3
3
1
5106257
0
4
1
1
1
2
2
2
1
3
3
1
5106258
0
6
1
1
1
4
2
2
0
5
5
1
MAX0030B
Flue Bracket Pack
4 Locking Nuts - 2 Slide Nuts
2 Wood Screws - 2 Wall Plugs
Fig. 10
Publication No. 5106227
Flue Kits and Options
9
Twin Flue with Vertical Balanced Flue
Terminal
Vertical Concentric
Terminal
Vertical
Terminal
Part No.5106213
98
Ø390
Flat Roof Flashing
Used in conjunction with the standard 60 mm twin
pipe system the Powermax Vertical system offers
an unobtrusive balanced flue terminal as an easy
to fit option for both pitched and flat roofs.
507
120
Pitched Roof Flashing
(approx)
1197
Can be angled to
align with roof
109
Air
Ø80
Flue
Ø80
Stabilising
Bracket
Concentric to Twin Adaptor
Ø80 - Ø60
Reducers
120 centres
Pitched
Roof
Flashing
All
dimensions
in mm
Roof
Reducer
(Ø80 to Ø60)
135˚
Bend
The separately supplied Vertical Terminal Kit (Part
No. 5106213) provides a combined air intake and
combustion gas outlet in a concentric
arrangement. Below the roof the terminal
changes into a twin pipe system.
Separate roof flashing units should be ordered for
pitched or flat roofs. Roof pitches from 15° to 55°
are catered for by selecting one of three roof
flashing units.
P231
P232
P233
P236
Fig. 11
Vertical
Terminal
The twin flue system allows greater flexibility
when siting the appliance. It offers up to 12 m of
flue pipe and 12 m of air pipe, which must be
reduced to accommodate a number of bends for
more difficult applications. The minimum length is
1 m.
for
for
for
for
pitches 15° to 25°
pitches 25° to 45°
pitches 35° to 55°
flat roofs
To connect the Powermax HE to the vertical
terminal, a twin flue pipe kit (Part No. 5106260) is
required. This contains a range of extension
air/flue pipes and bends to enable the terminal to
be sited up to 2.5 m from the boiler. The maximum
overall length of the complete flue system must
not exceed the limits shown in Fig. 2, Page 3.
All additional flue lengths, flue bends and other
kits should be purchased separately as required.
See Pages 8 and 9.
Flue
Air
Read the ‘Guidance Notes’ on Page 2 in
conjunction with the following notes prior to
installation.
Extension
1m min
to
12m max
Flue Pipe Ø60
Flue Air
Air Pipe Ø60
MAX0035B
Flue Duct
a. The Powermax is a condensing appliance and
the flue system must have a generous fall
back to the appliance (nominally 2°) and be
adequately supported. This will ensure the
correct trouble free disposal of condensate
produced in the flue during normal operation.
b. All flue components contain rubber lip seals to
ensure both ease of assembly and excellent
sealing. Refer to Page 6 before cutting.
Fig. 12
10 Twin Flue with Vertical Balanced Flue Terminal
Publication No. 5106227
Note: Damage to the seals could result in
condensate/flue products leakage from the flue
system.
Note: Due to the high efficiency and reduced
flue gas temperature of the Powermax HE, little
or no buoyancy is generated in a vertical length
of the 60 mm Ø flue pipe and installations
should therefore be designed with this in mind.
Flat Roof Flashing
Felt Roof
100mm Felt Collar
Bitumen
Bottom Felt
Fixing Flat Roof Flashing
Installation of the flat roof flashing unit must be
carried out by a competent flat roofing contractor.
The following notes are for the contractor’s
guidance. Avoid locating the flat roof flashing in a
position where standing water is likely to
accumulate.
For built up felt roofs, see Fig. 13.
1. Cut 180 mm diameter service opening through
roof construction and first layer of felt.
2. Bed flange of unit on to felt with bitumen.
3. Dress top layer(s) of felt over flange of unit.
4. Star cut a hole in the top-most layer and finish
by detailing a 100 mm high felt collar around
upstand.
5. Apply a butyl or mastic sealant around the
spigot on the flashing unit and carefully lower
the terminal into position, ensuring that the
spigot seats securely inside the terminal rim.
6. From inside the building fit the 131 mm
diameter pipe support bracket around the
projecting flue pipe and screw flanges to
support timber or structure. Ensure flue
terminal is positively secured and vertical.
Top Felt Layer
Ø180
Roof Construction
Fig. 13
Flat Roof Flashing
Asphalt Roof
Apply sealant to
the edge such as
butyl or mastic
before fitting terminal
Asphalt
Ø180
MAX0042A
Roof Construction
Fig. 14
For Asphalt Roofs, see Fig. 14.
1. Cut 180 mm diameter service opening through
roof construction and sheathing felt and firmly
locate the flashing unit in position over it.
2. Dress asphalt over aluminium flange and up
neck offset of flashing unit ensuring it does not
move from location.
3. Apply a butyl or mastic sealant around the
spigot on the flashing unit and carefully lower
the terminal into position, ensuring that the
spigot seats securely inside the terminal rim.
4. From inside the building fit the 131 mm
diameter pipe stabilising bracket around the
projecting flue pipe and screw flanges to
supporting timber or structure. Ensure flue
terminal is vertical and positively secured.
Publication No. 5106227
Flashing Kits - Flat & Pitched Roof 11
Twin Flue with Pitched Roof Terminal
500
74
500
184
135˚
Bend
Ø60
Pitched Roof Terminal
(25˚- 45˚)
The Pitched Roof Terminal must be ordered separately.
It is recommend that, where space and visual
considerations permit, a second similar terminal should
be used for the air supply, especially when the roof
pitch is less than 30°. As an alternative, combustion air
can be taken from a fully ventilated, unoccupied, roof
space providing the minimum free area of the vents is
no less than 234 cm2. Additional requirements are that
Once the Terminal is
fitted the Head MUST
be pivoted to the
horizontal position
Fig. 15
the air inlet pipe must not be less than 0.75 x length of
the flue pipe and the intake must be at least 300 mm
above the highest level of the ceiling insulation.
600 mm
min
apart
Roof Tiles
Pitched Roof
Terminal
(135˚ elbow fitted)
2 Pitched Roof Terminals
can be used
Support Bracket
Mini Terminal (sited in loft)
Extension
Support
Bracket
1.5m min
to
12m max
The Pipework Kit (Part No. 5106259) for the Pitched
Roof Terminal is based on a nominal 4.5 m of twin flue.
This allows, for example, up to 5 m of flue pipe between
boiler and flue terminal; plus up to 4 m of air pipe
between boiler and air terminal. The flue pipe must not
exceed 12 m; in which case the air pipe must not be
less than 9 m. The minimum length of flue pipe is 1.5 m
and the overall length is also governed by the number
of bends used - see calculation method on Page 15.
The components supplied with this kit are intended for
a typical application requiring 4.0 m to 4.5 m of air inlet
pipe with 2 bends plus 4.5 m to 5.0 m of flue pipe with
2 bends - See Fig. 16. Other configurations may be
used but a ‘horizontal’ run in the flue pipe should not
exceed 2 m and must not be allowed to dip, i.e. fall
below the horizontal and must always rise towards the
terminal. Any flue pipe accessible to occupiers of the
dwelling must be covered with protective ducts.
Fixing Pitched Roof Flashing
135˚
Bend
Flue Pipe
Warning
Note that the length
of the Air Inlet Pipe
MUST not be less
than 0.75 x length
of the Flue Pipe
Used in conjunction with the standard 60 mm diameter
twin pipe flue system, the Powermax Pitched Roof
Terminal (Part No. 5106164) provides an unobtrusive
alternative where horizontal mini terminals are not
practical. This terminal is supplied with a 0.5 m x 0.5 m
universal lead slate; thus it is suitable for use with tiles
and slate roofs with pitch angles of 25° to 45° (above
the horizontal).
Air Pipe
Flue Duct
Flue
MAX0041B
Air
1. Place terminal flashing in position ensuring the
upwards edge of lead flashing correctly underlaps
the previous course. Note: Additional sarking may
be required - see recommendation in BRE Defect
Action Sheet 10 - November 1982 - Pitched Roof
Sarking Felt Underlay Watertightness.
2. Fix any secondary batten needed to support
terminal and reinforce any previously cut battens.
3. Cut slates or tiles to achieve the 290 mm vertical x
220 mm horizontal opening for the upstand of the
terminal. Re-tile roof and dress lead flashing over
bottom course.
4. Fix support bracket so as to secure the flue pipe
near the terminal.
Fig. 16
12 Maximum & Minimum Lengths of Air/Flue Pipes
Publication No. 5106227
Twin Flue with Horizontal Mini Terminal
The twin flue system allows greater flexibility when
siting the appliance. It offers up to 12 m of flue and
12 m of air pipe, which must be reduced to
accommodate the number of bends for more
difficult applications. Both terminals should be
positioned to minimise the length of the air and flue
pipes. The distance between the terminals must not
be less than 360 mm and no greater than 2 m.
2˚ Angle
Flue Air
Twin Flue Mini
Terminals (Righthand)
Air
Flue
360mm minimum
Clearance centre to centre
Zone
Air
Possible Air Terminal positions
1 m flue pipe
1 m air pipe
2 x 92° swept bends
Air
b. All flue components contain rubber lip seals to
ensure both ease of assembly and excellent
sealing. Refer to Page 6 before cutting.
Note: Damage to the seals could result in
condensate/flue products leakage from the flue
system.
Important: The flue terminal MUST NOT be sited
below the air terminal. See Fig. 17.
Warning: The flue pipe becomes very hot when
appliance is working. Householders should be
warned not to touch exposed pipe e.g. beyond
protective duct within loft. The flue pipe should be
insulated or ducted if accidental contact is likely.
Air Exclusion
Zone
Air
Air
Flue
Mini Terminal Clearances
Read the ‘Guidance Notes’ on Page 2 in conjunction
with the following notes prior to installation.
a. The Powermax HE is a condensing boiler and
the flue system must have a generous fall back
to the appliance (nominally 2°) and be
adequately supported. This will ensure the
correct trouble free disposal of condensate
produced in the flue during normal operation.
View
of
Outside
Wall
Minimum
360 mm
centres
apart
Mini Terminal
(Ø60 x 500)
Fig. 17
150˚ Bend
Extension
92˚
Bend
Flue Pipe
Air Pipe
1m min
to
12m max
Flue Duct
Flue
Twin Flue Mini
Terminals
(Rear)
Air
MAX0043B
All additional flue lengths, flue bends and other kits
should be purchased separately as required. See
Pages 8 and 9.
Air
Flue
Maximum Flue Length: 12 m flue pipe
12 m air pipe
2 x 92° swept bends
Minimum Flue Length
Fixed Flue
Terminal position
MAX0036B
The Mini Terminal flue system provides an
unobtrusive arrangement. Separate 60 mm
diameter air inlet and flue terminal assemblies can
be positioned in different locations on the same wall
subject to similar wind conditions. The mini
terminals are also visually less obtrusive and are
available in a small range of colours to assist with
the sympathetic re-furbishment of older buildings.
Flue
Air
Fig. 18
Publication No. 5106227
Twin Flue with Horizontal Mini Terminal 13
Mark the positions of the air/flue terminals and core drill 70
mm (2¾) diameter holes. If the wall is clad with a
combustible material an additional 25 mm wide area must
be removed around flue liner.
With care it is possible to core drill from inside and maintain
a clean, undamaged hole on the outside wall, but where
damage to the outside wall occurs this must be made good
to ensure a satisfactory weather seal when terminals are in
position. Terminals should be inserted through the wall
liner from outside to facilitate weather sealing.
a. Measure the wall thickness and cut the liner to this
length. Cut plain end opposite flange.
b. Fit the liner through the hole making good internal and
external rendering where necessary. Apply ‘mastic’ type
sealant to the last 25 mm of the liner behind the flange
(or to the outer part of the core-drilled holes) prior to
fitting liner to help make a weather seal between the
liner and the external leaf of the wall.
c. Slide the stainless steel cone along the terminal pipe,
followed by the large flexible seal as indicated in Fig.
19. Apply high temperature (red) silicone sealant to
ensure the terminal is weather sealed to the liner.
a. Measure and cut the first pair of flue pipes away from
the appliance. Push pipes fully into the sockets on top
of the boiler whilst also fitting the flue duct prepared as
above.
b. Measure and cut next pair of air/flue pipes.
c. Prepare pipe support brackets as required before
engaging pipes with the socket of preceding pipes or
bends.
d. Push pipes together as before taking care not to
dislodge seals. When cutting and fitting flue pipes on
extended flue systems, allow approx. 5 mm clearance
at the bottom of each joint - see Fig. 7.
e. Repeat above procedure to reach terminal. Ensure
that air inlet and flue gas connections are correctly
made and are not inadvertently reversed.
f. Fix pipe supports to masonry or woodwork so that
flue/air pipes are held securely in position.
g. Check especially that all joints within any duct or other
void are correctly engaged and sealed before fixing
the ductwork.
Flexible
Seal
d. Working from outside the property, push the mini
terminal through the liner until the large seal is correctly
positioned against the outside wall.
e. Centralise flue pipe in liner using spacer if required.
Slide the internal wall plate over terminal pipe and
secure to wall using the plugs and screws provided.
Tighten clip to secure terminal.
Note: Make any final adjustment to the position of the
external seal before tightening clip.
Outer
Wall
Wall Plate
&
Clamp
Inner
Wall
MAX0044A
Installing Mini Terminal Flues
Wall Liner
(Cut to length
Terminal
Outer Wall
Plate
Fig. 19
Assembling Air/Flue Pipes
360
Refer to Guidance Notes on Pages 6 & 7.
The flue pipes must be assembled with the plain end of
pipe or fitting nearest the boiler and the female (socket)
end furthest from the boiler. Check that a seal is fitted in
every socket.
Always adjust length of pipes by cutting and de-burring
plain end so that it does not damage or disturb the seal.
Remove burrs from inside and outside of pipe and ensure
the pipe is clean and free from oil and grease.
Twin Flue
Mini
Terminals Air
(Lefthand)
150˚
Bend
92˚ Bend
Flue
Extension
(cut to 443)
135˚ Bend
Extension
from boiler
Extension
Flue
135˚
Bend
Air
Flue
360
minimum
Any generally “horizontal” run of flue pipe MUST NOT
FORM A LOW POINT at which condensate could
accumulate.
Top
View
of
Boiler
92˚
Bend
Extension
Fig. 20
30˚
offset
92˚
Bend
443 Nominal
Length (minimum)
Air
14 Twin Flue with Horizontal Mini Terminal
Side
View
150˚ Bend
MAX0038A
Publication No. 5106227
Guidance on Unusual Twin Flue Installations
Table of Flue Resistance Factors :
The following notes offer guidance regarding the
relationship between the maximum flue length and the
number of bends allowed in a twin flue system.
Component
factor
Mini Terminal (500 mm)
(each)
Pitched Roof Terminal
Vertical Terminal (inc. twin pipe adaptor)
5.0
7.0
6.6
60
60
60
60
60
60
1.2
2.1
3.8
5.5
7.2
10.6
In order to simplify the calculation, the following three
factors are used:1. Maximum System Factor
A figure of 100 is used and represents the maximum
resistance that can be applied to the appliance before
there is a notable reduction in its heat output.
2. Fittings Factor
This figure is calculated and represents the total
resistance of all the flue / air fittings in the proposed
system. e.g. bends, terminals and essential pipes such
as those rising from the boiler.
mm
mm
mm
mm
mm
mm
Bend
Bend
Bend
Bend
-
Air
Air
Air
Air
Air
Air
/
/
/
/
/
/
Flue
Flue
Flue
Flue
Flue
Flue
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
-
0.25 m (each)
0.5 m (each)
1.0 m (each)
1.5 m (each)
2.0 m (each)
3.0 m (each)
92°
135° (45° Bend)
150° (30° Bend)
165° (15° Bend)
4.0
3.4
2.6
1.4
Note: The above component factors are to be
cumulatively subtracted from the total system factor
of 100 (See Below).
3. Pipe Factor
This figure is calculated and represents the remaining
resistance left for the flue / air pipe lengths in the
proposed system after subtracting (2) from (1).
Ensure that both flue and air pipes are counted.
Worked Example
Note: Any flue and air pipe combination between the
minimum and maximum lengths may be used in
conjunction with any of the listed fittings, provided that
the Maximum System Factor of 100 is not exceeded.
To calculate the maximum allowable air/flue pipe length
for the system shown in Fig. 21.
1. Establish the terminals, bends and essential
pipework (e.g. that rising from top of boiler) and add
the resistance factors obtained from the table above.
2 Mini
Terminal
Factor
2 x 5 = 10.0
4 off 92° Bends
2 off 135° Bends
2 off Mini Terminals
Add: Essential Pipework 2 off 1.5 m Air/Flue Pipes
Fittings Factor
2 135˚
Bends
Factor
2 x 3.4 = 6.8
16.0 (4 x 4)
6.8 (2 x 3.4)
10.0 (2 x 5)
=
=
11.0 (2 x 5.5)
43.8
2. Subtract this Fittings Factor from 100
i.e 100 - 43.8 = Pipe Factor = 56.2
4 92˚
Bends
3. Divide this Pipe Factor by the resistance factors
appropriate for the flue being designed.
e.g. 3 off 1 m Air/Flue Pipes = 11.4
6 off 2 m Air/Flue Pipes = 43.2
Total = 54.6
Factor
4 x 4 = 16.0
2 1.5m Pipes
above boiler
Factor
2 x 5.5 = 11.0
=
=
=
4. Compare this total of to the available Pipe Factor:
54.6 £ 56.2 so this system is acceptable.
Flue
MAX0039B
Air
Fig. 21
Publication No. 5106227
Guidance on Unusual Twin Flue Installations 15
Publication No.
5106227 - Iss. 04
(07/2003)
General Enquiries
Tel.
08706 060 780
Sales
Tel.
Fax.
08706 060 403
01772 695 416
Technical *
Tel.
08706 060 955
Service *
Tel.
Fax.
08706 060 933
08706 060 966
Literature Request
Tel.
08706 060 623
Spares
Tel.
08706 000 454
*
To aid continuous improvement and staff training, calls to this
line may be monitored or recorded.
All descriptions and illustrations provided in this leaflet have been
carefully prepared but we reserve the right to make changes and
improvements in our products which may affect the accuracy of the
information contained in this leaflet. All goods are sold subject to our
standard Conditions of Sale which are available on request.
BAXI POTTERTON
A Trading Division of Baxi Heating UK Ltd
Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN
Website www.potterton.co.uk
company
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