Alpha Alpha CD EasyFlue User manual

Installation Instructions
KIT CONTENTS
1. GENERAL
Note: These flues MUST ONLY be used with the Alpha Condensing boilers.
a. The Alpha Easy-Flue is suitable for straight horizontal flues only and can be extended up to the maximum lengths
given in Section 4.
b. The Alpha CD Easy-Flue is suitable for providing two options for management of the exhaust flue gas/plume emitted
from the terminal. They are:-
i. Divert the plume at 45° by altering the terminal of the the Easy-Flue.
ii. Extend the inner flue duct by using Plume Management accessories to re-locate the terminal to an area where the
plume will not cause a nuisance. Note: When fitting plume management accessories, ensure there is always a
slope towards the Easy-Flue assembly in the wall by a minimum of 25-30 mm per metre and there is no part of the
pipework where condensate/rain will collect.
Refer to Section 5 for full details.
c. The Easy-Flue includes a 90° bend, (no separate 90° bend is required).
d. Ensure the Easy-Flue outer duct is installed horizontally (please note that the Easy-Flue inner duct already has a pre-
determined slope towards the boiler for condensate to run back towards the boiler) and when extending the flue with flue
extensions, these flue extensions must be installed with a slope downwards towards the boiler by a minimum of 25-30
mm per metre.
e. The flue system must be installed in accordance with BS 5440:1.
f. The boiler must be installed in accordance with the installation instructions supplied with the Alpha condensing boiler.
g. The CD Easy-Flues are suitable for use in the flue length ranges shown in the tables below.
Note: Where the length is less than the minimum or more than the maximum, refer to Section 4.
Alpha CD Easy-Flue
(with Plume Management Facility)
CD Easy-Flue 500 mm Part No. 6.2000510
CD Easy-Flue 1000 mm Part No. 6.2001010
Fig. 1 - Rear Flue
CD50 Boiler
CD Easy-Flue
500 mm
1000 mm
B (mm)
Max
440
885
Min
230
675
HE Boiler
CD Easy-Flue
500 mm
1000 mm
B (mm)
Max
510
955
Min
300
745
CDR Boiler
CD Easy-Flue
500 mm
1000 mm
13R/18R
515
960
24R
545
990
13R/18R
305
750
24R
335
780
B Max (mm) B Min (mm)
Rear Flue
(B)
*With Premier pack
CD C/X/S Boiler
CD Easy-Flue
500 mm
1000 mm
*500 mm
*1000 mm
B (mm)
Max
535
980
*495
*940
Min
325
770
*285
*730
Inside, outside flue sealing collarsSealing tape
90° bend
Clamp (two screws)
Clamp (three screws)
Flue terminal
supplied fitted
Easy-Flue

2
2. INSTALL THE BOILER
a. Fit the boiler in accordance with the installation instructions supplied with the Alpha condensing boiler - Sections 4.1 to 4.5.
b. Use the template (supplied with the boiler) to mark the flue position and cut a 110 mm diameter flue hole (or use a
107 mm core drill).
Notes: i. Ensure the hole is cut horizontally.
ii. If the Easy-Flue is being fitted internally, cut a 130 mm diameter flue hole (or use a 127 mm core drill).
Refer to Section 3, paragraph (c) or Section 4.
3. FIT THE FLUE
The following procedure applies to fitting an Alpha CD Easy-Flue to both rear or side exit flue - horizontally only.
Note: If extending the Easy-Flue refer to Section 4.
a. Determine the overall length (L) of flue required, (see Fig. 3) as follows:-
Rear flue L = wall thickness (B) + *65 mm (or 85 mm for CD13/18R or 55 mm for CD24R or 160 mm for CD50
or 90 mm for HE)
*Add 40 mm when Premier Pack is used
Side flue L = wall thickness (B) + distance between boiler and wall (C) + 145 mm (or 120 mm for CDR or 150 mm
for HE)
Side flue (CD50) L = wall thickness (B) + distance between boiler and wall (C) + X
(L/H side X = 105 mm, R/H side X = 345 mm)
b. Adjust the telescopic section of the flue to the distance 'L', ensuring that the two labels marked 'TOP' are aligned,
then seal and secure the joint between the ducts with the sealing tape supplied.
Note: Always ensure that there is a minimum overlap of 25 mm when fully extending the telescopic section.
c. Pass the flue assembly through the wall (from inside or outside).
Note: Internal fitting - If there is no access to make good the outside wall, locate the flue sealing collar onto the outer duct
of the flue immediately before the terminal grille onto the location provided. Push the flue assembly through the 130 mm flue
hole, so that the collar completely passes through the wall. Then pull the flue assembly back into the correct position. Visually
check that the collar is sealing the outside wall and that it is not restricting any of the openings of the flue terminal.
Fig. 4 - Fitting the flue from inside
Fig. 2 - Side Flue
d. Position the clamp (two screws) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position.
Secure in position using the sealing tape supplied and the clamp. Ensure the tape is located centrally over both the bend
and boiler adaptor.
e. Fit the inside flue sealing collar over the Easy-Flue. Fit the outside flue sealing collar onto the flue immediately
before the terminal grille onto the location provided.
Side Flue
(B+C)
CD C/X/S Boiler
CD Easy-Flue
500 mm
1000 mm
Max
450
895
Min
240
685
B + C (mm)
CD50 Boiler
CD Easy-Flue
500 mm L/H flue
500 mm R/H flue
1000 mm L/H flue
1000 mm R/H flue
Max
490
250
935
695
Min
300
60
725
485
B + C (mm)HE Boiler
CD Easy-Flue
500 mm
1000 mm
Max
445
890
Min
235
680
B + C (mm)
CDR Boiler
CD Easy-Flue
500 mm
1000 mm
Max
475
920
Min
265
710
B + C (mm)
Fig. 3

3
f. Slide the clamp (three screws) over the outer duct and pull the flue assembly towards the bend, locating the inner
duct into the seal joint on the bend. Ensure the labels marked 'TOP' are positioned at the top before securing the flue
assembly to the bend with the clamp (three screws) located centrally over the joint.
Note: Check the flue terminal protrudes 90 mm out of the wall and the inner duct of the terminal is positioned
correctly (see Fig. 5).
g. Make good the inside wall by pushing the inside flue sealing collar up to the wall.
4b. EXTENDING THE FLUE - Fig. 6
Note: The flue assembly length must not exceed the maximum length stated, including the equivalent lengths of any
extensions, bends etc, used for plume management components. CD boilers must not exceed the maximumum of an
equivalent horizontal flue length of 12 m and HE boilers must not exceed 3 m.
a. When the flue length required is more than the maximum stated in Section 1, paragraph (g), refer to the table below
and Figs 1 and 2.
90
Outer duct clamp
Inner duct seal joint
Inner duct seal joint
90° bend
Clamp and
tape
Terminal
Flue sealing collar
Note: Ensure the outer flue duct is horizontal
Boiler side
CD Easy-Flue
Ensure the inner duct within
the terminal is at the top.
The inner duct must
be positioned to slope towards
the boiler
Note:
HE
CD13R/18R
CD24R
CD50
CD C/X/S
70 mm
65 mm
35 mm
140 mm
40 mm*
HE
CD13R/18R
CD24R
CD50
CD C/X/S
165 mm
160 mm
130 mm
235 mm
140 mm*
Note: * Add 40 mm when Premier Pack is used
20
Model
CD C/S/X
CD13R/18R
CD24R
CD50
HE
All models
All models
Rear Flue length (B)
Up to maximum:-
11.935 m
11.915 m
11.945 m
11.84 m
2.91 m
Refer to Fig. 1
Refer to Fig. 1
Side Flue length (B + C)
Up to maximum:-
11.85 m
11.875 m
11.875 m
LHS 11.895 m
RHS 11.655 m
2.845 m
Refer to Fig. 2
Refer to Fig. 2
Comments
Alpha CD 750 mm flue extension (Part No. 6.2000750)
or 1000 mm extension (Part No. 6.2001050)
is required to extend the range of telescopic flue.
Refer to Section 4 for instructions
on how to extend the flue.
Note: A 130 mm flue hole (127 mm core drill) is
required in the wall.
Within the standard Easy-Flue 1000 mm
(Part No. 6.20001010) telescopic range.
Within standard Easy-Flue 500 mm
(Part No. 6.2000510) telescopic range.
*Subtract 40 mm if
Premier Pack is used
*
Fig. 5 - Rear flue
4a. REDUCING THE FLUE
When the flue length required is less than the minimum stated in Section 1, paragraph (g), refer to the table below and
Figs. 1 and 2.
Model
CD C/S/X
HE
CD13R/18R
CD24R
CD50
CD C/S/X
HE
CD13R/18R
CD24R
CD50
Less than above
Rear Flue length (B)
Between:-
510 mm & 700 mm
490 mm & 680 mm
95 mm & 685 mm
125 mm & 715 mm
20 mm & 610 mm
Between:-
110 mm & 260 mm
90 mm & 240 mm
95 mm & 245 mm
125 mm & 275 mm
20 mm & 170 mm
Side Flue length (B + C)
Between:-
30 mm & 620 mm
25 mm & 615 mm
55 mm & 645 mm
55 mm & 645 mm
LHS 70mm & 660mm
RHS 20mm & 420mm
Between:-
30 mm & 180 mm
25 mm & 175 mm
55 mm & 205 mm
55 mm & 205 mm
LHS 70mm & 220mm
RHS N/A
Comments
Discard first telescopic section of Easy-Flue 1000 mm
(i.e. not with terminal) and cut to required length.
Discard first telescopic section of Easy-Flue 500 mm
(i.e. not with terminal) and cut to required length.
Terminal may protrude somewhat from the outside wall.

4
b. Use the template (supplied with the boiler) to mark the required flue position, ensuring there is the correct slope
towards the boiler.
c. Determine the overall flue length as described in Section 3, paragraph (a) to determine the number of Alpha CD 750
or 1000 mm flue extensions required.
d. Assemble the flue extensions together by locating the inner duct into the seal joint and secure each extension
together with the clamps supplied (three screws). Ensure that the clamps are positioned centrally over the joints.
Note: If it is required to cut an extension, DO NOT cut the end of the inner duct that incorporates the seal joint.
Ensure the inner duct end without the seal joint is cut so that it is 20 mm longer than the outer duct.
e. Adjust the telescopic section of the Easy-Flue to the required length and secure the Easy-Flue with the sealing tape
supplied. Fit the Easy-Flue to the extensions by locating the inner duct into the seal joint and secure with the clamp
(three screws), ensuring it is located centrally over the joint.
f. Mark the end of the flue assembly 'TOP' where it is connected to the boiler, so that the 'TOP' of the flue terminal is
aligned with the 'TOP' at the boiler end of the flue assembly.
g. Pass the complete flue assembly through the wall.
h. Position the clamp (two screws) supplied, over the bend. Fit the bend to the boiler and rotate to the correct position
and secure in position using the sealing tape supplied and the clamp. Ensure the tape is located centrally over both the
bend and boiler adaptor.
i. Slide the clamp (three screws) over the outer duct and pull the flue assembly towards the bend, locating the inner
duct into the seal joint on the bend.
j. Secure the flue assembly to the bend with the clamp (three screws) ensuring it is positioned centrally over the joint,
ensuring the 'TOP' marked on the outer duct is positioned at the top.
Note: Check the flue terminal protrudes 90 mm out of the wall and that the inner duct of the terminal is positioned
correctly, i.e. the inner duct within the terminal is at the top. See Fig. 6.
k. Make good the outside wall by fitting a flue sealing collar onto the location provided immediately behind the flue
terminal grille. Make good the inside wall as required.
Note: If flue sealing collars are being used to make good the inside wall, then they will need to be fitted before
assembling the flue.
HE
CDR
CD50 LHS
CD50 RHS
CD C/S/X
225 mm
195 mm
180 mm
420 mm
220 mm
HE
CDR
CD50 LHS
CD50 RHS
CD C/S/X
130 mm
100 mm
85 mm
325 mm
125 mm
90
45 (25 for CD50)
Boiler front
Outer duct clamp
Inner seal joint
Inner seal joint
Flue length (L)
Clamp
and tape
90° bend
Seal joint
CD Easy-Flue
Note: Ensure outer flue duct of Easy-Flue is horizontal
Note: Ensure the flue extension slopes
downwards towards the boiler by a
minimum of 25 - 30 mm per metre
CD Flue extension
Flue sealing
collar
Flue
terminal
Ensure the inner duct within
the terminal is at the top.
The inner duct must
be positioned to slope towards
the boiler
Note:
20
Fig. 6 - Side flue

5
5. FIT PLUME MANAGEMENT COMPONENTS - (OPTIONAL)
The following procedures detail the options for management of the exhaust flue gas/plume emitted from the terminal.
a. The terminal supplied with the Easy-Flue can be altered to divert exhaust flue gas/plume at an angle of 45° from the
terminal. Three directions can be selected upwards, to the left and to the right.
i. Release the screw (1) securing the terminal and remove the terminal by turning anti-clockwise (2) and pulling it
from the flue assembly (3) as shown in Fig. 7.
ii. Release the two screws (4) securing the end part of the terminal. Reposition this part (5) at an angle of 45° onto
the terminal and secure with the two screws previously removed, as shown in Fig. 7.
Note: Do not overtighten the screws.
iii. Locate the terminal in one of the three positions, as required, by turning clockwise and secure in position using
the screw previously removed as shown in Fig. 7.
Note: Altering the terminal to give this 45° deflection reduces the maximum equivalent flue length by 0.9 m.
Fig. 7
b. The CD Easy-Flue can be converted to allow the inner flue duct to be extended so as to position the terminal in an
area where the exhaust flue gas/plume will not cause a nuisance. This can be done before or after installation of the
flue, providing there is access to the terminal from outside.
i. Release the screw securing the terminal and remove the terminal by turning anti-clockwise and pulling it from the
flue assembly.
ii. Locate a 93° Plume Management bend into the flue assembly and rotate it to the direction required.
iii. Connect to the 93° bend the required Plume Management components as detailed and refer to Fig. 8.
Notes:
1.The wall support brackets must be used to secure the Plume Management pipework to the wall and
prevent disconnection of the 93° bend from the flue assembly or any other component.
2.Each joint must be secured with one of the screws provided to prevent accidental disconnection.
3.Ensure there is always a slight slope towards the flue assembly fitted in the wall and there is no part of
the plume management pipework where condensate/rain will collect and cause a blockage or any
restriction.
iv. Terminate the Plume Management pipework by fitting the terminal previously removed and secure in position with
the screw previously removed. Refer to Fig. 8.
v. The Plume Management components available for extending the inner flue duct are as follows:-
Plume Management 93° bend 60 mm dia. (each 93° bend equivalent to 1.3 m flue length)
Plume Management 45° bend 60 mm dia. (each 45° bend equivalent to 0.9 m flue length)
Plume Management 1000 mm extension 60 mm dia. (equivalent to 1 m flue length)
60 mm dia. wall bracket

Fig. 8
Note: The equivalent horizontal flue assembly length + the equivalent plume management length (PM length) must not
exceed the maximum flue length stated for each boiler, i.e.
Alpha CD boiler maximum equivalent flue length must not exceed 12 metres.
Alpha HE boiler maximum equivalent flue length must not exceed 3 metres.
Note:
1. Ensure each joint is
secured with the screw
supplied.
2. Ensure there is always
a slight slope towards
the CD Easy-Flue so
that there is no part of
the pipework where
condensate will collect.
Leaflet compiled and designed by Publications 2000, Tel [phone]/D232
These instructions have been carefully prepared but we reserve the right to
alter the specification at any time in the interest of product improvement.
© Alpha Therm Limited 2009.
Alpha Therm Limited.
Nepicar House, London Road, Wrotham Heath,
Sevenoaks, Kent TN15 7RS
Tel: [phone]
email: [email protected]
website: www.alpha-innovation.co.uk