Flue Gas System Guide

Flue Gas System Guide Flue systems for wall hung condensing boilers from 33kW to 1040kW in cascade

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Index

1. Flue Systems 1.1 1.2 1.3 1.4 1.5

Flue information and guidelines………….... Open flue system…………………….…….… Room sealed system…………….…………. Examples of flue gas systems……………... Available flue systems per boiler……….……

3 3 4 5 6

2. Design and sizing information 2.1

2.2 2.3 2.4 2.5

Boiler maximum flue lengths…….……..…...

Thision S Plus………………………...

Thision L Evo……………….…………

Thision L Eco……………….……….… Safe flue termination…………………………. IGEM-UP 10…………………………………... BS6644 – 70kW to 1.8MW………..………….. BS5440 – Up to 70kW………………..………

6 6 7 7

8

9 10

11

3. Flue components 3.1 3.2

3.3 3.4

3.5 3.6

Available flue components……………..…….. Thision S Plus flue components……..……….

Concentric flue……………..…..……..

Two pipe flue system……………..…… Thision L Evo flue components……….…..…

Concentric flue……….…………..……

Two pipe flue system……………….. Thision L Eco flue components………..……

Concentric flue………………..….…..

Two pipe flue system………..………. Flexible flue components…………..….……… Cascade flue components……..……………

13 14 14

14 15 15 15

16 16

16

17

18

4. Flue component dimensions

4.1 4.2 4.3 4.4 4.5

Concentric flue parts dimensions...………… PPs flue parts dimensions……………………. Cascade flue dimensions………..………….. Flexible flue dimensions…………..………… Cascade flue dimensions…………………….

20 23 24 25 27

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1. Flue Systems

1.1 Flue information and guidelines

Requirements and regulations

Regulations for the construction of flue gas systems are very different for each country. It should

be ensured that all national regulations with regards to flue gas systems are respected.

Pay attention to the following recommendations when dimensioning a flue gas system.

The flue gas system must be properly calculated to ensure safe operation of the system.

Flue gas system components should be removable for maintenance purposes.

Horizontal flue sections must have an incline of no less than 3° back towards the boiler.

Only materials which are heat resistant, resistant to flue gases and aggressive condensate

and also CE approved may be used.

It is the responsibility of the installer to ensure the integrity of the flue and/or chimney

system before commissioning the boiler.

Any terminal that is less than 2 metres above finished floor or ground level must be

guarded. This also applies when terminals are positioned above flat roofs and balconies to

where there is regular unimpeded access. Please see IGEM-UP10 section for more

information on termination.

Please contact Elco UK office for more information for configurations.

1.2 Open flue systems

Open flue systems can be designed where the combustion air supply

is taken from the room or from the surrounding area where the boiler

is installed.

The flue combustion gases are taken from the boiler and terminated

at a higher level to the air intake or a different termination location to

avoid contaminating the air supply with the flue gas. Elco recommend

that single wall plastic flue pipe (PPs) be used for open flue systems.

When designing a flue gas pipe, please ensure that the horizontal

lengths have a 3° fall towards the boiler to aid in any condensate

draining. It is not necessary to make a separate condensate drain in

the flue gas system as the condensate will be drained via the boiler

syphon.

In addition to this, we also recommend that flue brackets are used at 1 metre increments to support

the flue pipe installation. The flue pipe should also be designed to be as straight as possible to

utilise the maximum length of the flue that the boiler can run. If a bend is unavoidable, we advise

that 90° bends not be installed directly one after another.

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Open flue systems continued…

When using an open flue system, Elco recommends that

an air inlet cover or air filter must be fitted on the air inlet

connection on the boiler, to stop any debris entering the

air supply and causing issues with the boilers

combustion. The flue system must be fitted with flue

pipes that have seamless connections only to avoid

leaks.

The maximum temperature of the flue gas for the wall

hung boiler range that we supply is 77°C so no protective

measures or clearances towards combustible objects

needs to be taken.

1.3 Room sealed flue systems

Room sealed flue can be constructed with either concentric flue pipe

or single pipe plastic flue (PPs). These type of systems are defined

by taking the combustion air supply from outside the room the boiler

is located.

With concentric flue pipe the combustion air is supplied and the flue

gas extracted through one concentric coaxial pipe. The combustion

air is supplied through the gap between the external painted

aluminium air pipe and the internal plastic flue pipe. Flue gases are

extracted through the internal plastic pipe (PPs).

When designing a room sealed system please ensure that the

horizontal lengths must have a 3° fall towards the boiler to aid in any

condensate draining. It is not necessary to make a separate

condensate drain in the flue gas system as the condensate will be

drained via the boiler syphon.

In addition to this, we also recommend that flue brackets be used at 1

metre increments to support the flue pipe installation. The flue pipe

should also be designed to be as straight as possible to utilise the

maximum length of the flue that the boiler can run. If a bend is

unavoidable then they must not be installed directly one after another.

The maximum temperature of the flue gas for the wall hung boiler

range that we supply is 77°C so no protective measures or

clearances towards combustible objects needs to be taken.

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1.4 Examples of flue gas systems

Combustion air

drawn from the

room

B23 External flue gas exhaust. Air drawn from the room.

C13

Air/exhaust gas routing through outside wall in the same pressure range. Exhaust gas/fresh air supply system through outside wall. The Terminal outlets from separate combustion and air supply circuits shall fit inside a square of 50 cm for boilers with a heat input to 70 kW and 100 cm with a heat input from 70 up to 100 kW.

C33

Flue gas exhaust and air suction duct from outside with roof terminal in the same range of pressure. The Terminal outlets from separate combustion and air supply circuits shall fit inside a square of 50 cm and distance between the planes of the two orifices shall be less than 50cm for boilers with a heat input below 70 kW. A square of 100 cm and distance between the planes of the two orifices shall be less than 100 cm with a heat input above 70 kW.

C43 Individual or shared flue gas exhaust and air suction through flue ducting built into the building

C53 Flue gas exhaust leading outside and air suction duct through external wall not in the same range of pressure.

C63

Air and exhaust connection to separate tested and supplied air/exhaust pipes. Basement / floor installation. Air and exhaust venting via exterior wall. Exhaust venting through heat insulated exhaust pipe or moisture resistant pipe. Exhaust line (standing air layer) at exterior wall. The terminals for the supply of combustion air and for the evacuation of combustion products shall not be installed on opposite walls of the building.

C83 Flue gas exhaust through individual or shared flue ducting built into the building. Air suction through external wall.

Combustion air

drawn from

outside

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1.5 Available flue systems per boiler

Concentric Flue (mm) Plastic Single Pipe Flue (PPs) (mm) Thision S Plus 80/125 100/150 Thision S Plus 80 100 110 125 130

34 34 46 46 54 54

Thision L Evo 80/125 100/150 Thision L Evo 80 100 110 125 130

60 60 70 70 80 80

100 100 120 120

140 140

Thision L Eco 80/125 100/150 Thision L Eco 80 100 110 125 130

70 70 100 100 120 120

2. Design and sizing information

2.1 Boiler maximum flue lengths

Thision S Plus

Maximum length in metres for concentric room sealed installations 80/125 100/150

Changes of direction

0 2 3 4 0 2 3 4

34 25 13.6 7.9 2.2 40 34.2 31.3 28.4

46 12 30 19.4 14.1 8.8

54 11 30 15.4 8.1 0.8

Maximum length in metres for single pipe open or room sealed installations

80mm 100mm Changes of

direction 0 2 3 4 0 2 3 4

34 30 22 18 14 80 77.1 75.7 74.3

46 12 55 49.9 47.3 44.7

54 11 50 42.9 39.3 35.8

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2.1 Boiler maximum flue lengths continued…

Thision L Evo

Thision L Evo 80/125 100/150

(m) (m) 60 14 38 Equivalent length in m

70 12 33 Concentric flue Bend R = D Bend R = D

80 7 23 gas system 90°/87° 45°/43°

100 11 80/125 1.5 1

120 7 100/150 1.5 1

Thision L Evo 80 100 110 125 130

60 17 62 70 13 52 65 Twin pipe flue Equivalent length in m

80 7 36 47 gas system 80 100 110 125 130

100 13 23 56 88 Straight Pipe 1 1 1 1 1

120 8 13 43 65 90°/87° Bend 1.5 1.8 2 2.2 2.2

140 5 14 23 45°/43° Bend 0.8 0.9 1 1 1

*Please be advised that we do not offer concentric flue for the Thision L Evo 140 boiler.

**Please be advised that we do not supply 130mm PPs flue.

Thision L Eco

Maximum length in metres for concentric room sealed installations

100/150 Changes of direction 0 2 3 4

70 25 22 20 18

100 15 12 10 8

120 8 5 3 1

Maximum length in metres for single pipe open or room sealed installations

100mm Changes of direction 0 2 3 4

70 63 59 57 55

100 35 31 29 27

120 12 8 6 4

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2.2 Safe flue termination

In this section we aim to advise which laws and guidance are to be used in which situation. This

document will not cover every regulation but it will provide guidance as to which regulation

applies to certain situations.

The guide will look at the more common standards used to advise the requirements for flue and

ventilation installations and is not to be used as a standalone reference for regulations relating

to flue.

Please also refer to the installation and planning manuals for the specific boiler were there may

be specific information relating to flue installation standards.

When dealing with domestic installations that have a net input up to 70kW, these will be covered

by BS5440.

If the same appliance under the 70kW limit was to be installed in a commercial property then

this now needs to meet the requirements of IGE UP10 & BS6644.

However if a boiler is installed in a cascade arrangement and then exceeds the total input of

70kW then it falls under the commercial flue and ventilation requirements.

What is mandatory and what is just guidance?

British Standards (such as BS5440) are a mandatory requirement and have to be adhered

to. The approved documents offer guidance on how to comply and are only legally binding if

they are stipulated in the manufacturers installation manual. It is important to follow the

guidelines as they may be used in a court of law as the minimum expectation of a

competent person when installing a safe heating system.

The Clean Air Act is a mandatory requirement set out in Government legislation. It was

introduced in 1956 to reduce air pollution reacting to the Great Smog of London in 1952, in

that it helped the development of laws to help protect the environment.

This act targeted areas in major towns and cities, in these areas only fuels that produced

smokeless fuels could be used, also moving power stations away from main cities and

making it so that the height of certain chimneys being increased to avoid low level

contamination.

Nowadays smog is not as much of an issue as it was, but amendments of the Clean Air Act

have maintained control of emissions and the height of flue systems being more conscious

of pollution at lower levels.

Gas Safe (Gas Safety Installation and Use Regulations) is now mandatory and is there to

set out the requirements for safe installations and for working on gas installations.

IGE/IGEM is a guidance in a similar fashion to the British Standards but these are used by

industry experts as a current best practice and are in line with international and national

legislation and standards. The most relevant being IGEM UP 10 – Installation of flued gas

appliances in industrial and commercial premises.

On the following page is an extract from IGEM UP10 in relation to termination positions for

appliances over 70kW net input.

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2.3 IGEM-UP 10

Single pipe flue minimum height of termination above a roof relating to number 1

Boiler Model Thision L Eco Boilers Thision L Evo Boilers

L Eco 100 L Eco 120 L Evo 80 L Evo 100 L Evo 120 L Evo 140

Above Roof 475mm 605mm 335mm 420mm 505mm 590mm

For other appliances use the calculation: Distance = 4.5675 (net heat input) - 19.723 For all sloped roofs over a 20° pitch the terminal must be 1.5 metres away.

If the flue terminates within 2.5 metres of an adjacent structure, the heights will apply to above the adjacent structure. Elco concentric roof terminals terminates 700mm above roof level and therefore the above need not apply.

Minimum termination distances relating to numbers 2, 3 & 6



Open Flue 1865mm 2135mm 1565mm 1740mm 1925mm 2105mm

For other open flue fan draught appliances use the calculation: Distance = 9.5156 x (net heat input) + 833.91

Room Sealed 875mm 1085mm 650mm 785mm 925mm 1060mm

For other room sealed fan draught appliances use the calculation: Distance = 7.232 x (net heat input) + 93.708

Minimum horizontal termination to opposing flat surfaces/terminals relating to number 10



Flat Surfaces 3115mm 3775mm 2395mm 2825mm 3265mm 3705mm

For other appliances use the calculation: Distance = 23.126 x (net heat input) + 618.84

Terminals 2735mm 3285mm 2135mm 2490mm 2860mm 3225mm

For other appliances use the calculation: Distance = 19.32 x (net heat input) + 647.59

Termination positions for appliances over 70kW net input

Key to Diagram:

1 – Minimum termination height for ridged and flat roofs

2 – Minimum horizontal termination distance from openings e.g. doorways, windows, ventilation grilles, etc.

3 – Minimum horizontal termination distance from adjacent walls or obstructions

4 – Minimum distance to be 200mm for fan assisted appliances, 300mm for room sealed natural draught appliances. See BS5440.

5 – Minimum distance to be 150mm, see BS5440

6 – Minimum termination distance from openings e.g. doorways, windows, ventilation grilles, etc.

7 – Minimum distance between the flue terminals is to match the flue centres of our boilers when mounted on a cascade frame.

8 – Minimum distance below terminal or opening – 2.5 metres

9 – Minimum termination 2000mm above ground and a terminal guard must be fitted if less than 3000mmm.

10 – Opposing a terminal or flat surface.

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2.4 BS6644 – 70kW to 1.8MW

Open Flued Type B and Room sealed Type C Appliances Installed within an Enclosure (Natural ventilation requirements direct to Outside Air.)

Flue type Ventilation direct to outside air Ventilation to an internal space

Open flue Type B 5 cm² 10 cm² Not permitted Not permitted

Room sealed Type C 5 cm² 5 cm² 10 cm² 10 cm²

Open Flued Appliances Installed within a Boiler Room (Natural ventilation requirements direct to Outside Air.)

Open flue Type B Ventilation direct to outside air

Low Level (Free Area / kW) 4 cm²

High Level (Free Area / kW) 2 cm²

Balanced Flued Appliances Installed within a Boiler Room (Natural ventilation requirements direct to Outside Air.)

Room sealed Type C Ventilation direct to outside air

Low Level (Free Area / kW) 2 cm²

High Level (Free Area / kW) 2 cm²

Room sealed appliances with an Maximum Operating Pressure not exceeding 100 mbar in ventilated

occupied spaces with an air change rate exceeding 0.5 air changes per hour do not require additional

ventilation. If the air changes rate is below 0.5 per hour, 2 cm 2 kW -1 ventilation at high and at low level

shall be required.

Open Flued Appliances Installed with a Draught Diverter (Mechanical ventilation flow rate requirements direct to Outside Air.)

System Type & Operational Time Grille Location Ventilation direct to outside air

Low Level Inlet (m3/h / kW) 2.8

High Level Extract (m3/h / kW) (Difference Between Inlet and Extract Air)

2.07 +/- 0.18

Open Flued Appliances Installed without a Draught Diverter (With or without stabilizers) (Mechanical ventilation flow rate requirements direct to Outside Air.)

System Type & Operational Time Grille Location Ventilation direct to outside air

Low Level Inlet (m3/h / kW) 2.6

High Level Extract (m3/h / kW) (Difference Between Inlet and Extract Air)

1.35 +/- 0.18

Where high level discharge openings are not mechanically assisted, the free area must be calculated as detailed above. All air inlet and extract fans must be fitted with automatic controls (interlocks) causing safety shut-down or lockout of the installed gas burning appliances in the event of an inlet or extract air flow failure.

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2.5 BS5440 – Up to 70kW

Open Flued Appliances installed within a Room (Natural ventilation requirements direct to Outside Air.)

Total rated net input not in excess of (70 kW – 7 kW) x 5cm² = Ventilation opening free area Open Flued

Open Flued appliances Installed within a compartment (Natural ventilation requirements.)

Ventilation Route Grille Location

Ventilation to room or internal space. (The internal space ventilated into must be ventilated as detailed above to outside air.)

Ventilation direct to outside air

Low Level (Free Area/kW) 20 cm² 10 cm²

High Level (Free Area/kW)

10 cm² 5 cm²

Balanced Flued Appliances Installed within an Enclosure (Natural ventilation requirements)

Ventilation Route Grille Location

Ventilation to room or internal space. Ventilation direct to outside air

Low Level (Free Area/kW) 10 cm² 5 cm²

High Level (Free Area/kW)

10 cm² 5 cm²

Air Vent Position Appliance Input (kW)

Fanned Draught Distance (mm)

A Above a Terminal

0 to 7 300

>7 to 14 300

>14 to 32 300

>32 300

B Below a Terminal

0 to 7 300

>7 to 14 300

>14 to 32 300

>32 300

C Horizontally to a Terminal

0 to 7 300

>7 to 14 300

>14 to 32 300

>32 300

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2.5 BS5440 – Up to 70kW continued…

No part of the chimney outlet shall be less

than 1500mm measured horizontally to the

roof surface or 600mm above the ridge.

If the chimney penetrates the dotted area,

and distance A is less than 1500mm, then

distance B shall not be less than 600mm.

Examples of the structure referred to above

include a parapet, dormer window or

chimney stack.

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3. Flue Components

3.1 Available Flue Components

21

9

Available Flue Parts:

1. Wall Terminal

2. 2000mm Concentric Pipe

3. 500/1000mm Concentric Pipe

4. 90° Concentric Bend

5. 45° Concentric Bend

6. Vertical Adaptor

7. Roof Terminal

8. Flat Roof Flashing

9. Pitched Roof Flashing

10. Wall Bracket

11. Concentric Increaser

12. 2000/1000/500mm PPs Pipe

13. 90° PPs Bend

14. 45° PPs Bend

15. Plume Kit

16. PPs Increaser

17. Bird Mesh Stainless Steel Guard

18. Air Filter

19. Concentric to Parallel Adaptor

20. Air Inlet Cover

21. Parallel to Concentric Adaptor

22. PPs Reducer

*Products supplied may differ from image

1

3

2

13

12

14 15

8

16

17

18

7

11

10

6

5

4

19

20 22

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3.2 Thision S Plus Flue Components

Concentric Flue Systems

Item Flue Component 80/125 100/150

2 1950mm Length 3791646 3791303

3 1000mm Length 3791641 3791304

3 500mm Length 3791642 3791305

4 87°/93° Bend 3791643 3791306

5 45° Bend 3791644 3791307

1 Wall Terminal 3791645 3791308

1 + 4 Wall Terminal Kit * FLUE-B-WALL FLUE-B-EVOWALL

7 Roof Terminal 3791640 3791309

8 Flat Roof Slate 3791613 3791617

9 Pitched Roof Slate 3791614 3791618

10 Flue Bracket 3791612 3791616

15 Plume Kit 3791639 3791480

*Wall terminal kit includes wall terminal and 87°/93° bend

Single/Two Pipe Flue Systems

Item Flue Component 80mm 100mm UV Resistant 80mm

12 1950mm Length 3791584 3791297

12 1000mm Length 3791573 3791299 3791577

12 500mm Length 3791585 3791594 3791578

13 87°/93° Bend 3791574 3791300 3791579

14 45° Bend 3791575 3791301 3791580

17 Mesh Terminal 3791582 3791607 3791582

10 Flue Bracket 3791576 3791302 3791581

15 Plume Kit 3791639 3791480 3791639

Accessories

Item Flue Component Part Code

11 80/125 to 100/150 Concentric Increaser 3791570

16 80mm to 100mm Single Pipe Increaser 3791662

19 80/125 Concentric to Parallel Adapter 3791658

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Elco do not supply 130mm PPs flue, if this is required then please contact a specialist flue supplier.

3.3 Thision L Evo Flue Components

Concentric Flue Systems

Item Flue Component 80/125 100/150 110/150

2 1950mm Length 3791646 3791303

3 1000mm Length 3791641 3791304 3791621

3 500mm Length 3791642 3791305 3791622

4 87°/93° Bend 3791643 3791306 3791623

5 45° Bend 3791644 3791307 3791624

1 Wall Terminal 3791645 3791308 3791768

1 + 4 Wall Terminal Kit * FLUE-B-WALL FLUE-B-EVOWALL FLU-110/150-WALL

7 Roof Terminal 3791640 3791309 3791625

8 Flat Roof Slate 3791613 3791617 3791617

9 Pitched Roof Slate 3791614 3791618 3791618

10 Flue Bracket 3791612 3791616 3791616

15 Plume Kit 3791639 3791480


Single/Two Pipe Flue Systems

Item Flue Component 80mm 100mm 110mm 125mm UV Resistant

80mm

12 1950mm Length 3791584 3791297 3791345 3791609

12 1000mm Length 3791573 3791299 3791595 3791608 3791577

12 500mm Length 3791585 3791594 3791578

13 87°/93° Bend 3791574 3791300 3791596 3791610 3791579

14 45° Bend 3791575 3791301 3791597 3791611 3791580

17 Mesh Terminal 3791582 3791607 3791607 3791619 3791582

10 Flue Bracket 3791576 3791302 3791626 3791612 3791581

15 Plume Kit 3791639 3791480 3791639

8 Flat Roof Slate 3791613

9 Pitched Roof Slate 3791614

20 Air Inlet Cover 452002280

Accessories

Item Flue Component Part Code

21 100/100 to 80/125 Concentric Adaptor 3791648




22 100mm to 80mm Reducer 3791650

16 100mm to 110mm Increaser 3590307

16 100mm to 125mm Increaser FLUE0039AA000

22 130mm to 125mm Reducer 3590308

20 130mm Air Inlet Cover 452002300

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3.4 Thision L Eco Flue Components

Concentric Flue System

Item Flue Component 100/150

2 1950mm Length 3791303

3 1000mm Length 3791304

3 500mm Length 3791305

4 87°/93° Bend 3791306

5 45° Bend 3791307

1 Wall Terminal 3791308

1 + 4 *Wall Terminal Kit FLUE-B-EVOWALL

7 Roof Terminal 3791309

8 Flat Roof Slate 3791617

9 Pitched Roof Slate 3791618

10 Flue Bracket 3791616

15 Plume Kit 3791480


Single/Two Pipe Flue System

Item Flue Component 100mm

12 1950mm Length 3791297

12 1000mm Length 3791299

12 500mm Length 3791594

13 87°/93° Bend 3791300

14 45° Bend 3791301

17 Mesh Terminal 3791607

10 Flue Bracket 3791302

15 Plume Kit 3791480

18 Air Filter 3905046

20 Air Inlet Cover 452002280

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The image on the left is an example

installation of a flexible flue solution where the

air is being taken in via the chimney cover and

then down through the chimney into the

150mm connection on the wall plate, where it

will then be taken into the boiler via concentric

flue pipe.

The flue gas is being taken from the boiler

through concentric flue pipe to the wall plate,

where it is connected to the flexible flue and

taken out through the flexible pipe to the

termination at the chimney cover.

This solution allows the boiler to operate as a

room sealed device taking combustion air from

the brick chimney which is ventilated to allow

air to be taken from outside. We recommend

that the chimney is swept prior to installation to

reduce the risk of dirt to be drawn into the

boiler.

This is mostly used in older buildings where

modification of the building is prohibited.

3.5 Flexible Flue Components

At Elco Heating Solutions we can offer a flexible flue solution for when the flue

gas system needs to be routed through an existing chimney/void such as in listed

buildings where amendments to the building layout cannot be made.

We have a simple starter kit that has been assembled to make it easier when

selecting the required items. The starter kit includes a chimney cover, bottom

bend and support, 5 spider brackets, flexible and rigid couplings and the

installation tool.

Adding this kit to the appropriately sized flexible flue liner and the concentric/PPs

flue from the boiler, this gives you a kit that will allow you to take the flue gas to

the desired termination location as per the image.

Example of a 110mm Flexible Flue Installation

Flue Component 80mm 110mm

12.5m Flexible Flue Liner FLUEBRECAA500

15m Flexible Flue Liner FLUECRECAA600

25m Flexible Flue Liner FLUEBREDAA600 FLUECREDAA600

Rigid to Flexible Adaptor FLUEBREMAA600 FLUECREMAA700

Flexible to Flexible Adaptor FLUEBREFAA600 FLUECREFAA600

Flexible to Rigid Adaptor FLUEBREGAA700 FLUECREGAA700

Bracing Brackets (Pack of 5) FLUEBREJAA500 FLUECREJAA500

Chimney Cover c/w Flex to Rigid Adaptor FLUEBRCTAA500 FLUECRCTAA500

Chimney Support Bend FLUEBKCRAA000 FLUECKCRAA000

Starter Kit BRFY.AA.000 CRJEAA000

100-110 Increaser FLUE113795

Mesh Terminal FLUE173121 FLUE173121

Mesh Terminal

FLUE173121

Chimney Cover

FLUECRCTAA500

Bracing Brackets

FLUECREJAA500

15m Flexible Flue Liner

FLUECRECAA600

Chimney Support Bend

FLUECKCRAA00

100/150 Wall Plate

FLUECBDDAA600

100 to 110 Increaser

FLUE113795

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3.6 Cascade Flue Components

We currently do not do cascade flue for the Thision S

Plus. If you wish to install a cascade flue system for

the Thision S Plus range, please contact a specialist

flue supplier.

Elco only supply the cascade flue header as pictured,

the flue pipe exiting the cascade flue header will need

to be sourced via a flue specialist. The air intake

header will be need to be sourced by a flue specialist.

Please see the relative boiler operation and

installation manual for the information regarding

cascade flue system lengths and diameters.

Thision L Evo

Flue Component DN150 DN200

2 Boilers In-Line Cascade Flue 452001320 452001420





3 Boilers Back to Back Cascade Flue 452001520 452001640






Thision L Eco













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3.4 Cascade Flue Components continued…

Thision L Evo Cascade Flue Accessories

Flue Component Part Code

Cover for Combustion Air Inlet 100mm For L Evo 60 – 120 Models

452002280

Cover for Combustion Air Inlet 130mm For L Evo 140 Model

452002300

Cascade Flue System Adaptor for Thision L Evo 140 452001760

Thision L Eco Cascade Flue Accessories


2 Boiler In-Line Cascade Flue Fixation Rail 452004435 452004435





3 & 4 Boiler Back to Back Cascade Flue Fixation Rail 452004435 452004435



Air Filter 3905046

Cover for Combustion Air Inlet 100mm 452002280

*A cover for the air intake is supplied with the cascade flue set for the Thision L Eco boilers

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4. Flue Component Dimensions

4.1 Concentric flue parts dimensions

Concentric Wall Terminal

1 Part Part Code D1 D2 D3 L1 X1

80/125 3791635 80 125 220 955 800

2 100/150 3791309 100 150 230 870 690

110/150 3791768 110 150 230 870 690

3

Concentric Roof Terminal

Part Part Code D1 D2 D3 D4 L1 L2 X1

80/125 3791635 80 125 140 190 1150 250 600

4

Concentric Roof Terminal

Part Part Code D1 D2 D3 L1 X1

100/150 3791633 100 150 175 1195 420

110/150 3791659 110 150 175 1195 420

1

2

4 3

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4.1 Concentric flue parts dimensions continued…

1

Concentric 90° Bend

Part Part Code D1 D2 L1 L2 X1

80/125 3791643 80 125 130 120 80

100/150 3791306 100 150 130 145 95

110/150 3791623 110 150 145 130 95

2

Concentric 45° Bend

Part Part Code D1 D2 L1 L2 X1

80/125 3791644 80 125 90 90 40

100/150 3791307 100 150 110 120 70

110/150 3791624 110 150 120 110 70

3

1000mm Concentric Straight Length

Part Part Code D1 D2 L1 X1

80/125 3791641 80 125 1000 950

100/150 3791304 100 150 1000 944

110/150 3791621 110 150 1000 950

500mm Concentric Straight Length


80/125 3791642 80 125 500 450

100/150 3791305 100 150 500 450

110/150 3791622 110 150 500 450

4

1950/2000mm Concentric Straight Length Part Part Code D1 D2 L1 X1

80/125 3791646 80 125 1950 1890

100/150 3791297 100 150 1950 1945

4

2 1

3

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4.1 Concentric flue parts dimensions continued…

1

80/125 to 100/150 Concentric Increaser

Part Part Code D1 D2 D3 D4 L1 X1

80/125 3791664 80 125 100 150 165 110

80/125 to 110/150 Concentric Increaser

Part Part Code D1 D2 D3 D4 L1 X1

80/125 3791659 80 125 110 150 165 115

2

100/100 to 80/125 Concentric Adaptor

Part Part Code D1 D2 D3 L1 L2 X1 X2

100/100 3791648 100 80 125 65 145 305 180

130/130 to 110/150 Concentric Adaptor


130/130 3791647 130 110 150 65 145 305 180

3

100/100 to 100/150 Adaptor


100/100 3590656 110 100 150 80 179 284 148

4

100/100 to 110/150 Adaptor


100/100 3791653 100 110 150 52 163 320 175

1

2 3 4

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4.2 PPS flue parts dimensions

1

2000mm PPs Straight Length Part Part Code D1 L1 X1

80 3791584 80 1950 1895

100 3791593 100 1945 1890

110 3791345 110 1950 1895

125 3791609 125 2075 2000


80 3791573 80 100 945

100 3791299 100 995 940

110 3791595 110 1000 945

125 3791608 125 1075 1000


80 3791585 80 500 445

100 3791594 100 495 440

1000mm UV Resistant PPs Straight Length

Part Part Code D1 L1 X1

80 3791577 80 100 945

500mm UV Resistant PPs Straight Length


80 3791578 80 500 445

2

90° Bend PPs and UV Resistant PPs

Part Part Code D1 L1 L2 X1

80 3791574 80 130 120 75

100 3791300 100 145 130 90

110 3791596 110 120 110 60

125 3791610 125 145 150 70

3

45° Bend PPs and UV Resistant PPs

Part Part Code D1 L1 L2 X1

80 3791575 80 90 90 45

100 3791301 100 110 120 75

110 3791597 110 90 85 35

125 3791611 125 100 100 35

2 1 3

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4.3 Accessory parts dimensions

1

Stainless Steel Mesh Terminal


90mm AT-3791582 90 125 47

120mm AT-3791607 120 130 60

160mm AT-3791619 160 140 60

200mm AT-3791620 200 140 60

2

Flat Roof Flashing

Part Part Code D1 D2 X1

80/125 AT-3791613 135 410 100

100/150 AT-3791617 170 450 100

3

Pitched Roof Flashing

Part Part Code D1 L1 α (°)

80/125 AT-3791614 142 500 25° - 45°

100/150 AT-3791618 172 500 25° - 45°

4

PPs Increaser


80 to 100 3791662 80 100 165 110

80 to 110 3791651 80 110 140 85

100 to 110 3791652 100 110 160 105

5

80/125 to 80/80 PPs Adaptor

Part Part Code D1 D2 D3 D4 L1 L2 L3 X1 X2

80/125 3791658 80 80 80 125 175 150 255 130 120

6

Plume Kits

Part Part Code D1

80mm AT-3791639 80

100mm AT-3791480 100

4

1 2

3

2

5

6

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4.4 Flexible flue dimensions

1

80mm Flexible Flue Liner


12.5m AT-3791586 80 12.5m 1490

25m AT-3791587 80 25m 1490

110mm Flexible Flue Liner

Part Part Code D1 D2 X1

15m AT-3791598 110 15m 1490

25m AT-3791599 110 25m 1490

2

Chimney Support Bend

Part Part Code D1 L1 L2 L3 L4 X1

80mm AT-3791591 80 120 130 212 390 80

110mm AT-3791605 110 120 110 230 390 65

3 100mm to 110mm Increaser


100-110 AT-3791652 100 110 160 105

4

Flexible Flue Brackets (5 Pack)

Part Part Code D1 D2 L1

80mm AT-3791589 80 40 400

110mm AT-3791602 110 40 400

5 100mm to 110mm Increaser

Part Part Code D1 L1 X1 X2

110mm AT-3791601 110 190 50 50

1 2 3

4

5

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4.4 Flexible flue parts dimensions continued…

1

Chimney Cover for Flexible Flue

Part Part Code D1 D2 L1

80mm FLUEBRCTAA500 48 246 188

110mm FLUECRCTAA500 72 246 188

2

Flex to Flex Adaptor


80mm FLUEBREFAA600 80 187 87

110mm FLUECREFAA600 110 187 87

1 2

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4.5 Cascade flue dimensions

The cascade flue kits that are supplied for the Thision L Eco boilers are built from individual kits and then

multiplied dependant on how many boilers is in the installation. For example, if you have 4 boilers on an

in-line cascade frame then the kit will come with 4 sections of cascade flue and so on.

So the overall length of the cascade flue will be the individual kits multiplied by the number of boilers.

Each individual section comes with a vertical single skin pipe to be used to take the flue gas into the

cascade flue header. This section will be supplied in a 500mm length. To achieve the 3° incline back to

the boilers this length will need to be cut down to facilitate this requirement.

Thision L Eco DN150 In-Line Cascade Flue

Thision L Eco DN200 In-Line Cascade Flue

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4.5 Cascade flue dimensions continued…

Thision L Eco DN150 Back to Back Cascade Flue

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Thision L Eco DN200 Back to Back Cascade Flue

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The cascade flue kits that are supplied for the Thision L Evo boilers is a 2 boiler version of the casade

header, however further additional extension kits and are added on depending on how many boilers is in

the installation. For example, if you have 4 boilers on an in-line cascade frame then the kit will come with

one 2 boiler in-line cascade flue set and 2 additional extension kits of cascade flue.

The overall length of the cascade flue will be the 2 boiler cascade header plus the individual extension kits

multiplied by the number of boilers.

Each extension kit comes with a vertical single skin pipe to be used to take the flue gas into the cascade

flue header. This section will be supplied in a 500mm length. To achieve the 3° incline back to the boilers

this length will need to be cut down to facilitate this requirement and this information can be found in the

cascade installation manual for the Thision L Evo boiler.

DN150 In-Line Cascade Flue

603mm

1493mm

205mm Centre to Centre

285mm

DN150

100mm 100mm

621mm

362mm DN200 In-Line Cascade Flue

1493mm


DN200

100mm 100mm

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DN200 Back to Back Cascade Flue

DN150 Back to Back Cascade Flue

100mm

100mm

100mm

100mm

100mm

100mm

100mm

100mm

DN200

439mm

684mm

1422mm



685mm

488mm



1401mm

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DN150 In-Line Cascade Flue Extension

100mm

DN150

689mm

DN200 In-Line Cascade Flue Extension

100mm

715mm

DN200

DN150 Back to Back Cascade Flue Extension

DN200 Back to Back Cascade Flue Extension

100mm

100mm

DN150

690mm

100mm

100mm

710mm

DN200

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Elco Heating Solutions 3 Juniper West, Fenton Way, Southfields Business Park,

Basildon, Essex, SS15 6SJ

Tel: 01268 546700 Fax: 01268 888250

www.elco.co.uk

This publication is issued subject to alteration or withdrawal without notice. The

illustrations and specifications are not binding in detail. All offers and sales are subject

to the Company’s current terms and conditions of sale.

Flue Gas System Guide

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