Viessmann Flue gas system Installation Instructions Manual Download Page 2

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Installation instructions

for contractors

Flue gas system

for Vitocrossal (type CU3), Vitodens and Vitoladens

Safety instructions

Please follow these safety instructions closely to prevent accidents and
material losses

Safety instructions explained

Please note

This symbol warns against

the risk of material losses and

environmental pollution.

Note

Details identified by the word “Note”

contain additional information

installation, initial start-up, inspection,

maintenance and repairs must only be

carried out by a competent person (heating

engineer/installation contractor).

Before working on the equipment/heating

system, isolate the power supply (e.g.

by removing a separate mains fuse or by

means of a mains isolator) and safeguard

against unauthorised reconnection.

When using gas as a fuel, also close the

main shut-off valve and safeguard against

unauthorised reopening.

Repairing components which fulfill a safety

function can compromise the safe operation

of your heating system.

For replacements, use only original spare

parts supplied or approved by Viessmann.

Dispose after installation

5458 035 GB 04/20

Summary of Contents for Flue gas system

Page 1: ...ions Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 67500 Fax 44 1952 675040 E mail info uk viessmann com ...

Page 2: ...ion maintenance and repairs must only be carried out by a competent person heating engineer installation contractor Before working on the equipment heating system isolate the power supply e g by removing a separate mains fuse or by means of a mains isolator and safeguard against unauthorised reconnection When using gas as a fuel also close the main shut off valve and safeguard against unauthorised...

Page 3: ...itocrossal 300 and the Vitoladens 300 T n Keep flue paths as short as possible with the fewest number of bends possible n Check the gaskets in all female connections n Use only the special gaskets supplied with the boiler Required tools equipment n Rope for lowering the flue gas system into a duct length chimney height plus 3 metres n Saw and file for trimming and chamfering the pipe sections n Po...

Page 4: ...ked by testing the O2 content in the combustion air annular gap test The flue is reckoned to be sufficiently sound if the O2 content in the combustion air deviates by no more than the following values from the reference value The reference value results after the self adjustment of the test equipment for flues with general Building Regulations approval 0 4 by vol for other flues 0 2 by vol Flue ga...

Page 5: ...General installation instructions cont 4 5458 035 GB Removing the flue pipe from the balanced flue pipe if required System size 60 and 80 ...

Page 6: ...Regulations and certified to the appropriate EC Gas Equipment Directive System Certification System certification to DVGW VP 113 and EC Gas Equipment Directive 90 396 EEC in conjunction with PPs flue pipes offered by Skoberne 5 5458 035 GB Vitodens 100 W CE 0085 BN Vitodens 200 W CE 0085 BR 0432 Vitodens 222 F CE 0085 BR 0433 Vitodens 343 F 242 F CE 0085 BO 0338 ...

Page 7: ...llers are required to notify building control when they have installed or exchanged a gas appliance in a residential dwelling this can be done via Gas Safe Gas Safe will then issue either a Building Compliance Certificate for England and Wales or a Declaration of Safety Scotland Northern Island Isle of Man or appliances out of the scope of Building Regulations to the homeowner which will confirm t...

Page 8: ...st be designed and constructed specifically for this purpose An existing cupboard or compartment may be used provided it is modified accordingly BS 7698 2000 gives details of the essential features of cupboard compartment design including airing cupboards The Vitodens range does not require compartment ventilation n Where installation will be in an unusual location special procedures may be necess...

Page 9: ... mm H From a surface facing the terminal 600 mm I Facing terminals 1200 mm J From opening door window in carport into dwelling 1200 mm K Vertically from a terminal on same wall 1500 mm L Horizontally from a terminal on same wall 300 mm M Adjacent to opening 300 mm N Below carport roof not recommended Minimum distance from terminal Boundary Walkway or patio Car space 2 5m 2 1m 2 5m Not under a car ...

Page 10: ...uisance and that the terminal will not obstruct the passageway n Where the lowest part of the terminal is 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 painted surface n Where the terminal is fitted within 850 mm of a plastic or painted gutter or 450 mm of painted eaves an aluminium shi...

Page 11: ...or checking the secondary ventilation The condensate drainage from the flue to the boiler must be ensured through a gradient of at least 3 approx 50 mm m Route the flue over the roof observe the roof clearance perpendicular to the roof inclination 400 mm according to the building regulation 10 5458 035 GB ...

Page 12: ...Balanced flue sliding coupling Fixing clamp 11 5458 035 GB A Combustion air B Flue gas C Inspection aperture Max total flue length up to the boiler flue connection at system temperature 50 30 C Vitodens 100 W Rated output range kw 9 11 11 26 0 30 0 35 0 max length m system size 60 100 20 15 15 Vitodens 200 W Rated output range 4 8 6 5 8 8 8 8 17 0 17 0 30 0 30 0 19 0 26 0 30 0 35 0 45 0 60 0 80 0 ...

Page 13: ...e E Combustion air Max total flue length up to the boiler flue connection at system temperature 50 30 C Vitodens 100 W Rated output range kw 9 11 11 26 0 30 0 35 0 max length m system size 60 100 20 15 15 Vitodens 200 W Rated output range 4 8 6 5 8 8 8 8 17 0 17 0 30 0 30 0 19 0 26 0 30 0 35 0 45 0 60 0 80 0 105 0 max length m system size 60 100 20 20 15 15 system size 80 125 20 15 system size 100...

Page 14: ...e system The combustion air is drawn from the room via an opening immediately by the chimney entry room interconnection bezel An adequate combustion air supply must be safeguarded inside the room as specified by the TRGI 86 96 point 5 5 through an interconnection with adjacent rooms n Minimum volume of the interconnected rooms 4 m3 per kW rated output n Apertures in connection doors min 150 cm2 13...

Page 15: ...ng n Support bend n Support rail n Duct cover n Spacers 3 pce 3 Flue Pipe 2 m long 1 m long 0 5 m long Flue bend for use in corbelled chimneys 30 or 15 4 Inspection piece straight 5 Balanced flue inspection piece straight 6 Balanced flue room interconnection bezel 7 Balanced flue pipe 1 m long 0 5 m long 8 Balanced flue bend 87 or 2 x 45 or Balanced flue inspection tee or Balanced flue inspection ...

Page 16: ... to secure support rail 1 2 Insert support rail 1 into the drilled hole and secure with screws or mortar on the front duct wall 3 Position support bend 2 and secure with the pin in a hole in the support rail 4 Secure installation rope 3 externally on the lowest vertical pipe section 15 5458 035 GB ...

Page 17: ... the pipe descend into the duct on the end of the rope 7 Remove the rope and push the lowest pipe into support bend 2 8 Let the highest pipe section 9 terminate approx 50 mm below the top edge of the duct 9 Secure the lower part of duct cover 5 10 System size 60 to 100 mm Push on aluminium terminal pipe 6 Note For weight reasons never trim aluminium terminal pipe 6 System size 125 to 200 mm Trim t...

Page 18: ...ue wall bezel 10 and push it against the duct opening Open flue operation Push on ventilation bezel 11 and push it against the duct opening Note The gap created is designed to provide secondary ventilation for the duct An additional ventilation grille is not required Open flue operation with combustion air supply via interconnected rooms Push the flue pipe suitably trimmed to size onto the support...

Page 19: ...ue bend 87 or 2 x 45 or Balanced flue inspection tee or Balanced flue inspection bend Balanced flue sliding coupling 10 Max total flue length up to the boiler flue connection at system temperature 50 30 C Vitodens 100 W Rated output range kw 9 11 11 26 0 30 0 35 0 max length m system size 60 100 20 15 15 Vitodens 200 W Rated output range 4 8 6 5 8 8 8 8 17 0 17 0 30 0 30 0 19 0 26 0 30 0 35 0 45 0...

Page 20: ...start with a smooth section at the bottom If necessary trim off a piece of flue pipe n Draw in the flue exclusively from top to bottom n Subject to duct size insert spacers at a distance of up to 2 m n Arrange a spacer before and after any deviation and any inspection piece n The flue must not contact the duct wall 1 Remove union ring 1 and retaining ring 2 from the adaptor from the standard duct ...

Page 21: ... flue gas flow 6 Position line ties 6 supplied around the ring of spacers 5 and tighten securely 1 Push union 1 onto flexible flue 3 2 Place retaining ring 2 into the second groove of flexible flue 3 3 Position retaining ring 7 into the first groove of flexible flue 3 4 Connect union ring 1 with inspection piece 8 Routing through a duct cont 20 5458 035 GB ...

Page 22: ...12 and click into place 8 Hook safety rope 14 into the drilled holes of duct cover 9 Connection to a moisture resistant chimney Routing through a duct cont Condensing boilers can be connected to moisture resistant chimneys to EN 13384 1 if the chimney manufacturer has verified their suitability on the basis of the specified flue gas values For this local conditions e g heating water return tempera...

Page 23: ...58 035 GB 1 Boiler flue connection 2 Flue Pipe 2 m long 1 m long 0 5 m long 4 Inspection piece straight 5 Flue bend 87 or 2 x 45 or Inspection tee 87 A Plug in adaptor B Flue gas C Secondary ventilation D MR chimney E Inspection aperture F Ventilation air ...

Page 24: ...50 kW an above roof extension is required see page 28 Rated output kW 50 50 a min mm 400 1 000 1 Boiler flue connection 2 Balanced flue roof outlet 3 Pipe outlets for Klöber roof tiles order the corresponding Klöber tile on site or Universal roof tile or Flat roof collar 4 Balanced flue inspection piece straight optional 5 Balanced flue sliding coupling optional Balanced flue bend 87 or 2 x 45 Bal...

Page 25: ...les or flat roof collars in accordance with manufacturer s details n Integrate the flat roof collar into the roof skin according to the flat roof guidelines n Ceiling opening min diameter 105 mm system size 60 130 mm system size 80 160 mm system size 100 n Secure the roof outlet with a clamp only after the installation has been completed n Position the roof outlet from the top onto tiles or the fl...

Page 26: ... 8 17 0 17 0 30 0 30 0 19 0 26 0 30 0 35 0 45 0 60 0 80 0 105 0 max length m system size 60 100 10 10 10 10 system size 80 125 10 6 system size 100 150 15 15 Vitodens 222 F Rated output range kw 4 8 6 5 8 8 8 8 19 0 26 0 30 0 35 0 max length m system size 60 100 10 10 10 10 Vitodens 242 F Rated output range kw 4 8 6 5 19 0 26 0 max length m system size 60 100 10 10 Allowed for are 2 bends 87 incl ...

Page 27: ...ernal pipe of above roof extension 1 onto roof outlet 2 and secure with 3 screws provided 2 Push black pipe section 3 onto roof outlet 2 and secure with 3 screws provided 3 Push roof outlet 2 with above roof extension 1 onto the balanced flue 4 Secure the above roof extension 1000 mm long with clip 4 provided and with guy ropes ...

Page 28: ... 100 1 Remove top part 1 of the roof outlet 2 Push above roof extension 2 onto the roof outlet 3 Push top part 1 onto above roof extension 2 Note For extensions 1 m secure the roof outlet with guy ropes can be secured to the above roof extension 5458 035 GB 27 ...

Page 29: ...ed flue external wall connection incl wall bezels 3 Protective grille 4 Balanced flue pipe 1 m long 0 5 m long 5 Balanced flue bend 87 or 2 x 45 Fixing clamp 28 5458 035 GB Note Not for the Vitocrossal or the Vitoladens Route the connecting pipe with a slope of at least 3 approx 50 mm m ...

Page 30: ...rox 50 mm m towards the boiler Horizontal wall terminal cont Installation Max total flue length up to the boiler flue connection at system temperature 50 30 C Vitodens 100 W Rated output range kw 9 11 11 28 0 30 0 35 0 max length m system size 60 100 8 8 8 Vitodens 200 W Rated output range 4 8 6 5 8 8 8 8 17 0 17 0 30 0 30 0 19 0 26 0 30 0 35 0 45 0 60 0 80 0 105 0 max length m system size 60 100 ...

Page 31: ...e 1 95 m long 1 m long 0 5 m long 5 Wall bezel 6 Fixing clamp 7 Balanced flue inspection piece straight optional External wall pack with 8 Balanced flue bend 87 9 Balanced flue air intake Balanced flue pipe 1 95 m long 1 m long 0 5 m long Balanced flue roof outlet with a high roof overhang above the roof Universal roof tile or Pipe outlet for Klober roof tiles order the corresponding Klober tile o...

Page 32: ...nced flue sliding coupling 3 below the roof outlet n Install pipe outlets for Klöber or universal roof tiles in accordance with manufacturer s details n Position the roof outlet from the top onto tiles n Connect the external wall line from below 31 5458 035 GB Routing over an external connection cont Installation Max total flue length up to the boiler flue connection at system temperature 50 30 C ...

Page 33: ... options 2 x 45 bends 1 pipe 1m long Deduct 3m from the max possible standard concentric horizontal flue length and add the standard plume kit max length to give max length of entire flue system ie 6m 3m 2m 5m max Preparing for installation Plume kit installation instructions The plume kit enables the relocation of the flue outlet of a standard horizontal flue system to another position and is ava...

Page 34: ...ion cont Flue kit installation instructions 1 Start 2 Remove the nozzle of the wall terminal with a tool screwdriver 3 Fit the 87 elbow with skirt into the inner flue pipe twisting it into the correct position 5458 035 GB 33 ...

Page 35: ...d 7 Connect the 87 bend with bird mesh to the last pipe 5 Fix flue pipe to the wall with clips 6 Continue step 4 and 5 until the desired height is reached Preparing for installation Flue kit installation instructions 34 5458 035 GB ...

Page 36: ...5458 035 GB 35 ...

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