Viessmann Vitocaldens 222-F Installation Instructions Manual Download Page 5

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Danger

Leaking or blocked flue systems
or an insufficient supply of com-
bustion air cause life threatening
poisoning due to carbon monox-
ide in the flue gas.

Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able
to be closed off.

Required tools/equipment

■ Rope for lowering the flue system

into a shaft (length: chimney height
plus 3 m)

■ Saw and file for trimming and cham-

fering the pipe sections

■ Power drill for securing the shaft

cover and the support rail

General installation information

(cont.)

5780 223 GB

Summary of Contents for Vitocaldens 222-F

Page 1: ...Installation instructions for contractors VIESMANN Flue system for condensing boilers Flue system 5780 223 GB 5 2016 Dispose after installation ...

Page 2: ...gulations to be observed National installation regulations Statutory regulations for the preven tion of accidents Statutory regulations for environmen tal protection Codes of practice of the relevant trade associations All current safety regulations as defined by DIN EN DVGW TRGI TRF VDE and all locally applicable standards a ÖNORM EN ÖVGW TR Gas ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VKF and ...

Page 3: ...utory requirements 9 Gas safety installation and use regulations current issue 9 Boiler position 10 Routing through a shaft 15 Installation information 15 Rigid flue 16 Flexible flue 26 Installation in a disused chimney 36 Installation requirements 36 Installation 38 Vertical outlet for pitched or flat roofs 41 Maximum flue length 42 Installation 44 External wall connection 47 Installation 49 Rout...

Page 4: ...x 1 m To avoid damage and leaks isolate the flue system from sources of vibra tion e g ventilation systems Check the gaskets in all female con nections are correctly seated Prior to installation lubricate all gas kets with the lubricating paste provi ded Only use the special gaskets sup plied with the boiler Female plug in connections in the flue gas path must always point in the direction of flow...

Page 5: ...e system functions correctly Apertures for combus tion air supply must not be able to be closed off Required tools equipment Rope for lowering the flue system into a shaft length chimney height plus 3 m Saw and file for trimming and cham fering the pipe sections Power drill for securing the shaft cover and the support rail General installation information cont 5780 223 GB ...

Page 6: ... connection of the incoming balanced flue component 2 Shorten the ongoing balanced flue pipe to create a gap of 120 mm between the pipe section and the balanced flue pipe 3 Push the slide coupling onto the ongoing flue pipe 4 Open the collar and push it over the ongoing balanced flue pipe 5 Pull the slide coupling out and push it onto the incoming flue pipe 6 Align the collar and close the toggle ...

Page 7: ...d for classifying a flue as sufficiently gas tight In pressurised flues that are surroun ded by combustion air room sealed the tightness can be checked by test ing the O2 content in the combustion air annular gap test The flue is considered sufficiently gas tight if the O2 content in the com bustion air does not deviate from the reference value by more than the fol lowing values The reference valu...

Page 8: ...s 222 W CE 0085BR0432 CE 0085CN0050 Vitodens 242 F CE 0085BU0051 CE 0085CN0050 Vitodens 300 W CE 0085BR0433 CE 0085CM0463 Vitodens 333 F CE 0085BU0052 CE 0085CM0463 Vitodens 343 F CE 0085BU0052 CE 0085CM0463 Vitoladens 300 C CE 0035BS104 CE 0035CO106 Vitoladens 300 T CE 0035BO107 Vitoladens 300 W CE 0035BM112 CE 0035CO107 Vitoladens 333 F CE 0035BM112 CE 0035CO107 Vitorondens 200 T CE 0035CL102 Vi...

Page 9: ...ition if I S 813 Domestic Gas Installations The current Building Regulations and references should be made to the current ETCI rules for elec trical installation It should also be in accordance with the relevant recommendations in the cur rent editions of the following British Standards and Codes of Practice BS 5449 BS 5546 BS 5440 1 BS 5440 2 BS 6798 BS 7593 BS 6891 IGE UP 7 and IS 813 for IE All...

Page 10: ...n doubt advice must be sought from the Insti tute of Gas Engineers If the appliance is to be installed in a room containing a bath or shower any electrical switch or control utilis ing mains electricity must be so situ ated that it cannot be touched by a person using the bath or shower Attention is drawn to the require ments of BS 7671 the current I E E Wiring Regulations and in Scotland the elect...

Page 11: ...aves 200 d Below a balcony 200 e From vertical drain or soil pipes 150 f From internal and external corners 300 g Above adjacent ground or balcony level roof 300 h From a surface facing the terminal 600 i Facing terminals 1200 j From opening door window 1200 k Vertically from a terminal on same wall 1500 l Horizontally from a terminal on same wall 300 m Adjacent to opening 300 n Below carport roof...

Page 12: ...acent wall 300 p From adjacent opening window 1000 q From another terminal 600 r Minimum height 300 s Minimum distance measured perpendicular to roof covering 400 t Beside or above an opening rooflight 600 u Below an opening rooflight 2000 Installations requirements cont 5780 223 GB ...

Page 13: ...13 Minimum distance from terminal 2 5 m A A Boundary Not under a car port Installations requirements cont 5780 223 GB ...

Page 14: ...14 2 1 m B Avoid access routes and patios B Walkway or patio 2 5 m C Minimum distance to car parking space C Car space Installations requirements cont 5780 223 GB ...

Page 15: ...de the shaft Alternatively separate on site routing for the ventilation air and the flue gas may be used In the installation room at least one inspection port must be provided in the flue system for inspection cleaning and for testing the pressure if required If the flue is not accessible from the roof a second inspection port must be provi ded behind the chimney cleaning hatch in the attic Provid...

Page 16: ...ng Flue bend for use in corbelled chimneys 30 or 15 4 Inspection piece straight 5 Balanced flue inspection piece straight 6 Balanced flue wall 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 bend 9 Balanced flue slide coupling Fixing clamp Balanced flue adaptor 7 60 100 mm to 7 80 125 mm Maximum flue lengt...

Page 17: ...zes a bal anced flue adaptor is required The following components are taken into consideration for the maximum flue lengths Balanced flue connection pipe 0 5 m long 1 balanced flue bend 87 and 1 sup port bend 87 or 2 balanced flue bends 45 and 1 sup port bend 87 Subtract other bends tees and straight lengths from the maximum length using the following values Balanced flue connection pipe 0 5 m lon...

Page 18: ...er flue connection 2 Standard shaft pack Comprising Support bend Support rail Shaft cover Spacers 5 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 Flue bend 87 or 2 x 45 or Inspection tee 87 6 Ventilation bezel Adaptor 7 60 mm to 7 80 mm Routing through a shaft cont 5780 223 GB ...

Page 19: ...and straight lengths from the maximum length using the following values Connection pipe 0 5 m long 0 5 m Connection pipe 1 m long 1 m Flue bend 45 0 3 m Flue bend 87 0 5 m Inspection tee 0 3 m Open flue operation with combustion air supply via interconnected rooms Only possible with system sizes 60 and 80 The connection piece to the shaft is constructed as part of the balanced flue system The comb...

Page 20: ...nd Support rail Shaft cover Spacers 5 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 air inlet adaptor 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 bend Routing through a shaft ...

Page 21: ...in the support rail 04 Attach installation rope C to the outside of the lowest vertical pipe section 05 Subject to shaft size install a spacer D every 2 to 5 m and for each profiled piece e g inspection piece or bend Bent ends facing up 06 Apply lubricating paste and push the pipes into each other with a slight twisting motion 07 Lower the pipes into the shaft using installation rope C 08 Remove t...

Page 22: ...125 to 200 mm 11 System size 60 to 100 mm Push on terminal pipe G Note For weight reasons never trim ter minal pipe G System size 125 to 200 mm Trim final pipe section G without female connection The pipe should be as flush as possible with fitted flue collar H 50 0 20 500 E K G F H System size 250 mm 12 Push on flue collar H and fasten safety rope K to the lower part Routing through a shaft cont ...

Page 23: ...d provides secon dary ventilation to the shaft No additional ventilation grille is required Open flue operation with combus tion air supply via interconnected rooms Push the flue pipe onto the support bend Slide on air inlet adaptor O and secure it to the shaft Fitting a metal shaft cover For routing a plastic flue inside a twin flue shaft in conjunction with a solid fuel boiler The metal end piec...

Page 24: ...end approx 80 mm below the top edge of the shaft B A 2 Push on metal pipe section A If required use an extension acces sories 3 Position shaft cover B and secure to the shaft with the fixing materials provided Routing through a shaft cont 5780 223 GB ...

Page 25: ...t cover 2 x D C A B Ø D 400 A Chimney extension made from soot fire resistant material B Stainless steel extension C Shaft cover on site The shaft cover as a common down draught plate chimney cowl must be provided on site Routing through a shaft cont 5780 223 GB ...

Page 26: ...ht for installation in the flexible flue 4 Flexible flue 5 Connection piece for connecting residual lengths of the flexible flue Pipe lowering attachment with 20 m rope 6 Balanced flue inspection piece straight 7 Wall bezel 8 Balanced flue pipe 1 m long 0 5 m long 9 Balanced flue bend 87 or 2 x 45 or Balanced flue inspection tee or Balanced flue inspection bend qP Balanced flue slide coupling Bala...

Page 27: ... 25 25 25 25 20 15 System size 100 m 22 17 20 20 The following components are taken into consideration for the maximum flue lengths Balanced flue connection pipe 0 5 m long 1 flue bend 87 and 1 support bend 87 or 2 flue bends 45 and 1 support bend 87 Subtract other bends tees and straight lengths from the maximum length using the following values Connection pipe 0 5 m long 0 5 m Connection pipe 1 ...

Page 28: ...on pieces Support rail Shaft cover Spacers 5 pce 3 Inspection piece straight for installation in the flexible flue 4 Flexible flue 5 Connection piece for connecting residual lengths of the flexible flue Pipe lowering attachment with 20 m rope 6 Inspection piece straight 7 Flue pipe 1 m long 0 5 m long 8 Flue bend 87 or 2 x 45 or Inspection tee 87 9 Ventilation bezel Adaptor 7 60 mm to 7 80 mm Rout...

Page 29: ... Subtract other bends tees and straight lengths from the maximum length using the following values Connection pipe 0 5 m long 0 5 m Connection pipe 1 m long 1 m Flue bend 45 0 3 m Flue bend 87 0 5 m Inspection tee 0 3 m Installation Danger To ensure correct function route the flexible flue at a maximum angle of 45 from the vertical Never pull the flexible flue pipe over sharp edges during instal l...

Page 30: ...ugh the centre of the rear shaft wall to secure support rail A 2 Insert support rail A into the drilled hole and secure to the front shaft wall with screws or mortar Fitting an inspection piece connection piece or connector 1 2 3 1 A B C D Routing through a shaft cont 5780 223 GB ...

Page 31: ...B until it clicks into posi tion Fitting the pipe lowering attachment and drawing the flexible flue into the shaft A B C 01 Compress the end of flexible flue A into a slightly oval shape Insert plate B of the pipe lowering attachment into the 3rd groove of the flue pipe 02 Push leading cone C onto flexible flue A The end of the flue pipe must be completely covered 03 Secure the rope to the loop of...

Page 32: ... A from the top downwards into the shaft Never pull the flue over sharp edges 07 Remove the pipe lowering attach ment from the flue G F 08 Fit connector F to flue A see page 30 09 Position support bend G and use the pin to secure it in a hole in the support rail 10 Coat connector F with lubricating paste and push into support bend G Routing through a shaft cont 5780 223 GB ...

Page 33: ...ition reducer ring C on the base of shaft cover B 5 Click spacer tooth of mounting ring D into the 3rd groove of flexi ble flue A See page 30 6 Insert gasket E into the 1st groove of flexible flue A 7 Push terminal pipe F onto mount ing ring D until it clicks into posi tion 8 Hook safety rope G into the drilled hole in shaft cover B 9 Push cowl H over terminal pipe F and click into place on shaft ...

Page 34: ...Pull flexible flue A up far enough to allow mounting ring C to be fit ted Click mounting ring C into the 3rd groove of flexible flue A See page 30 5 Insert gasket D into the 1st groove of flexible flue A 6 Push adaptor E onto mounting ring C until it clicks into position 7 Push terminal pipe F into adaptor E 8 Push cowl G onto terminal pipe F and secure Routing through a shaft cont 5780 223 GB ...

Page 35: ...nd push it against the shaft opening Open flue operation Slide ventilation bezel C onto the pipe and push it against the shaft opening Note The gap created provides secon dary ventilation to the shaft No additional ventilation grille is required Open flue operation with combus tion air supply via interconnected rooms Push the flue pipe onto the support bend slide air inlet adaptor D onto the pipe ...

Page 36: ...300 D C B A 90 A Disused chimney B Balanced flue pipe for connecting the flexible flue C Chimney connection plate D Vitodens Installation in recesses below disused chimneys Recess height min 1200 mm Installation in a disused chimney 5780 223 GB ...

Page 37: ...m size 100 m The following components are taken into consideration for the maximum flue lengths Balanced flue connection pipe 0 5 m long 1 flue bend 87 and 1 support bend 87 or 2 flue bends 45 and 1 support bend 87 Subtract other bends tees and straight lengths from the maximum length using the following values Connection pipe 0 5 m long 0 5 m Connection pipe 1 m long 1 m Flue bend 45 0 3 m Flue b...

Page 38: ...ermine the position of the bal anced flue terminal and create an aperture 7 approx 140 mm A in the bottom of the shaft 02 Pull flexible flue B into the shaft from the top See page 31 Installation in a disused chimney cont 5780 223 GB ...

Page 39: ...connection plate C upwards and secure Do not tighten the screws at this stage so the chimney connection plate can be aligned when the Vitodens is being fitted 05 Push balanced flue pipe D in chimney connection plate C upwards by approx 40 mm Installation in a disused chimney cont 5780 223 GB ...

Page 40: ...40 C D 06 Install the Vitodens in the recess Vitodens installation and service instructions Installation in a disused chimney cont 5780 223 GB ...

Page 41: ...itched or flat roofs If the balanced flue system is routed through roof spaces that are not used as accommodation run the flue through an additional metal pipe as protection against mechanical damage TRGI 2008 When several roof outlets are installed side by side Observe a minimum clear ance of 1 5 m between outlets and to other building structures e g skylights in accordance with TRGI 2008 Observe...

Page 42: ... 4 Balanced flue inspection piece straight 5 Balanced flue slide coupling 6 Balanced flue bend 87 or 2 x 45 Balanced flue pipe 1 m long 0 5 m long 7 Fixing clamp Balanced flue adaptor 7 60 100 mm to 7 80 125 mm Maximum flue length Vitodens 100 W type WB1B 10 m Vitodens 100 W type B1HA and B1KA Vitodens 111 W Rated heating output kW 19 26 0 30 0 35 0 System size 60 100 m 10 10 8 8 System size 80 12...

Page 43: ...ve system sizes a bal anced flue adaptor is required The following components are taken into consideration for the maximum flue lengths 2 balanced flue bends 87 Subtract other bends tees and straight lengths from the maximum length using the following values Balanced flue bend 45 0 5 m Balanced flue bend 87 1 m Balanced flue inspection tee 0 5 m Vertical outlet for pitched or flat roofs cont 5780 ...

Page 44: ...tructions Integrate the flat roof collar into the roof skin according to the flat roof guidelines Ceiling roof penetration min diame ter 105 mm system size 60 130 mm system size 80 160 mm system size 100 Secure the roof outlet to the roof structure with a clamp only after installation has been completed Position the roof outlet on the roof tiles or flat roof collar from above Connect the balanced ...

Page 45: ... the flat roof directive C D E F D G B H A A Flat roof collar B Gravel ballast layer C Insulation layer D Aeration layer E Thermal insulation F Insulation G Ceiling H Flue pipe Vertical outlet for pitched or flat roofs cont 5780 223 GB ...

Page 46: ...oof outlet B and secure with 3 screws provided 2 Push black pipe section C onto roof outlet B and secure with 3 screws provided 3 Push roof outlet B with above roof extension A onto the balanced flue pipe 4 Secure the 1 m above roof exten sion with clamp D provided and the ropes Vertical outlet for pitched or flat roofs cont 5780 223 GB ...

Page 47: ...n be fastened to the above roof extension External wall connection Note Cannot be used with the Vitocrossal or Vitoladens Install an inspection port in the bal anced flue pipe for inspection and cleaning Recommendation Use the balanced flue slide coupling to facilitate installa tion of the balanced flue pipe Route the connection piece with a fall of at least 3 approx 50 mm m Vertical outlet for pi...

Page 48: ...ue pipe 1 m long 0 5 m long 5 Balanced flue bend 87 or 2 x 45 or Balanced flue inspection tee or Balanced flue inspection bend 6 Balanced flue inspection piece straight 7 Balanced flue slide coupling Fixing clamp Balanced flue adaptor 7 60 100 mm to 7 80 125 mm Maximum flue length Vitodens 100 W type WB1B 10 m External wall connection cont 5780 223 GB ...

Page 49: ...em size 100 m 13 9 15 15 Note For alternative system sizes a bal anced flue adaptor is required The following components are taken into consideration for the maximum flue lengths 2 balanced flue bends 87 Subtract other bends tees and straight lengths from the maximum length using the following values Balanced flue bend 45 0 5 m Balanced flue bend 87 1 m Balanced flue inspection tee 0 5 m Installat...

Page 50: ...in diameter 105 mm system size 60 130 mm system size 80 160 mm system size 100 2 Push external wall connection A with wall bezel B into the wall opening 3 Slide on internal wall bezel C 4 If the external wall connection ter minates 2 m above ground level near public roads fit a protective grille on site fixing materials 5 Connect the balanced flue connec tion pipe from the inside and route with a ...

Page 51: ...External wall pack with 8 Balanced flue bend 87 or ex ternal wall bend 87 9 External wall air inlet section qP Balanced flue pipe or external wall pipe 1 95 m long 1 m long 0 5 m long qQ Balanced flue roof outlet for a large roof overhang qW Universal roof tile or Pipe outlet for Klöber roof tiles Provide a suitable Klöber roof tile on site qE External wall terminal for short protrusion above the ...

Page 52: ...aximum length using the following values Balanced flue bend 45 0 5 m Balanced flue bend 87 1 m Balanced flue inspection tee 0 5 m Installation 1 Create an opening in the wall min diameter 105 mm system size 60 130 mm system size 80 160 mm system size 100 2 Push external wall bend 8 with wall bezel 5 into the wall opening from the outside 3 Fit air inlet section 9 as near as possible to external wa...

Page 53: ...nstall pipe outlets for Klöber or universal roof tiles in accordance with manufacturer s instructions Position the roof outlet onto the roof tiles from above Connect the external wall pipe from below Elbow in the external routing for a short roof overhang Elbow with 45 bend qR Fit bal anced flue inspection piece 7 Elbow with 30 bend qR Bal anced flue inspection piece 7 not required Fit external wa...

Page 54: ... 1 pipe 1 m long C Plume kit standard delivery plus 2 bends 45 1 pipe 1 m long Observe the max length of the entire balanced flue For the standard plume kit deduct 3 m from the max possible pipe length When using an additional 87 bend or two 45 bends reduce the max length by 1 m Plume kit 5780 223 GB ...

Page 55: ...1 2 1 Disengage and remove the end piece of the external wall connec tion 2 Insert external wall connection into the wall 3 3 Push the flue bend into the external wall connection Plume kit cont 5780 223 GB ...

Page 56: ...56 35 4 35 35 4 Insert screws into the wall in accordance with the pipe length Plume kit cont 5780 223 GB ...

Page 57: ...e chosen method of routing 6 Position the supplied fixing clamps and secure with the screws 7 Insert the rodent protection into the uppermost bend Note The rodent protection should be inserted into the end piece of the plume kit Plume kit cont 5780 223 GB ...

Page 58: ...58 5780 223 GB ...

Page 59: ...59 5780 223 GB ...

Page 60: ...hropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5780 223 GB Subject to technical modifications ...

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