elco THISION L Evo 60, THISION L Evo 70, THISION L Eco 70, THISION L Eco 100, THISION L Evo 100 System Manual
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Flue Gas System Guide
Flue systems for wall hung condensing boilers from 33kW to 1040kW in cascade
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
Page 2 of 33
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.
Page 3 of 33
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.
Page 4 of 33
1.4 Examples of flue gas systems
B23
C13
Air/exhaust gas routing through outside wall in the same pressure
and 100 cm with a heat input from 70 up to 100 kW.
C33
C43
C53
C63
Air and exhaust connection to separate tested and supplied
building.
C83
Combustion air
Combustion air
drawn from the
room
External flue gas exhaust. Air drawn from the room.
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
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.
drawn from
outside
Individual or shared flue gas exhaust and air suction through flue
ducting built into the building
Flue gas exhaust leading outside and air suction duct through external
wall not in the same range of pressure.
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
Flue gas exhaust through individual or shared flue ducting built into
the building. Air suction through external wall.
Page 5 of 33
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
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
2. Design and sizing information
2.1 Boiler maximum flue lengths
Thision S Plus
Page 6 of 33
2.1 Boiler maximum flue lengths continued…
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
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
Thision L Evo
*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
Page 7 of 33
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.
Page 8 of 33
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
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
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
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
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.
Page 9 of 33
2.4 BS6644 – 70kW to 1.8MW
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 flue Type B
Ventilation direct to outside air
Low Level (Free Area / kW)
4 cm²
High Level (Free Area / kW)
2 cm²
Room sealed Type C
Ventilation direct to outside air
Low Level (Free Area / kW)
2 cm²
High Level (Free Area / kW)
2 cm²
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
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
Open Flued Type B and Room sealed Type C Appliances Installed within an Enclosure (Natural
ventilation requirements direct to Outside Air.)
Open Flued Appliances Installed within a Boiler Room (Natural ventilation requirements direct to
Outside Air.)
Balanced Flued Appliances Installed within a Boiler Room (Natural ventilation requirements direct to
Outside Air.)
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.)
Open Flued Appliances Installed without a Draught Diverter (With or without stabilizers) (Mechanical
ventilation flow rate requirements direct to Outside Air.)
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.
Page 10 of 33
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