Vaillant PFGHRD 60, PFGHRD 100 Installation Instructions Manual

Installation instructions

For the installer

GB, IE

Installation instructions

PFGHRD 60/100

Passive Flue Gas Heat Recovery Device

Vaillant PFGHRD A5 - 12/12

- 2 -

Explanation of symbols

Symbol that denotes danger:

- Imminent danger to life

- Risk of severe personal injury

- Risk of minor personal injury

The PFGHRD is an integral part of the ue system
and as such should be tted in accordance with
the manufacturer's ue instructions.

Product description

The PFGHRD (Passive Flue Gas Heat Recovery
Device) is designed as a complimentary energy
saving system that can be connected to a

condensing combination boiler. This appliance

recovers latent energy from ue gases produced

by condensing combination boilers. The energy

from ue gases is used to preheat incoming

domestic cold water. The PFGHRD heat exchanger

increases domestic hot water eciency and

therefore reduces gas consumption, CO

2

emissions and waste of sanitary water.

The PFGHRD is included in SAP Appendix Q, under
Passive Flue Gas Heat Recovery Devices.

Vaillant - PFGHRD 60/100

Contents of package

1. PFGHRD unit

2. Support bracket

3. Wall fixing screws

4. Unit fixing screws

5. Installation manual

6. SAP label (attached to product)

7. Wall template

8. Flue anchor bracket (attached to product)

Technical information

DHW system
Max. water pressure
Min. operating pressure

10.0* bar

0.2 bar

* Use a pressure­reducing device
to achieve this, if
necessary.

Connections
Water connections 15 mm

General dimensions
Height
Width
Depth

276 mm
376 mm
262 mm

Weights
Empty
Full

6.6 kg

9.4 kg

Boiler applications
Condensing boilers only ecoTEC plus

ecoTEC pro

Flue Connections (60/100)
Top
Bottom

60 - 100 mm
60 - 100 mm

General
DHW Heat exchanger
Inner casing

Outer casing
Water content

Stainless steel
PP According to
EN 14471-1
ABS

2.8 litres

a

INSTALLATION

Vaillant PFGHRD A5 - 12/12

- 3 -

Maximum flue length
ecoTEC exclusive 832/838
Vertical
Horizontal

3 m

1 m + elbow

Maximum flue length
ecoTEC plus 824/pro 24
Vertical
Horizontal

10 m
6 m + elbow

Maximum flue length
ecoTEC plus 831/pro 28
Vertical
Horizontal

7 m
3 m + elbow

Maximum flue length
ecoTEC plus 837/937
Vertical
Horizontal

5 m
2 m + elbow

(Further ue lengths/bends may be used, but a loss in output of
1% is incurred for every additional metre).

General installation conditions

Assess the overall height of the installation
including PFGHRD and choose the appropriate
flue system arrangement (see 3. Installation
diagram).

In situations where the water pressure exceeds
10 bar, it should be reduced to the permitted
water pressure.

To allow pipework to be installed behind the
boiler we recommend the use of the 308650
spacing frame.

No requirement for expansion vessel or mixing
valve, see Commissioning page 7.

PFGHRD Installation

1. The hot and cold water pipes are positioned

at the bottom of the PFGHRD near the water
connections.

Inlet
Cold mains water

Outlet
Pre-heated water

NOTE: No soldering of joints should be
undertaken in close vicinity to the PFGHRD or
boiler as this may cause damage.

2. Dimensions.

A

Distance from the flue outlet centre line to
inside wall face, A = 130mm, if using a spacing
frame, A = XXmm.

INSTALLATION

Vaillant PFGHRD A5 - 12/12

- 4 -

466

434

384

35

recoFLUE

Trim ring

Measurement from
top of air intake

Air intake

Flue adaptor

3. Installation diagram.

INSTALLATION

Vaillant PFGHRD A5 - 12/12

- 5 -

Installation sequence

1. Fix the PFGHRD template to the wall ensuring

that there is sufficient clearance to the ceiling.
Ensure that the centre line of the template
is vertical and at least 250mm from any side
wall to allow for mounting of the boiler and
pipework. Ensure there is at least 1320mm
clearance from the flue centreline to any surface
below to allow for installation of the boiler.

2. Mark and drill holes for the PFGHRD and
boiler mounting brackets, all as per the wall
template. Mark the centre of the flue. Remove
the wall template and drill the flue hole. Note
that if you intend to use a spacing frame, use
the information provided with the spacing frame
to drill additional holes as required.

3. Secure the PFGHRD bracket and the boiler
mounting bracket to the wall.

4. Fix boiler to wall according to manufacturers
instruction.

INSTALLATION

Vaillant PFGHRD A5 - 12/12

- 6 -

5. Mount the PFGHRD onto the flue outlet of
the boiler and onto the support bracket. Attach
to the support bracket with the fixings provided
and secure the flue clamp.

6. Connect the water pipes. Use the correct
materials that can be combined with stainless
steel.

7. Connect the flue system to the PFGHRD
in accordance with the boiler installation
instructions. Ensure the flue clamps are fitted
and secured. Ensure that the flue anchor
bracket attached to the PFGHRD is secured to
the flue system by the screw provided.

8. Note that the overall flue length should not
exceed the figures shown in the table on page
3, to allow for the additional resistance of the
PFGHRD.

INSTALLATION

Vaillant PFGHRD A5 - 12/12

- 7 -

FLUE ANCHOR
BRACKET &
SCREW

9. The PFGHRD is ready for commissioning.

Commissioning

1. Complete installation and pipework of the

boiler according to the installation instructions.
Ensure tightness of all flue joints.

2. Open the cold water supply and cold water
inlet valve of the appliance and check all
connections for water leaks.

3. Turn on hot water tap and flush the PFGHRD
until it is completely filled with water and no
noise is audible.

4. The PFGHRD is ready for use.

5. Commission the boiler in accordance with the

installation instructions.

To prevent corrosion of the boiler or PFGHRD
and also on the air/flue gas duct, note the
following:

Do not use sprays, solvents, chlorinated cleaning
agents, paint, adhesives or similar substances
in the vicinity of the boiler. Under unfavourable
circumstances, these substances may cause
corrosion.

All mains water heated by the ecoTEC range of
combination boilers will be classed as Category
2 fluid (potable water) and small expansion
volumes created during warm up must be
allowed to flow back into the supply pipe. No
back flow prevention is necessary with this
appliance as the very small expansion volume is
unlikely to heat the incoming service pipe above
25 Deg C.

Note that where back flow prevention devices
are fitted (this may include water meters)
these can prevent the permitted expansion into
the cold supply. This along with the effects of
pumping and / or water hammer can result in
a pressure build-up that may cause damage
to the boiler (and other household devices
such as showers). Vaillant cannot accept
responsibility for damage caused to the boiler
or its surroundings where an appliance has
been fitted to supplies with mechanical back
flow prevention. In these cases the requirement
would be that a competent installer correctly
installs a suitable shock arrestor / mini­expansion vessel adjacent to the boiler in the
cold water supply pipe.

INSTALLATION

0020******_00 GBIE 052012 – Subject to change

Manufacturer

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