Viessmann Vitocrossal 200 CM2 Series, Vitodens 050-T, Vitocrossal 300 CT3B, CT3U Series, Vitodens 050-W Installation Instructions Manual
...Page 1
Installation instructions
for contractors
VIESMANN
Flue system
for condensing boilers
Flue system
5780 223 GB 5/2016
Dispose after installation.
Page 2
2
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!
Please note
This symbol warns against the
risk of material losses and environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
intended for authorised contractors.
■ Work on gas installations must only
be carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified
electrician.
Regulations to be observed
■ National installation regulations
■ Statutory regulations for the prevention of accidents
■ Statutory regulations for environmental 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 EKAS guideline
1942: LPG, part 2
Working on the system
■ Isolate the system from the power
supply (e.g. by removing the separate fuse or by means of a mains isolator) and check that it is no longer
'live'.
■ Safeguard the system against reconnection.
■ Where gas is used as the fuel, close
the main gas shut-off valve and safeguard it against unintentional reopening.
Safety instructions
5780 223 GB
Page 3
3
Installation sequence
General installation information............................................................................ 4
■ Design............................................................................................................... 4
■ Flue gas temperature protection....................................................................... 4
■ Installation information...................................................................................... 4
■ Required tools/equipment................................................................................. 5
■ Fitting the balanced flue slide coupling............................................................. 6
■ Tightness test.................................................................................................... 7
■ Certification of the balanced flue system.......................................................... 7
■ System certification........................................................................................... 8
Installations requirements.................................................................................... 9
■ Statutory 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
Routing over an external wall............................................................................... 51
■ Maximum flue length......................................................................................... 52
■ Installation......................................................................................................... 52
Plume kit............................................................................................................... 54
■ Routing options................................................................................................. 54
Index
5780 223 GB
Page 4
4
Design
Prior to installation, check that the maximum possible pipe length will not be
exceeded.
Max. possible pipe lengths in relation to
the boiler used:
Flue systems technical guide
Flue gas temperature protection
The flue pipes are approved for flue
gas temperatures up to 120 °C.
With Viessmann condensing boilers,
internal safeguards ensure that the
maximum permissible flue gas temperature is not exceeded.
Installation information
■ The component overviews for the different types of routing also apply to
floorstanding condensing boilers.
■ Keep flue gas routes short and with
the fewest number of bends possible.
■ Route horizontal connection pipes
with a fall of ≥ 3° (approx. 50 mm/m)
towards the boiler.
■ Support horizontal connection pipes
at intervals of approx. 1 m.
■ To avoid damage and leaks, isolate
the flue system from sources of vibration (e.g. ventilation systems).
■ Check the gaskets in all female connections are correctly seated.
■ Prior to installation, lubricate all gaskets with the lubricating paste provided.
■ Only use the special gaskets supplied with the boiler.
■ Female plug-in connections in the
flue gas path must always point in the
direction of flow.
■ Only use the components supplied
with the Viessmann flue system.
■ Push the pipes into each other with a
slight twist.
■ Balanced flue pipes can be trimmed
in their assembled state.
Do not carry out commissioning until
the following conditions are met:
■ Free passage through the flue gas
pipes.
■ Flue system with positive pressure is
gas-tight.
■ Apertures for ensuring sufficient combustion air supply are open and cannot be closed off.
■ Applicable regulations on installing
and commissioning flue systems
have been followed.
General installation information
5780 223 GB
Page 5
5
Danger
Leaking or blocked flue systems
or an insufficient supply of combustion air cause life threatening
poisoning due to carbon monoxide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combustion 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 chamfering the pipe sections
■ Power drill for securing the shaft
cover and the support rail
General installation information
(cont.)
5780 223 GB
Page 6
6
Fitting the balanced flue slide coupling
Note
The slide coupling enables a gap of
approx. 45 mm to be covered. Prior to
installation, compensate for surplus or
insufficient length on the incoming pipe.
1.
120
4.
3.
5.
6.
2.
1. Push the pipe section into the
female 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
fasteners.
General installation information
(cont.)
5780 223 GB
Page 7
7
Tightness test
After installation, flue systems routed
through a shaft must be tested for tightness by the flue gas inspector [check
local regulations].
■ Pressurised flues which are routed
inside buildings and which are not
surrounded by combustion air
(open flue) must be pressure-tested.
For the pressure test, a leak detector
is used to pump air into the flue,
which has been sealed at the top and
bottom, until a pressure of 200 Pa
has built. This pressure is maintained
while the volume of air leaking out is
established.
A leakage rate of up to
0.006 l/(s x m2), relative to the internal surface area, is permitted for
classifying a flue as sufficiently gastight.
■ In pressurised flues that are surrounded by combustion air (room sealed),
the tightness can be checked by testing 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 following values. The reference value is
established following the self-adjustment of the test meter:
– For flues with general Building
Regulations approval 0.4 % by vol.
– For other flues 0.2 % by vol.
Note
Observe country-specific regulations.
Certification of the balanced flue system
The balanced flue system is CE designated and approved in accordance with
EN 14471 (see flue systems technical
guide).
General installation information
(cont.)
5780 223 GB
Page 8
8
System certification
System certification to EC Gas Appliances Directive EU/2009/142/EC in conjunction with PPs flues offered by
Skoberne.
Vitocaldens 222-F CE-0085CO0306
Vitocrossal 200, type CM2 CE-0085BQ0021
Vitocrossal 300, type CU3 CE-0085BN0570
Vitocrossal 300, type CM3 CE-0085BN0569
Vitocrossal 300, type CT3B, CT3U CE-0085AQ0257
Vitodens 050-T CE-0085CQ0290
Vitodens 050-W CE-0085CP0029
Vitodens 100-E CE-0085BT0029
Vitodens 100-W, 111-W CE-0085BT0029, CE-0063CQ3356
Vitodens 111-F CE-0085CN0050
Vitodens 200-W CE-0085BR0432, CE-0085CN0050
Vitodens 222-F CE-0085BU0051, CE-0085CN0050
Vitodens 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
Vitorondens 222-F CE-0035CL102
Vitosolar 200-F CE-0085CM0184
Vitosolar 300-F CE-0035CO107
Vitosorp 200-F CE-0085CO0146
Vitotwin 300-W CE-0085CM0150
Vitovalor 300-P CE-0085CP0028
Note
Affix the "System certification" and
"Flue system ..." labels clearly visible
near the flue system or on the boiler.
The labels are supplied with the technical documentation.
General installation information
(cont.)
5780 223 GB
Page 9
9
Statutory requirements
The appliance is suitable only for installation in GB and IE and should be
installed in accordance with the rules in
force. In GB a Gas Safe Registered
Installer must carry out the installation.
It must be carried out in accordance
with the relevant requirements of the:
Gas safety (installation and use) regulations (current issue)
It is in your own interest and safety to
ensure that the law is complied with.
In addition to the above regulations,
this appliance must be installed in
accordance with the current IEE Wiring
Regulations for electrical installation
(BS 7671), local Building Regulations,
the Building Standards (Scotland)
(Consolidation) Regulations, bye laws
of the local water undertaking and
Health and Safety Document NO. 635,
The Electricity at Work regulations
1989, In Ireland (IE), the installation
must be carried out by a Competent
Person and installed in accordance with
the current edition if I.S.813 "Domestic
Gas Installations", The current Building
Regulations and references should be
made to the current ETCI rules for electrical installation.
It should also be in accordance with the
relevant recommendations in the current 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 Registered installers 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 that the work has
been carried out by a competent Gas
Safe Registered Installer. This document will be used to form part of the
Home Information Pack (HIP).
!
Please note
Manufacturers instructions must
not be taken
in any way as overriding statutory obligations.
Installations requirements
5780 223 GB
Page 10
10
Boiler position
The following limitations must be
observed when siting the boiler:
■ The boiler is not suitable for external
installation. The position selected for
the installation should be within the
building, unless otherwise protected
by a suitable enclosure and must
allow adequate space for installation,
servicing and operation of the appliance and for air circulation around it.
■ The position must allow for a suitable
flue system and terminal position.
The boiler must be installed on a flat
vertical wall capable of supporting the
weight of the appliance and any
ancillary equipment when full.
■ Due consideration should be given to
the routing of the condensate drain
from the chosen position.
■ If the boiler is to be fitted in a timber
framed building it should be fitted in
accordance with ige/up/7. If in doubt
advice must be sought from the Institute of Gas Engineers.
■ If the appliance is to be installed in a
room containing a bath or shower,
any electrical switch or control utilising mains electricity must be so situated that it cannot be touched by a
person using the bath or shower.
Attention is drawn to the requirements of BS 7671 (the current I.E.E
Wiring Regulations) and in Scotland
the electrical provisions of the Building Regulations applicable in Scotland.
■ A compartment used to enclose the
appliance must 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.
■ Where installation will be in an
unusual location, special procedures
may be necessary. BS 6798 gives
detailed guidance on this aspect.
Installations requirements
(cont.)
5780 223 GB
Page 11
11
Flue terminal position
Horizontal flue system
a
g
f
h,i
d,n
j
b,c
k
m
e
g
a
f
f
k
b,c
k
l
l
g
c
k
Position Minimum spacing
mm
a Directly below an opening window, air vent or
any other ventilation opening
300
b Below a gutter drain or soil pipe 75
c Below eaves 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 not recommended
Installations requirements
(cont.)
5780 223 GB
Page 12
12
Vertical flue systems
q
o
o
r
p
s
t
u
t
Position Minimum spacing
mm
o From adjacent 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
15
Installation information
Prior to installation, the local flue gas
inspector should check that the shaft to
be used is suitable and permissible
[where applicable].
Shafts that were previously connected
to oil or solid fuel boilers must be thoroughly cleaned by a chimney sweep.
Loose deposits comprising sulphur and
soot must not remain on the inside of
the chimney. Running a balanced flue
pipe through the shaft is then not
required. If thorough cleaning is impossible, if chloride deposits are present or
if the shaft is silted up, a separate balanced flue pipe must be used inside 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 provided behind the chimney cleaning hatch
in the attic.
Provide an inspection port at the base
of the shaft for inspecting the secondary ventilation. Safeguard condensate
drainage from the flue to the boiler with
a fall of at least 3° (approx. 50 mm/m).
The flue system must protrude above
the roof line. Observe 400 mm protrusion from the roof parallel to the roof
slope according to FeuVo [or local regulations].
Routing through a shaft
5780 223 GB
Page 16
16
Rigid flue
Room sealed operation
B5
2
A
3
2
3
2
4
3
2
2
6798 71
A
C
B
C
A
Supply air
B
Flue gas
C
Inspection port
1
Boiler 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
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 length
Vitodens 100-W, type WB1B: 10 m
Routing through a shaft
(cont.)
5780 223 GB
Page 17
17
Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W
Rated heating output kW 26.0 26.0 30.0 35.0
System size 60/100 m 15 15 15 15
System size 80/125 m 25 20 20 20
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size
60/100
m 20 20 20 15 — — — —
System size
80/125
m 25 25 25 25 20 15 — —
System size
100/150
m — — — — 25 20 20 20
Note
For alternative system sizes, a balanced 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 support bend 87°
or
■ 2 balanced flue bends 45° and 1 support bend 87°
Subtract other bends, tees and straight
lengths from the maximum length using
the following values:
■ Balanced flue connection pipe 0.5 m
long: 1 m
■ Balanced flue connection pipe 1 m
long: 2 m
■ Balanced flue bends 45°: 0.5 m
■ Balanced flue bends 87°: 1 m
■ Balanced flue inspection tee: 1.5 m
Routing through a shaft
(cont.)
5780 223 GB
Page 18
18
Open flue operation
3
2
3
4
3
2
2
2
2
1 65 4
A
B
A
D
E
C
3
A
Secondary ventilation
B
Flue gas
C
Inspection port
D
Supply air vent
E
Supply air
1
Boiler 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
19
Maximum flue length
Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W
Rated heating output kW 19 26.0 30.0 35.0
System size 60 m 15 15 20 20
System size 80 m 20 20 20 20
Note
For system size 80, an adaptor is
required.
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size 60 m 20 20 20 15 — — — —
System size 80 m 25 25 25 25 20 15 — —
System size 100 m — — — — 25 20 20 20
The following components are taken
into consideration for the maximum flue
lengths:
■ 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 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 combustion air is drawn
from the room via an opening immediately by the chimney entry (air inlet
adaptor).
An adequate combustion air supply, as
specified by the TRGI 2008, must be
ensured inside the room by means of
an interconnected combustion air supply:
■ Minimum volume of the interconnected rooms, 4 m3 per kW rated heating
output
■ Vents in the connecting doors min.
150 cm
2
Routing through a shaft
(cont.)
5780 223 GB
Page 20
20
3
3
2
4
3
2
2
578
6
C
1
C
B
A
E
D
A
Supply air
B
Flue gas
C
Secondary ventilation
D
Aperture for interconnected air
supply
E
Inspection port
1
Boiler 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
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
(cont.)
5780 223 GB
Page 21
21
Installation
Ø 12
D
C
B
A
01.
Drill a 7 12 mm hole through the
centre of the rear shaft wall to
secure support rail A.
02.
Insert support rail A into the drilled hole, and secure to the front
shaft wall with screws or mortar.
03.
Position support bend B and use
the pin to secure it in a hole 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 the rope and push the
lowest pipe into support bend B.
Routing through a shaft
(cont.)
5780 223 GB
Page 22
22
345
50
+0
-20
G
K
H
F
E
System size 60 to 100 mm
09.
Have highest pipe section E ending approx. 50 mm below the top
edge of the shaft.
10. Secure the lower part of shaft
cover F.
50
+0
-20
≈ 360
G
H
K
F
E
System size 125 to 200 mm
11. System size 60 to 100 mm:
Push on terminal pipe G.
Note
For weight reasons, never trim terminal 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.)
5780 223 GB
Page 23
23
Fitting the connection pipe
M
L
1. Only for balanced flue operation:
Trim final ventilation air pipe L of
the connection pipe so that it ends
level with the internal shaft wall surface.
N
O
2. Balanced flue operation:
Slide balanced flue wall bezel
M
onto the pipe and push it against
the shaft opening.
Open flue operation:
Slide ventilation bezel N onto the
pipe and push it against the shaft
opening.
Note
The gap created provides secondary ventilation to the shaft.
No additional ventilation grille is
required.
Open flue operation with combustion 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 piece must protrude into
the shaft by a length that is equal to or
greater than the flue pipe diameter.
If necessary, use the stainless steel
extension which is available as an
accessory.
Routing through a shaft
(cont.)
5780 223 GB
Page 24
24
200
80±10
50
1. Have the highest pipe section 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 (accessories).
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
25
Stainless steel extension in conjunction with on-site shaft 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 downdraught plate (chimney cowl) must be
provided on site.
Routing through a shaft
(cont.)
5780 223 GB
Page 26
26
Flexible flue
Room sealed operation
68qP91 7
2
A
2
5
2
4
2
3
2
2
B
A
C
C
A
Supply air
B
Flue gas
C
Inspection port
1
Boiler flue connection
2
Standard shaft pack (flexible)
Comprising:
■ Support bend
■ Connection 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
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
Balanced flue adaptor
7
60/100 mm to 7 80/125 mm
Routing through a shaft
(cont.)
5780 223 GB
Page 27
27
Maximum flue length
Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W
Rated heating output kW 19 26.0 30.0 35.0
System size 80 m 20 20 20 20
Note
For system size 80, an adaptor is
required.
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size 60 m 18 18 — — — — — —
System size 80 m 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 m long: 1 m
■ Flue bend 45°: 0.3 m
■ Flue bend 87°: 0.5 m
■ Inspection tee: 0.3 m
Routing through a shaft
(cont.)
5780 223 GB
Page 28
28
Open flue operation
2
2
1 976
A
D
E
C
2
2
5
2
4
2
3
B
A
8
A
Secondary ventilation
B
Flue gas
C
Inspection port
D
Supply air vent
E
Supply air
1
Boiler flue connection
2
Standard shaft pack (flexible)
Comprising:
■ Support bend
■ Connection 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
Routing through a shaft
(cont.)
5780 223 GB
Page 29
29
Maximum flue length
Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W
Rated heating output kW 19 26.0 30.0 35.0
System size 80 m 20 20 25 25
Note
For system size 80, an adaptor is
required.
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size 60 m 18 18 — — — — — —
System size 80 m 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:
■ 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 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 installation.
Note:
■ Always draw the flue pipe in from the
top downwards.
■ Observe flow direction (arrow on
components).
■ Subject to shaft size, install spacers
at intervals of max. 2 m.
■ Insert a spacer before and after any
change in direction and any inspection piece.
■ The flue must not come into contact
with the shaft wall.
Routing through a shaft
(cont.)
5780 223 GB
Page 30
30
Fitting the support rail inside the shaft
Ø 12
A
1.
Drill a 7 12 mm hole through 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
31
1.
Trim flexible flue pipe A cleanly at
a right angle.
2. Click spacer tooth of mounting
ring B into the 3rd groove of flexible flue A.
3.
Insert gasket C into the 1st groove
of flexible flue A.
4. Push inspection piece, connection
piece or connector D onto mounting ring B until it clicks into position.
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 the
pipe lowering attachment.
Routing through a shaft
(cont.)
5780 223 GB
Page 32
32
E
D
E
A
04.
Push spacer D onto flue A (bent
ends in flue gas flow direction).
05.
Position cable ties E provided
around the ring of spacers D and
tighten.
06.
Pull flexible flue 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
33
Fitting a plastic shaft cover
200
H
G
F
E
D
C
B
A
1.
Route flexible flue A through shaft
cover B.
2.
Trim flexible flue A 200 mm above
the top edge of the shaft.
3.
Position base of shaft cover B on
the shaft and secure.
4.
Only for 7 60 and 80 mm:
Position reducer ring C on the
base of shaft cover B.
5. Click spacer tooth of mounting
ring D into the 3rd groove of flexible flue A. See page 30.
6.
Insert gasket E into the 1st groove
of flexible flue A.
7.
Push terminal pipe F onto mounting ring D until it clicks into position.
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
cover B.
Routing through a shaft
(cont.)
5780 223 GB
Page 34
34
Fitting a metal shaft cover
~50
G
E
F
D
C
B
A
1.
Route flexible flue A through
retainer B.
2.
Position retainer B on the shaft.
3.
Trim flue A approx. 50 mm above
the retaining plate of retainer B.
4.
Pull flexible flue A up far enough
to allow mounting ring C to be fitted.
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
35
Fitting the connection pipe
B
A
1. Only for balanced flue operation:
Trim final ventilation air pipe A of
the connection pipe so that it ends
level with the internal shaft wall surface.
D
C
2. Balanced flue operation:
Slide balanced flue wall bezel
B
onto the pipe and 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 secondary ventilation to the shaft.
No additional ventilation grille is
required.
Open flue operation with combustion air supply via interconnected
rooms:
Push the flue pipe onto the support
bend, slide air inlet adaptor D onto
the pipe and secure it to the shaft.
Routing through a shaft
(cont.)
5780 223 GB
Page 36
36
Installation requirements
190
150
1200
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
37
Maximum flue length
Vitodens 100-W, type B1HA and B1KA
Rated heating output kW 19 26.0 30.0 35.0
System size 80 m 20 20 20 20
Note
For system size 80, an adaptor is
required.
Vitodens 200-W
Rated heating output kW 13 19 26 35
System size 60 m 18 18 — —
System size 80 m 25 25 25 25
System 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 bend 87°: 0.5 m
■ Inspection tee: 0.3 m
Installation in a disused chimney
(cont.)
5780 223 GB
Page 38
38
Installation
A
B
140
01. Determine 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
39
C
D
03.
Secure flexible flue B to chimney
connection plate C. See page 30.
04.
Push chimney 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
41
07.
Pull balanced flue pipe D downwards and push it into the boiler
flue connection as far as it will go.
Ensure that the gasket is seated
correctly in chimney connection
plate C.
08. Tighten the fixing screws of chim-
ney connection plate C.
09.
Secure balanced flue pipe D to
chimney connection plate C with
the self-tapping screw supplied.
10. Fit the shaft cover. See page 33.
Vertical outlet for pitched 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 clearance of 1.5 m between outlets and to
other building structures (e.g. skylights)
in accordance with TRGI 2008.
Observe the clearance of the flue outlet
above the roof (see diagram). If the
rated heating output is ≥ 50 kW, an
above-roof extension is required (see
page 46).
Installation in a disused chimney
(cont.)
5780 223 GB
Page 42
42
a
1
3
4
5
7
B
A
2
6
A
Supply air
B
Flue gas
Rated heating output
kW ≤50 ≥50
a (min.) mm 400 1000
1
Boiler flue connection
2
Balanced flue roof outlet
3
Pipe outlets for Klöber roof
tiles
Provide a suitable Klöber roof tile
on site.
or
Universal roof tile
or
Flat roof collar
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 80/125 m 13 13 11 11
Vertical outlet for pitched or flat roofs
(cont.)
5780 223 GB
Page 43
43
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size
60/100
m 10 10 10 10 — — — —
System size
80/125
m 13 13 13 11 10 6 — —
System size
100/150
m — — — — 13 9 15 15
Note
For alternative system sizes, a balanced 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 223 GB
Page 44
44
Installation
Balanced flue roof outlet
2
7
6
3
!
Please note
Ensure the specified minimum
lengths above the roof are
observed.
Never trim roof outlets above
the roof.
■ Install pipe outlets for Klöber roof
tiles, universal roof tiles or flat roof
collars in accordance with manufacturer's instructions.
■ Integrate the flat roof collar into the
roof skin according to the flat roof
guidelines.
■ Ceiling/roof penetration (min. diameter):
– 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 flue connection pipe from below.
Vertical outlet for pitched or flat roofs
(cont.)
5780 223 GB
Page 45
45
Roof construction in line with 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
46
Fitting an above-roof extension
System sizes 60 and 80
3x
3x
B
A
C
D
C
B
C
B
1. Push the internal pipe of above-roof
extension A onto roof 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
47
System size 100
A
B
1.
Remove top section A of the roof
outlet.
2.
Push above-roof extension B onto
the roof outlet.
3.
Push top section A onto aboveroof extension B.
Note
For extensions ≥ 1 m, secure the
roof outlet with ropes. The ropes
can 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 balanced flue pipe for inspection and
cleaning.
Recommendation: Use the balanced
flue slide coupling to facilitate installation of the balanced flue pipe.
Route the connection piece with a fall
of at least 3° (approx. 50 mm/m).
Vertical outlet for pitched or flat roofs
(cont.)
5780 223 GB
Page 48
48
651 7 4 42
B
A
3
A
Supply air
B
Flue gas
1
Boiler flue connection
2
Balanced flue external wall
connection
(incl. wall bezels)
3
Grille
4
Balanced flue 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
49
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 80/125 m 13 13 11 11
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size 60 m 10 10 10 8 — — — —
System size 80 m 13 13 13 11 10 6 — —
System size 100 m — — — — 13 9 15 15
Note
For alternative system sizes, a balanced 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
Installation
C
B
A
a
b
c
Balanced flue system 7 60/100 mm and 7 80/125 mm
External wall connection
(cont.)
5780 223 GB
Page 50
50
Balanced flue system
(7 mm)
60/100 80/125
a (mm) ≤ 475 ≤ 710
b (mm) 155 165
c (mm) 704 952
Telescopic balanced flue external
wall connection
Balanced flue system
(7 mm)
60/100
a (mm) ≥373 - ≤ 533
b (mm) 154
c (mm) ≥617 - ≤ 777
C
B
A
730
475
160
Balanced flue system 7 100/150 mm
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 connection A
with wall bezel B into the wall
opening.
3.
Slide on internal wall bezel C.
4. If the external wall connection terminates ≤ 2 m above ground level
near public roads, fit a protective
grille (on-site fixing materials).
5. Connect the balanced flue connection pipe from the inside and route
with a fall of min. 3° (approx.
50 mm/m) towards the boiler.
External wall connection
(cont.)
5780 223 GB
Page 51
51
21
6
7
8
9
qP
5
B
5
3
qQ
qW
43
A
2 m:
qR
A
7
C
qE
qR
qP
A
Flue gas
B
Supply air
C
Elbow in the external wall routing
for a short roof overhang
1
Boiler flue connection
2
Balanced flue inspection tee,
87°
or
Balanced flue inspection bend,
87°
3
Balanced flue slide coupling
4
Balanced flue pipe
1.95 m long
1 m long
0.5 m long
5
Wall bezel
6
Fixing clamp
7
Balanced flue inspection piece,
straight
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
roof)
qR
Balanced flue bend, 45° or ex-
ternal wall bend, 45°
or
Balanced flue bend, 30° or ex-
ternal wall bend, 30°
Balanced flue adaptor
7
60/100 mm to 7 80/125 mm
Routing over an external wall
5780 223 GB
Page 52
52
Maximum flue length
Vitodens 100-W
Rated heating output kW 19.0 26.0 30.0 35.0
System size 60/100 m 20 20 15 15
System size 80/125 m 25 25 20 20
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size
60/100
m 20 20 20 15 — — — —
System size
80/125
m 25 25 25 20 12 12 — —
System size
100/150
m — — — — 17 17 20 20
Note
For alternative system sizes, a balanced 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
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 wall bend 8.
4.
Secure interior wall bezel 5.
5. Connect the balanced flue connection pipe from the inside and route
with a fall of min. 3° (approx.
50 mm/m) towards the boiler.
6.
Use external wall clamps 6 to fit
the flue components to the external
wall at a consistent distance.
Position external wall clamps 6 in
intervals of max. 2 m.
Routing over an external wall
(cont.)
5780 223 GB
Page 53
53
7.
!
Please note
Ensure the specified minimum lengths above the roof
are observed.
Never trim roof outlets
above the roof.
Roof outlet
■ Use universal tiles or air vent tiles
with pipe outlets.
■ Position balanced flue slide coupling 3 underneath the roof outlet.
■ Install 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 balanced flue inspection piece 7.
■
Elbow with 30° bend qR: Balanced flue inspection piece
7
not required.
■
Fit external wall terminal qE
Routing over an external wall
(cont.)
5780 223 GB
Page 54
54
Routing options
A B
C
A
Plume kit standard delivery
B
Plume kit standard delivery
plus:
■ 2 bends 87°
■ 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
55
1.
2.
1. Disengage and remove the end
piece of the external wall connection.
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.
3535
4. Insert screws into the wall in
accordance with the pipe length.
Plume kit
(cont.)
5780 223 GB
Page 57
57
6.
7.
5.
5. Mount flue pipes and bends in line
with the 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
60
Viessmann Limited
Hortonwood 30, Telford
Shropshire, 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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