Viessmann Flue gas system, Vitodens 100-W, Vitodens 200-W, Vitodens 222-F, Vitodens 242-F Installation Instructions Manual

5458 035 GB Subject to technical modifications.

Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com

Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]

Installation instructions

for contractors

Flue gas system

for Vitocrossal (type CU3), Vitodens and Vitoladens

Safety instructions

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

Safety instructions explained

Please note

This symbol warns against
the risk of material losses and
environmental pollution.

Note

Details identified by the word “Note”
contain additional information

installation, initial start-up, inspection,
maintenance and repairs must only be
carried out by a competent person (heating
engineer/installation contractor).

Before working on the equipment/heating
system, isolate the power supply (e.g.
by removing a separate mains fuse or by
means of a mains isolator) and safeguard
against unauthorised reconnection.

When using gas as a fuel, also close the
main shut-off valve and safeguard against
unauthorised reopening.

Repairing components which fulfill a safety
function can compromise the safe operation
of your heating system.

For replacements, use only original spare
parts supplied or approved by Viessmann.

Dispose after installation

5458 035 GB 04/2010

!

1

General installation instructions

Engineering

Prior to the installation check that the
maximum possible flue length in
accordance with the technical guide for
the respective boiler will not be exceeded.

Flue gas temperature protection

The flues are approved for flue gas
temperatures up to 120°C

Measures inside the Viessmann condensing
boilers ensure that the maximum
permissible flue gas temperature will never
be exceeded.

Installation information

n The component overviews for the types

of routing also apply to the Vitocrossal
300 and the Vitoladens 300-T.

n Keep flue paths as short as possible with

the fewest number of bends possible.

n Check the gaskets in all female

connections.

n Use only the special gaskets supplied

with the boiler.

Required tools/equipment

n Rope for lowering the flue gas system

into a duct (length: chimney height plus 3
metres).

n Saw and file for trimming and chamfering

the pipe sections.

n Power drill for securing the duct cover and

the support rail.

n Plug-in fem. connections in the flue must

always point in the flow direction.

n Only use the components supplied with

the PP flue gas system.

n Twist the pipes slightly whilst pushing

them in.

n Inner and outer pipe can be trimmed to

the same length.

2

5458 035 GB

General installation instructions (cont.)

Leak/soundness test

Flue gas system with Building Regulations approval ­Routing through a duct

After their installation, flue gas systems
routed through a duct must be tested for
soundness by a competent person as per
the Building regulations.

n Pressurised flues inside buildings that are

not surrounded by combustion air (open
flue) must be pressure tested.

To pressure test a flue, air is pumped into

the flue that has been sealed at the top
and bottom using a flue test device, until
a pressure of 200 Pa has built. Whilst
maintaining this pressure, the volume
of air that escapes through leaks is
established.

Up to a leakage rate of 0,006 litres/ (s x

m

2

), relative to the internal surface area,
is considered as indication that the flue is
sound.

n In pressurised flue gas systems that are

surrounded by combustion air (balance
flue), the soundness can be checked by
testing the O2 content in the combustion
air (annular gap test).

The flue is reckoned to be sufficiently

sound if the O

2

content in the combustion
air deviates by no more than the following
values from the reference value. The
reference value results after the self­adjustment of the test equipment:

– for flues with general Building

Regulations approval 0.4% by vol.

– for other flues 0.2% by vol.

Flue gas systems as technical units with Vitodens and Vitoladens

n Balanced flue roof outlet (C33x)

n Balanced flue external wall terminal (C13x)

n Routing over external walls (C53x)

n Separate ventilation and flue gas routing

(C53x)

We recommend that a simple soundness
test is carried out during the commissioning
of your system. For this it would be
sufficient to check the CO

2

concentration in
the combustion air at the annular gap of the
balanced flue pipe. The flue pipe is deemed
to be sound if the CO2 concentration in the

combustion air is no higher than 0.2% or
the O

2

concentration is at least 20.6%.

If higher CO

2

or lower O2 values are
measured, check the flue system for
soundness.

3

5458 035 GB

General installation instructions (cont.)

4

5458 035 GB

Removing the flue pipe from the balanced flue pipe
(if required)

System size 60 and 80.

General installation instructions (cont.)

System certification and Building Regulations
Approval

Note

This is to confirm that the flue system is approved to Building Regulations and certified to the
appropriate EC Gas Equipment Directive.

System Certification

System certification to DVGW-VP 113 and
EC Gas Equipment Directive 90/396/EEC
in conjunction with PPs flue pipes offered
by Skoberne.

5

5458 035 GB

Vitodens 100-W CE-0085 BN

Vitodens 200-W CE-0085 BR 0432

Vitodens 222-F CE-0085 BR 0433

Vitodens 343-F / 242-F CE-0085 BO 0338

Installation requirements

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.

Boiler Position

The following limitations must be observed
when siting the boiler:

n 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.

n 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.

n Due consideration should be given to the

routing of the condensate drain from the
chosen position.

n 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.

6

5458 035 GB 08/2007

!

Flue terminal position

n 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.

n 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.

n Where installation will be in an unusual

location, special procedures may be
necessary. BS 6798 gives detailed
guidance on this aspect.

Flue termination position
Horizontal flue system

7

5458 035 GB 08/2007

Position Minimum Spacing

A Directly below an openable window, air vent or any other 300 mm
ventilation opening

B Below a gutter, drain or soil pipe 75 mm

Flue terminal position (cont.)

Vertical flue systems

8

5458 035 GB 08/2007

Position Minimum Spacing

C Below eaves 200 mm

D Below a balcony 200 mm

E From vertical drain or soil pipes 150 mm

F From internal and external corners 300 mm

G Above adjacent ground or balcony level/roof 300 mm

H From a surface facing the terminal 600 mm

I Facing terminals 1200 mm

J From opening door/window in carport into dwelling 1200 mm

K Vertically from a terminal on same wall 1500 mm

L Horizontally from a terminal on same wall 300 mm

M Adjacent to opening 300 mm

N Below carport/roof not recommended

Minimum distance from terminal

Boundary

Walkway

or patio

Car

space

2.5m

2.1m

2.5m

Not under a car port Avoid access routes and patios Minimum distance to car

parking space

4

4

7

7

Flue terminal position (cont.)

Flue Terminal Location

Detailed recommendations for
flue installation are given in BS
5440:1. The following notes are
for general guidance.

n It is important that the position

of the terminal allows free
passage of air across it at all
times.

n It is essential to ensure that

products of combustion
discharging from the terminal
cannot re-enter the building
or any other adjacent building,
through ventilators, windows,
doors, other sources of
natural air infiltration or forced
ventilation / air conditioning.

n The minimum acceptable dimensions

from the terminal to obstruction and
ventilation openings are specified above
(BS 5440 Part 1).

n If the terminal discharges into a pathway

or passageway check that combustion
products will not cause nuisance and
that the terminal will not obstruct the
passageway.

n Where the lowest part of the terminal

is fitted within 850 mm of a plastic or
painted gutter, or 450 mm of painted
eaves, an aluminium shield at least 750
mm long must be fitted to the underside
of the painted surface.

n Where the terminal is fitted within 850

mm of a plastic or painted gutter, or 450
mm of painted eaves, an aluminium
shield at least 750mm long must be fitted
to the underside of the painted surface.

n The air inlet / flue outlet duct must not

be closer that 25 mm to combustible
material.

n Due to the high efficiency of the boiler

the terminal may emit a plume of vapour.
This is normal but positions where
this would cause a nuisance should be
avoided.

9

5458 035 GB 08/2007

Position Minimum Spacing

O From adjacent wall 300 mm

P From adjacent opening window 1000 mm

Q From another terminal 600 mm

R Minimum height 300 mm

S

Minimum distance measured perpendicular to roof covering

400 mm

Routing through a duct

Installation Information

Provide an inspection aperture at the base
of the duct for checking the secondary
ventilation. The condensate drainage from
the flue to the boiler must be ensured
through a gradient of at least 3° (approx.
50 mm/m).

Route the flue over the roof (observe
the roof clearance perpendicular to the
roof inclination 400 mm according to the
building regulation.

10

5458 035 GB

Routing through a duct (cont.)

Rigid flue

Balanced flue operation

1

Boiler flue connection

2

Standard duct pack

Comprising:

n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)

3

Flue Pipe

2 m long
1 m long

0.5 m long
Flue bend (for use in corbelled chimneys)
30° or 15°

4

Inspection piece, straight

5

Balanced flue inspection piece, straight

6

Balanced flue 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 sliding coupling

Fixing clamp

11

5458 035 GB

A

Combustion air

B

Flue gas

C

Inspection

aperture

Max. total flue length up to the boiler flue connection (at system temperature 50/30°C)

Vitodens 100-W Rated output range (kw) 9 11 11

26.0 30.0 35.0

max. length (m) - system size 60/100 20 15 15

Vitodens 200-W Rated output range 4.8 6.5 8.8 8.8 17.0 17.0 30.0 30.0

19.0 26.0 30.0 35.0 45.0 60.0 80.0 105.0

max. length (m) - system size 60/100 20 20 15 15 – – – –

- system size 80/125 – – – – 20 15 – –

- system size 100/150 – – – – – – 20 20

Vitodens 222-F Rated output range (kw) 4.8 6.5 8.8 8.8

19.0 26.0 30.0 35.0
max. length (m) - system size 60/100 20 20 15 15

Vitodens 242-F Rated output range (kw) 4.8 6.5

19.0 26.0
max. length (m) - system size 60/100 20 20

Routing through a duct (cont.)

Open flue operation

12

5458 035 GB

1

Boiler flue connection

2

Standard duct pack

Comprising:

n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)

3

Flue Pipe

2 m long
1 m long

0.5 m long
Flue bend (for use in corbelled chimneys)
30° or 15°

4

Inspection piece, straight

5

Balanced flue bend

87° or 2 x 45°
or

Balanced flue inspection tee

87°

6

Ventilation bezel

A

Secondary ventilation

B

Flue gas

C

Inspection aperture

D

Ventilation aperture

E

Combustion air

Max. total flue length up to the boiler flue connection (at system temperature 50/30°C)

Vitodens 100-W Rated output range (kw) 9 11 11

26.0 30.0 35.0

max. length (m) - system size 60/100 20 15 15

Vitodens 200-W Rated output range 4.8 6.5 8.8 8.8 17.0 17.0 30.0 30.0

19.0 26.0 30.0 35.0 45.0 60.0 80.0 105.0

max. length (m) - system size 60/100 20 20 15 15 – – – –

- system size 80/125 – – – – 20 15 – –

- system size 100/150 – – – – – – 20 20

Vitodens 222-F Rated output range (kw) 4.8 6.5 8.8 8.8

19.0 26.0 30.0 35.0
max. length (m) - system size 60/100 20 20 15 15

Vitodens 242-F Rated output range (kw) 4.8 6.5

19.0 26.0
max. length (m) - system size 60/100 20 20

Allowed for are 2 bends 87° (incl. support bends).

Routing through a duct (cont.)

Open flue operation with combustion air supplied via interconnected
rooms (only possible for system sizes 60 and 80)

The interconnection piece to the
duct is created from a balanced
flue system. The combustion air is
drawn from the room via an opening
immediately by the chimney entry
(room interconnection bezel).

An adequate combustion air supply
must be safeguarded inside the room
as specified by the TRGI ‘86/96, point

5.5, through an interconnection with
adjacent rooms:

n Minimum volume of the

interconnected rooms 4 m3 per kW
rated output

n Apertures in connection doors min.

150 cm

2

13

5458 035 GB

Routing through a duct (cont.)

14

5458 035 GB

A

Combustion air

B

Flue gas

C

Secondary ventilation

D

Room interconnection aperture

E

Inspection aperture

1

Boiler flue connection

2

Standard duct pack

Comprising:

n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)

3

Flue Pipe

2 m long
1 m long

0.5 m long
Flue bend (for use in corbelled chimneys)
30° or 15°

4

Inspection piece, straight

5

Balanced flue inspection piece, straight

6

Balanced flue room interconnection bezel

7

Balanced flue pipe

1 m long

0.5 m long

8

Balanced flue bend

87° or 2 x 45°
or

Balanced flue inspection tee

or

Balanced flue inspection bend

Routing through a duct (cont.)

Installation

1. Drill a ø 12 mm hole centrally into the

rear duct wall to secure support rail 1 .

2. Insert support rail

1

into the drilled hole,
and secure with screws or mortar on the
front duct wall.

3. Position support bend

2

and secure with

the pin in a hole in the support rail.

4. Secure installation rope

3

externally on

the lowest vertical pipe section.

15

5458 035 GB

Routing through a duct (cont.)

Duct cover, system size 60 to 100 mm

Duct cover, system size 125 to 200 mm

5. Subject to duct size, install a spacer

4

every 2 to 5 m and at each profiled piece
(e.g. inspection piece or bend). Bent ends
facing up

6. Push the pipes into each other whilst

slightly turning them (use lubricant), and
let the pipe descend into the duct on the
end of the rope.

7. Remove the rope and push the lowest

pipe into support bend

2

.

8. Let the highest pipe section

9

terminate
approx. 50 mm below the top edge of
the duct.

9. Secure the lower part of duct cover

5

.

10. System size 60 to 100 mm:

Push on aluminium terminal pipe

6

.

Note

For weight reasons, never trim aluminium

terminal pipe

6

.

System size 125 to 200 mm: Trim the

final pipe section

6

(without coupling), so

that it is as flush with fitted weather collar

7

as possible.

16

5458 035 GB

Routing through a duct (cont.)

11. Push on weather collar 7 and secure

safety rope 8 on the lower part.

12. Only for balanced operation: Trim the

last ventilation pipe of the connecting
line so that it reaches to the internal wall
of the duct.

13. Balanced flue operation: Push on

balanced flue wall bezel

10 and push it

against the duct opening.

Open flue operation: Push on ventilation

bezel

11 and push it against the duct

opening.

Note

The gap created is designed to provide

secondary ventilation for the duct.

An additional ventilation grille is not

required.

Open flue operation with combustion air

supply via interconnected rooms:

Push the flue pipe (suitably trimmed

to size) onto the support bend, push
on room interconnection bezel

12

and

secure it on the duct.

17

5458 035 GB

Routing through a duct (cont.)

18

5458 035 GB

Flexible flue

Balanced flue operation

A

Combustion air

B

Flue gas

C

Inspection aperture

1

Boiler flue connection

2

Standard duct pack

Comprising:

n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)

3

Inspection piece, straight (for installation

into the flexible flue (optional))

4

Flexible flue

5

Connecting pipe

for the connection of residual length of the
flexible flue

Pipe lowering attachment with 20m 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

Balanced flue sliding coupling

10

Max. total flue length up to the boiler flue connection (at system temperature 50/30°C)

Vitodens 100-W Rated output range (kw) 9 11 11

26.0 30.0 35.0

max. length (m) - system size 60/100 20 15 15

Vitodens 200-W Rated output range 4.8 6.5 8.8 8.8 17.0 17.0 30.0 30.0

19.0 26.0 30.0 35.0 45.0 60.0 80.0 105.0

max. length (m) - system size 60/100 20 20 15 15 – – – –

- system size 80/125 – – – – 20 15 – –

- system size 100/150 – – – – – – 20 20

Vitodens 222-F Rated output range (kw) 4.8 6.5 8.8 8.8

19.0 26.0 30.0 35.0
max. length (m) - system size 60/100 20 20 15 15

Vitodens 242-F Rated output range (kw) 4.8 6.5

19.0 26.0
max. length (m) - system size 60/100 20 20

Allowed for are 2 bends 87° (incl. support bends).

Routing through a duct (cont.)

Open flue operation

Connecting line to the duct for open flue operation or balanced flue operation with
combustion air supply via interconnected rooms, see “Rigid flue” on page 7.

Installation

Fit the support bend and the interconnecting pipe, from page 11.

Fitting the pipe lowering attachment and drawing the flexible flue into
the duct

Note

n The flexible flue must start with a smooth

section at the bottom. If necessary, trim
off a piece of flue pipe.

n Draw in the flue exclusively from top

to bottom.

n Subject to duct size, insert spacers at a

distance of up to 2 m.

n Arrange a spacer before and after any

deviation and any inspection piece.

n The flue must not contact the duct wall.

1. Remove union ring

1

and retaining ring

2

from the adaptor (from the standard

duct set).

2. Push union ring

1

onto flexible flue 3 .

3. Place retaining ring

2

into the second

groove of flexible flue 3 .

4. Fit union ring

1

to pipe lowering

attachment 4 and fit the rope.

19

5458 035 GB

Fitting an inspection piece

Note

Trim the flexible flue cleanly at right angles.

5. Push on spacers

5

onto the corrugated

area of flue

3

(bent ends towards the

flue gas flow).

6. Position line ties

6

supplied around the

ring of spacers 5 and tighten securely.

1. Push union

1

onto flexible flue 3 .

2. Place retaining ring

2

into the second

groove of flexible flue 3 .

3. Position retaining ring

7

into the first

groove of flexible flue 3 .

4. Connect union ring

1

with inspection

piece 8 .

Routing through a duct (cont.)

20

5458 035 GB

1. Route flexible flue

3

through duct cover

9

.

2. Position the lower part of duct cover

9

onto the duct and secure it there.

3. Position metal supporting ring

10

on the

lower part of duct cover 9 .

4. Push threaded ring

11

as far as possible

onto flexible flue 3 .

5. Trim flue

3

flush with the top of

threading ring

11

.

6. Screw terminal pipe

12

onto threading

ring

11

.

7. Invert weather hod

13

over terminal

piece

12

and click into place.

8. Hook safety rope

14

into the drilled holes

of duct cover 9 .

Connection to a moisture-resistant chimney

Routing through a duct (cont.)

Condensing boilers can be connected to
moisture-resistant chimneys to EN 13384­1, if the chimney manufacturer has verified
their suitability on the basis of the specified
flue gas values.

For this, local conditions (e.g. heating water
return temperature, connecting pipe design,
etc) must be taken into consideration.

As transition from the flue to the MR
chimney, use a plug-in adaptor, such as that
offered by Schiedel or an adaptor by Plewa.

21

5458 035 GB

Connection to a moisture-resistant chimney (cont.)

22

5458 035 GB

1

Boiler flue connection

2

Flue Pipe

2 m long
1 m long

0.5 m long

4

Inspection piece, straight

5

Flue bend

87° or 2 x 45°
or

Inspection tee

87°

A

Plug-in adaptor

B

Flue gas

C

Secondary ventilation

D

MR chimney

E

Inspection aperture

F

Ventilation air

Vertical outlet for sloping or flat roofs

When several roof outlets are installed side
by side, maintain a minimum clearance of 1.5
m between pipes and between flue terminals
and other structural elements. Observe the
clearance of the flue outlet above the roof
(see fig.). If the rated output is ≥50 kW, an
above roof extension is required (see page

28).

Rated output kW ≤ 50 ≥50

a (min.) mm 400 1 000

1

Boiler flue connection

2

Balanced flue roof outlet

3

Pipe outlets for Klöber roof tiles (order

the corresponding Klöber tile on site)

or

Universal roof tile

or

Flat roof collar

4

Balanced flue inspection piece,

straight (optional)

5

Balanced flue sliding coupling

(optional)

Balanced flue bend

87° or 2 x 45°

Balanced flue pipe

1 m long

0.5 m long

Fixing clamp

23

5458 035 GB

A

Ventilation air

B

Flue gas

Vertical outlet for sloping or flat roofs (cont.)

Installation

Balanced flue roof outlet

Please note

Ensure the specified minimum lengths

above the roof are observed.

Never trim roof outlets outside the roof.

n Install pipe outlets for Klöber roof tiles,

universal roof tiles or flat roof collars in
accordance with manufacturer’s details.

n Integrate the flat roof collar into the roof

skin according to the flat roof guidelines.

n Ceiling opening (min. diameter):

-105 mm (system size 60)

-130 mm (system size 80)

-160 mm (system size 100).

n Secure the roof outlet with a clamp only

after the installation has been completed.

n Position the roof outlet from the top onto

tiles or the flat roof collar.

n Connect the balanced flue from below.

24

5458 035 GB

!

Vertical outlet for sloping or flat roofs (cont.)

Roof construction according to the flat roof guideline

5458 035 GB

25

Max. total flue length up to the boiler flue connection (at system temperature 50/30°C)

Vitodens 100-W Rated output range (kw) 9 11 11

26.0 30.0 35.0

max. length (m) - system size 60/100 10 10 10

Vitodens 200-W Rated output range 4.8 6.5 8.8 8.8 17.0 17.0 30.0 30.0

19.0 26.0 30.0 35.0 45.0 60.0 80.0 105.0

max. length (m) - system size 60/100 10 10 10 10 – – – –

- system size 80/125 – – – – 10 6 – –

- system size 100/150 – – – – – – 15 15

Vitodens 222-F Rated output range (kw) 4.8 6.5 8.8 8.8

19.0 26.0 30.0 35.0
max. length (m) - system size 60/100 10 10 10 10

Vitodens 242-F Rated output range (kw) 4.8 6.5

19.0 26.0
max. length (m) - system size 60/100 10 10

Allowed for are 2 bends 87° (incl. support bends).

A

Flat roof collar

B

Gravel ballast layer

C

Insulation membrane

D

Ventilation membrane

E

Thermal insulation

F

Insulation

G

Ceiling

H

Flue

Vertical outlet for sloping or flat roofs (cont.)

Fit the above-roof extension

System size 60 and 80

26

5458 035 GB

1. Push the internal pipe of above-roof
extension 1 onto roof outlet 2 and secure
with 3 screws provided.

2. Push black pipe section 3 onto roof outlet
2 and secure with 3 screws provided.

3. Push roof outlet 2 with above-roof
extension 1 onto the balanced flue.

4. Secure the above-roof extension (1000 mm
long) with clip 4 provided and with guy
ropes.

Vertical outlet for sloping or flat roofs (cont.)

System size 100

1. Remove top part 1 of the roof outlet.

2. Push above-roof extension

2

onto the

roof outlet.

3. Push top part

1

onto above roof

extension

2

Note

For extensions ≤1 m, secure the roof

outlet with guy ropes (can be secured to
the above-roof extension).

5458 035 GB

27

Horizontal wall terminal

A

Combustion air

B

Flue gas

1

Boiler flue connection

2

Balanced flue external wall

connection (incl. wall bezels)

3

Protective grille

4

Balanced flue pipe

1 m long

0.5 m long

5

Balanced flue bend

87° or 2 x 45°

Fixing clamp

28

5458 035 GB

Note

Not for the Vitocrossal or the Vitoladens.

Route the connecting pipe with a slope of at
least 3° (approx. 50 mm/m).

29

5458 035 GB

1. Create a wall outlet (min. diameter):

n 105 mm (system size 60)

n 130 mm (system size 80)

2. Push external wall outlet

1

with wall

bezel

3

into the opening in the wall (drain

holes must be outside the wall).

3. Fit internal rawl plugs for wall bezel

2

.

4. Fit external rawl plugs for wall bezel

3

.

5. If the external wall outlet terminates near

public footpaths up to 2 m above the
ground, fit a protective grille.

6. Connect the balanced flue

interconnecting pipe from the inside and
route with a slope of at least 3° (aprox. 50
mm/m) towards the boiler.

Horizontal wall terminal (cont.)

Installation

Max. total flue length up to the boiler flue connection (at system temperature 50/30°C)

Vitodens 100-W Rated output range (kw) 9 11 11

28.0 30.0 35.0

max. length (m) - system size 60/100 8 8 8

Vitodens 200-W Rated output range 4.8 6.5 8.8 8.8 17.0 17.0 30.0 30.0

19.0 26.0 30.0 35.0 45.0 60.0 80.0 105.0

max. length (m) - system size 60/100 10 10 10 10 – – – –

- system size 80/125 – – – – 10 10 – –

- system size 100/150 – – – – – – 10 10

Vitodens 222-F Rated output range (kw) 4.8 6.5 8.8 8.8

19.0 26.0 30.0 35.0
max. length (m) - system size 60/100 10 10 10 10

Vitodens 242-F Rated output range (kw) 4.8 6.5

19.0 26.0
max. length (m) - system size 60/100 10 10

Allowed for are 2 bends 87° (incl. support bends).

Routing over an external wall

30

5458 035 GB

A

Flue gas

B

Combustion air

C

Step 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 sliding coupling (optional)

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 (optional)

External wall pack

with

8

Balanced flue bend

87°

9

Balanced flue air intake

Balanced flue pipe

1.95 m long
1 m long

0.5 m long

Balanced flue roof outlet

(with a high roof overhang above the roof)

Universal roof tile

or

Pipe outlet for Klober roof tiles

(order the corresponding Klober tile on site)

External wall terminal

(for a short roof overhang)

Balanced flue bend

45°

10

11

12

13

14

1. Create a wall outlet (min. diameter):

n 105 mm (system size 60)

n 130 mm (system size 80)

n 160 mm (system size 100).

2. Push external wall bend

8

with wall bezel

5

from the outside into the hole in the

wall.

3. Fit air intake

9

as near as possible to

external wall bend

8

.

4. Secure the wall bezel from the inside.

5. Connect the balanced flue inter-

connecting pipe from the inside and route
with a slope of at least 3° (approx. 50
mm/m) towards the boiler.

6. Fit sections with external wall clips at a

constant distance from the external wall.
Set external wall clips at centres of
up to 1 m.

7. Please note
Ensure the specified minimum

lengths above the roof are
observed. Never trim roof outlets
outside the roof.

n Use universal tiles or air vent

tiles with pipe outlets.

n Set balanced flue sliding coupling

3

below the roof outlet.

n Install pipe outlets for Klöber or

universal roof tiles in accordance

with manufacturer’s details.

n Position the roof outlet

from the top onto tiles.

n Connect the external

wall line from below.

31

5458 035 GB

Routing over an external connection (cont.)

Installation

!

Max. total flue length up to the boiler flue connection (at system temperature 50/30°C)

Vitodens 100-W Rated output range (kw) 9 11 11

26.0 30.0 35.0

max. length (m) - system size 60/100 20 15 15

Vitodens 200-W Rated output range 4.8 6.5 8.8 8.8 17.0 17.0 30.0 30.0

19.0 26.0 30.0 35.0 45.0 60.0 80.0 105.0

max. length (m) - system size 60/100 20 20 15 15 – – – –

- system size 80/125 – – – – 20 15 – –

- system size 100/150 – – – – – – 20 20

Vitodens 222-F Rated output range (kw) 4.8 6.5 8.8 8.8

19.0 26.0 30.0 35.0
max. length (m) - system size 60/100 20 20 15 15

Vitodens 242-F Rated output range (kw) 4.8 6.5

19.0 26.0
max. length (m) - system size 60/100 20 20

Allowed for are 2 bends 87° (incl. support bends).

A Plume kit standard delivery 2m max
length

Ensure the max. length of 3m (externally)
and 7m (internally) is not exceeded.

The max. length is reduced by 1m when
using a further 87° bend or 2x45° bends.

B Plume kit standard delivery additional
options:

 •2x87°bends

 •1pipe1mlong

C Plume kit standard delivery additional
options:

 •2x45°bends

 •1pipe1mlong

Deduct 3m from the max. possible standard
concentric horizontal flue length and add the
standard plume kit max length to give max.
length of entire flue system. ie. 6m - 3m +
2m = 5m max.

Preparing for installation

Plume kit installation instructions

The plume kit enables the relocation of the flue outlet of a standard horizontal flue system
to another position and is available as an optional extra, please contact your supplier for
further information.

Routing options

32

5458 035 GB

Preparing for installation (cont.)

Flue kit installation instructions

1. Start

2. Remove the nozzle of the

wall terminal with a tool
(screwdriver)

3. Fit the 87° elbow with skirt into the

inner flue pipe, twisting it into the

correct position.

5458 035 GB

33

4. Connect the pipe to the bend

7. Connect the 87° bend with bird

mesh to the last pipe

5. Fix flue pipe to the wall with clips

6. Continue step 4 and 5 until the

desired height is reached

Preparing for installation

Flue kit installation instructions

34

5458 035 GB

5458 035 GB

35