Vaillant Air/Flue Gas System User manual

For the competent person
Installation manual
Air/flue gas system
VKK ../3
GB
Installation manual

Legal information
Document type: Installation manual
Product: Air/flue gas system
–130 mm diameter system
–160 mm diameter system
–200 mm diameter system
Target group: Authorised competent person
Language: EN
Document number_version: 0020058722_04
Created on: 26.09.2012
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40 D-42859 Remscheid
Telefon [phone]‑0 Telefax [phone]‑28 10
[email protected] www.vaillant.de
© Vaillant GmbH 2012
These instructions, or extracts thereof, may only be printed with the written consent of Vaillant GmbH.
All designations of products in these instructions are brand names/trade marks of the companies in question.
We reserve the right to make technical changes.

Contents
0020058722_04 Air/flue gas system Installation manual 3
Contents
1 Notes on the documentation .............................. 4
1.1 Observing other applicable documents ................. 4
1.2 Storing documents................................................. 4
1.3 Applicability of the instructions .............................. 4
2 Safety .................................................................... 5
2.1 Action-related warnings ......................................... 5
2.2 Required personnel qualifications ......................... 5
2.3 General safety information .................................... 5
2.4 Intended use .......................................................... 7
2.5 Regulations (directives, laws, standards) .............. 8
3 System overview.................................................. 9
3.1 Combination options for systems with VKK........... 9
3.2 130 mm diameter system ...................................... 9
3.3 160 mm diameter, 200 mm diameter system ........ 9
4 Certified air/flue gas systems and
components ....................................................... 11
4.1 Certified air/flue gas systems and components,
130 mm diameter................................................. 11
4.2 Certified air/flue gas systems and components,
160 mm diameter................................................. 11
4.3 Certified air/flue gas systems and components,
200 mm diameter................................................. 11
4.4 Certified flue gas systems.................................... 12
5 System conditions............................................. 12
5.1 Maximum pipe lengths......................................... 12
5.2 General installation instructions........................... 17
6 Installing the 130 mm diameter system........... 18
6.1 Installation instructions ........................................ 18
6.2 Installing the basic set for shaft installation ......... 19
6.3 Flue gas connection and installing the
horizontal flue gas pipe........................................ 20
6.4 Installing the combustion air line ......................... 21
7 Installing the 160 mm diameter and 200 mm
diameter systems .............................................. 22
7.1 Installing the flue gas pipe in the shaft ................ 22
7.2 Installing a flue gas pipe on a support pipe
(optional).............................................................. 25
7.3 Installing the vertical roof duct ............................. 25
7.4 Installing the flue gas pipe on the external
wall....................................................................... 26
7.5 Stabilising the flue gas pipe................................. 30
7.6 Flue gas connection and installing the
horizontal flue gas pipe........................................ 31
7.7 Installing the combustion air line ......................... 31
8 Customer service............................................... 32
Index ................................................................................... 33

1 Notes on the documentation
4Installation manual Air/flue gas system 0020058722_04
1 Notes on the documentation
1.1 Observing other applicable documents
For the competent person:
–Installation instructions for the installed Vaillant product.
1.2 Storing documents
▶Pass these instructions and all other applicable docu-
ments on to the system operator.
The system operator should retain these instructions for fur-
ther use.
1.3 Applicability of the instructions
These instructions apply only for the Vaillant heat generator
named in the other applicable documents and referred to as
the "product" in this document.

Safety 2
0020058722_04 Air/flue gas system Installation manual 5
2 Safety
2.1 Action-related warnings
Classification of action-related warnings
The action-related warnings are classified in accordance
with the severity of the possible danger using the following
warning signs and signal words:
Warning symbols and signal words
Danger!
Imminent danger to life or risk of severe personal
injury
Danger!
Risk of death from electric shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental damage
2.2 Required personnel qualifications
These instructions are intended for the competent person.
2.2.1 Authorised competent person
The installation, assembly and removal, start-up, mainten-
ance, repair and decommissioning of Vaillant products and
accessories must only be carried out by authorised compet-
ent persons.
Note
Each competent person is qualified for specific
activities on the basis of their training. They must
only work on units if they have the required quali-
fication.
When working on the units, the competent persons must
observe all applicable directives, standards, laws and other
regulations.
2.3 General safety information
2.3.1 Informing the responsible departments
▶Before installing the flue pipe, inform the local gas supply
company and the district master chimney sweep.
2.3.2 Risk of poisoning due to escaping flue gas
Improperly installed flue gas pipes may cause flue gas to
escape.
▶Before starting up the product, check that the whole flue
pipe is securely fastened and sealed.
The flue gas pipe may become damaged by unforeseeable
external influences.
▶As part of the annual maintenance, inspect the flue gas
system in terms of:
–external faults such as brittleness and damage
–safe pipe connections and secure fastenings
2.3.3 Risk of death from leaks in the flue gas
route
Flue gas may escape from leaking pipes or damaged seals.
Mineral-oil-based greases can damage the seals.
▶Transport the pipes to the installation site only in the ori-
ginal packaging.
▶If the temperature is lower than 0 °C, warm the pipes
before beginning installation.
▶When installing the flue gas installation, use only flue
pipes of the same material.
▶Do not install any damaged pipes.
▶When connecting, always slide the pipes into the sleeve
until they reach a stop.
▶Shorten the flue pipes to the suitable lengths at right
angles along their smooth side.
5mm
15°
▶File off sharp burrs and chamfer the ends of the pipes be-
fore assembling them so that the seals are not damaged,
and dispose of the shavings.
▶Never use mineral-oil-based grease for the installation.
▶Only 130 mm diameter systems: if necessary, only use
water to facilitate installation.
▶Only 160 mm diameter and 200 mm diameter systems:
Use the lubricant supplied to facilitate installation.

2 Safety
6Installation manual Air/flue gas system 0020058722_04
1
2
▶When fitting the flue pipes, make absolutely sure the
seals are correctly positioned. The lip of the seal must
be facing inwards (1), not outwards (2).
▶Do not use any damaged seals.
Mortar residues, shavings, etc. in the flue pipe may restrict
the outward flow of the flue gas. Flue gas may escape into
the room.
▶After installation, remove all mortar residues, shavings,
etc. from the flue pipe.
Extensions that are not secured to the wall or ceiling may
bend and separate due to thermal expansion.
▶Secure each extension to the wall or ceiling using a pipe
clamp.
▶Where possible, use the original pipe clamps from the
product range.
–If you are using standard pipe clamps, the tension-
ing range must be between 130 mm, 160 mm and
200 mm, and the bearing capacity must be at least
200 kg.
–The distance between two pipe clamps must not be
greater than the length of the extension.
–The pipe clamps must be isolated from structure-
borne sound.
The flue gas pipe expands when warm. If the pipes are ob-
structed when expanding, this may lead to a forced fracture
and flue gases will escape.
▶Secure each of the pipe clamps to the wall or the ceiling
using a hanger bolt or threaded bolt M8/M10. This allows
for sufficient elasticity of the fastening in the event of
thermal expansion of the pipes.
▶Secure the pipe clamps using hanger bolts or stud bolts.
Loads on the flue gas guiding may damage the flue gas pipe
and lead to flue gas escaping.
▶Do not secure any loads to the flue gas guiding.
Mechanical impact loading of the flue gas pipe may damage
the flue gas pipe. Flue gases may escape.
▶Do not install the flue gas pipe in areas with mechanical
impact loading. The flue gas pipe can also be protected
against impact using protection devices that are created
on-site.
Standing condensate can damage the seals of the flue gas
pipe.
▶Route the horizontal flue pipe with a downward gradient.
–Downward gradient to the product: 3°
Note
3° corresponds to a downward gradient of
approx. 50 mm per metre of pipe length.
2.3.4 Risk of death from flue gas escaping from
openings in the flue pipe
All openings in the flue pipe that can be opened for inspec-
tion purposes must be closed before start-up and during op-
eration.
▶The openings of the flue pipe must only be opened by a
competent person.
2.3.5 Risk of fire and electronic damage caused
by missing lightning protection for the flue
gas installation
The product may be damaged by the effects of lightning and
this may lead to fires.
▶If the building is equipped with a lightning protection sys-
tem, incorporate the air/flue gas pipe into the lightning
protection.
▶If the vertical flue gas pipe contains materials made from
metal, incorporate it into the potential balancing system.
2.3.6 Risk of injury from snow falling from roofs
Where flue pipes penetrate the roof skin, the water vapour
contained in flue gas may precipitate as ice on the roof or the
roof structures in unfavourable weather conditions.
▶At the installation site, ensure that this ice build-up does
not slide from the roof.
▶If necessary, install an ice collection mesh.
2.3.7 Risk of suffocation from lack of rear
ventilation
The flue gas pipe is not ventilated from behind.
If the installation room for the product is not ventilated, there
is a risk of suffocation.
▶In the installation room, build a ventilation opening that
leads outside.
–Cross-sectional area: 150 cm²
2.3.8 Risk of corrosion in the flue gas installation
Sprays, solvents, cleaning agents, paints and adhesives may
contain substances that could lead to corrosion in the flue
gas installation in some circumstances when the product is
in operation.
▶Ensure that the combustion air that is guided to the
product is kept free of chemical substances that may
contain fluorine, chlorine, or sulphur, for example.
▶Only use appropriate Vaillant components for installing
the flue gas guiding.

Safety 2
0020058722_04 Air/flue gas system Installation manual 7
2.3.9 Inspect/clean chimneys to which former
solid fuel boilers were once connected
We recommend that you have chimneys inspected and
cleaned by a chimney sweep before the flue gas pipe is
installed if these chimneys were previously used to divert
flue gas away from solid-fuel-fired boilers but should now
supply combustion air. If it is not possible to adequately in-
spect/clean the chimney (e. g. due to construction features),
you can
–use a separate air supply or
–use open-flued operation for the system.
2.3.10 Risk of corrosion in the product caused by
using a chimney to which the former oil-
fired boiler was once connected
Chimneys that previously diverted the flue gas away from oil-
fired boilers should not be used to supply combustion air.
The combustion air may be charged with chemical deposits
and this leads to corrosion in the product.
2.3.11 Risk of fire due to insufficient clearance
▶Ensure that the flue gas pipe outside the shaft has a min-
imum clearance of 5 cm from flammable components.
2.3.12 Moisture damage caused by incorrect
installation location of the inspection elbow
An incorrect installation location leads to condensate leaking
from the lid of the opening for cleaning and may lead to cor-
rosion damage.
▶Install the inspection elbow in accordance with the illus-
tration.
2.3.13 Moisture damage caused by incorrect
installation location of the inspection T-
piece
An incorrect installation location leads to condensate leaking
from the lid of the opening for cleaning and may lead to cor-
rosion damage.
▶Install the inspection T-piece in accordance with the illus-
tration.
2.3.14 Material damage due to improper use
and/or unsuitable tools
Improper use and/or the use of unsuitable tools may result in
material damage.
▶Always use a suitable open-end spanner to tighten or
undo threaded connections.
▶Do not use pipe wrenches, extensions, etc.
2.4 Intended use
2.4.1 Intended use of the Vaillant air/flue gas
systems
Vaillant air/flue gas systems are constructed using state-of-
the-art technology in accordance with the recognised safety
rules and regulations. Nevertheless, there is still a risk of
injury or death to the system operator or others or of damage
to the products and other property in the event of improper
use or use for which the products are not intended.
The Vaillant air/flue gas systems named in this manual must
only be used in combination with the product types named in
this manual.
Any other use that is not specified in these instructions, or
use beyond that specified in this document, shall be con-
sidered improper use.
Intended use includes the following:
–observance of accompanying operating, installation and
servicing instructions for the Vaillant product as well as
for all other components of the system
–installing and fitting the product in accordance with the
product and system approval
–compliance with all inspection and maintenance condi-
tions listed in the instructions.
2.4.2 CE certification
The products are certified as boiler systems with attached
flue gas installation according to the EU gas appliances dir-
ective 90/396/EEC or 2009/142/EC.

2 Safety
8Installation manual Air/flue gas system 0020058722_04
This installation manual is a component of the certification
and is cited in the type testing certificate. In compliance
with the regulatory statutes of this installation manual, the
proof of usability of the products identified by Vaillant article
numbers that are designed for the flue pipe is provided. If
you do not use certified elements for the Vaillant flue pipe
when installing the products, this voids the CE conformity of
the product. We therefore strongly recommend that you fit
Vaillant air/flue gas systems.
2.5 Regulations (directives, laws, standards)
Please observe the existing national rules and regulations,
standards, laws and guidelines.

System overview 3
0020058722_04 Air/flue gas system Installation manual 9
3 System overview
Observe the maximum pipe lengths, see "Maximum pipe
lengths" (→Page 12).
3.1 Combination options for systems with VKK
130 mm diameter 160 mm diameter 200 mm diameter
VKK 806/3-E-HL
VKK 1206/3-E-HL
VKK 1606/3-E-HL
VKK 806/3-E-HL
VKK 1206/3-E-HL
VKK 1606/3-E-HL
VKK 2006/3-E-HL
VKK 2406/3-E-HL
VKK 2806/3-E-HL
3.2 130 mm diameter system
3.2.1 Flue gas pipe in the shaft, combustion air
from the installation room
▶Installing the 130 mm diameter system (→Page 18)
3.2.2 Flue gas pipe in the shaft, combustion air
through the external wall
▶Installing the 130 mm diameter system (→Page 18)
3.2.3 Flue gas pipe in the shaft, combustion air
from the shaft
▶Installing the 130 mm diameter system (→Page 18)
3.3 160 mm diameter, 200 mm diameter system
3.3.1 Flue gas pipe in the shaft, combustion air
from the installation room
▶Installing the flue gas pipe in the shaft (→Page 22)
▶Flue gas connection and installing the horizontal flue gas
pipe (→Page 31)
3.3.2 Flue gas pipe in the shaft, combustion air
through the external wall
▶Installing the flue gas pipe in the shaft (→Page 22)
▶Installing the combustion air line in the external wall
(→Page 31)
▶Flue gas connection and installing the horizontal flue gas
pipe (→Page 31)

3 System overview
10 Installation manual Air/flue gas system 0020058722_04
3.3.3 Flue gas pipe in the shaft, combustion air
from the shaft
▶Installing the flue gas pipe in the shaft (→Page 22)
▶Installing the combustion air line in the shaft (→Page 31)
▶Flue gas connection and installing the horizontal flue gas
pipe (→Page 31)
3.3.4 Flue gas pipe through the roof, combustion
air from the installation room
▶Installing the roof duct (→Page 26)
▶Flue gas connection and installing the horizontal flue gas
pipe (→Page 31)
3.3.5 Flue gas pipe through the roof, combustion
air through the external wall
▶Installing the roof duct (→Page 26)
▶Installing the combustion air line in the external wall
(→Page 31)
▶Flue gas connection and installing the horizontal flue gas
pipe (→Page 31)
3.3.6 Flue gas pipe on the external wall,
combustion air from the installation room
1. Installing the flue gas pipe on the external wall
(→Page 26)
2. Flue gas connection and installing the horizontal flue
gas pipe (→Page 31)
3.3.7 Flue gas pipe on the external wall,
combustion air through the external wall
▶Installing the flue gas pipe on the external wall
(→Page 26)
▶Installing the combustion air line in the external wall
(→Page 31)
▶Flue gas connection and installing the horizontal flue gas
pipe (→Page 31)

Certified air/flue gas systems and components 4
0020058722_04 Air/flue gas system Installation manual 11
4 Certified air/flue gas systems and
components
4.1 Certified air/flue gas systems and
components, 130 mm diameter
Components Art. no.
Basic set for shaft installation (PP),
130 mm diameter
0020042762
Spacer (PP), 7 pcs, 130 mm diameter 0020042763
Inspection opening with cover (PP),
130 mm diameter
0020042764
87° elbow (PP), 130 mm diameter 0020042765
45° elbow (PP), 130 mm diameter 0020042766
30° elbow (PP), 130 mm diameter 0020042767
15° elbow (PP), 2 pcs, 130 mm diameter 0020042768
Extension (PP), 1.0 m, 130 mm diameter 0020042769
Extension (PP), 2.0 m, 130 mm diameter 0020042770
Extension (PP), 0.5 m, 150 mm diameter 0020095543
Basic set for air intake, 130 mm diameter 0020060591
4.2 Certified air/flue gas systems and
components, 160 mm diameter
Components Art. no.
Unit connection (PP) with measurement open-
ing, 150 –160 mm diameter
0020095531
Basic set for shaft installation (PP), 160 mm
diameter
0020095533
Set for air intake (PP), 160 mm diameter 0020095535
End pipe (stainless steel), 0.5 m, 160 mm dia-
meter
0020095537
Installation aid with a line loop, 160 mm dia-
meter
0020095541
Extension (PP), 0.5 m, 160 mm diameter 0020095545
Extension (PP), 1.0 m, 160 mm diameter 0020095546
Extension (PP), 2.0 m, 160 mm diameter 0020095547
87° elbow (PP), 160 mm diameter 0020095552
87° elbow (PP) with inspection opening,
160 mm diameter
0020095554
45° elbow (PP), 160 mm diameter 0020095556
30° elbow (PP), 160 mm diameter 0020095558
15° elbow (PP), 160 mm diameter 0020095560
Inspection element (PP) 0.21 m, 160 mm dia-
meter
0020095561
Spacer (1 pc), 160 mm diameter 0020095563
Spacer (4 pcs), 160 mm diameter 0020095565
Vertical roof duct (PP), concentric, 160/186 mm
diameter
0020095567
Universal pitched roof tile (25° - 45°), black, for
roof duct, 160/186 mm diameter
0020095568
Universal pitched roof tile (25° - 45°), red, for
roof duct, 160/186 mm diameter
0020095569
Components Art. no.
Flat roof penetration collar (aluminium), for the
roof duct, 160/186 mm diameter
0020095570
External wall connection (stainless steel), elbow,
support console, external collar, 160/225 mm
diameter
0020095573
External wall pipe bracket (stainless steel),
225 mm diameter
0020095575
Extension (stainless steel) for external wall
laying, 0.5 m, concentric, 160/225 mm diameter
0020095577
Extension (stainless steel) for external wall
laying, 1.0 m, concentric 160/225 mm diameter
0020095579
Vertical roof duct (stainless steel) for external
wall laying, concentric, 160/225 mm diameter
0020095581
Opening piece (stainless steel), 160/225 mm
diameter
0020095583
Tile for pitched roof for 160/225 mm diameter
system, dependent on the angle
15° - 25°
25° - 35°
35° - 45°
0020095585
0020130600
0020130601
Flat roof penetration collar (stainless steel) for
160/225 mm diameter system, stainless steel
0020095587
Inspection element (stainless steel), 0.4 m,
160/225 mm diameter
0020095589
Support elbow mounting rail, long version, 500
mm
0020095539
Air clamp (stainless steel) for 160/225 mm
diameter
0020095540
45° elbow (stainless steel) for external wall
laying, concentric, 160/225 mm diameter
0020095544
Fastening clamp, 160 mm diameter 0020151162
4.3 Certified air/flue gas systems and
components, 200 mm diameter
Components Art. no.
Unit connection (PP) with measurement opening,
200 mm diameter
0020095532
Basic set for shaft installation (PP), 200 mm
diameter
0020095534
End pipe (stainless steel), 0.5 m, 200 mm dia-
meter
0020095538
Installation aid with line loop, 200 mm diameter 0020095542
Extension (PP), 0.5 m, 200 mm diameter 0020095549
Extension (PP), 1.0 m, 200 mm diameter 0020095550
Extension (PP), 2.0 m, 200 mm diameter 0020095551
87° elbow (PP), 200 mm diameter 0020095553
87° elbow (PP) with inspection opening, 200 mm
diameter
0020095555
45° elbow (PP), 200 mm diameter 0020095557
30° elbow (PP), 200 mm diameter 0020095559
Inspection element (PP), 0.5 m, 200 mm dia-
meter
0020095562

5 System conditions
12 Installation manual Air/flue gas system 0020058722_04
Components Art. no.
Spacer (stainless steel), 1 pc, 200 mm diameter
Note:
The spacer is bent in its film packaging. In the
as-delivered condition, the struts are straight.
The spacers must be put back into their round
shape before the installation.
0020095564
Spacer (stainless steel), 4 pcs, 200 mm diameter 0020095566
Spacer (stainless steel), 10 pcs, 200 mm dia-
meter
0020106436
External wall connection (stainless steel),
200/300 mm diameter, elbow, support console,
external collar
0020095574
External wall pipe bracket (stainless steel),
300 mm diameter
0020095576
Extension (stainless steel) for external wall lay-
ing, 0.5 m, concentric, 200/300 mm diameter
0020095578
Extension (stainless steel) for external wall lay-
ing, 1.0 m, concentric, 200/300 mm diameter
0020095580
Vertical roof duct (stainless steel) for external
wall laying, concentric, 200/300 mm diameter
0020095582
Opening piece (stainless steel), 200/300 mm
diameter
0020095584
Tile for pitched roof for 200/300 mm diameter
system, dependent on the angle:
15° - 25°
25° - 35°
35° - 45°
0020095586
0020130602
0020130603
Flat roof penetration collar (stainless steel) for
200/300 mm diameter system
0020095588
Inspection element (stainless steel) 0.66 m,
200/300 mm diameter
0020095590
Support elbow mounting rail, long version, 500
mm
0020095539
Air clamp (stainless steel) for 200/300 mm dia-
meter
0020095536
45° elbow (stainless steel) for external wall
laying, concentric, 200/300 mm diameter
0020095548
Fastening clamp, 200 mm diameter 0020151163
4.4 Certified flue gas systems
The certification also documents that the flue gas systems
are suitable for use with the product in accordance with the
instructions that are valid up to 08/2012.
5 System conditions
5.1 Maximum pipe lengths
5.1.1 Notes on the illustrations and the tables
Total pipe length L = L1 + L2 ...+ L3 ...+ L4 (of which max.
10.0 m is in the cold area, exterior external wall system).
When installing diversions in addition to those specified in
the tables, the maximum total pipe length L is reduced as
follows:
–by 1 m for each 87° diversion in the flue gas line and air
pipe
–by 0.5 m for each 45° diversion in the flue gas line and
air pipe
Pipe diameter for air supply through the shaft or external
wall:
–Diameter of the 130 mm flue gas pipe: Minimum diameter
of the 130 m supply line
–Diameter of the 160 mm or 200 mm flue gas pipe: Min-
imum diameter of the 160 m supply line.
Maximum vertical height in the shaft if flue gas pipe is
130 mm in diameter: 30 m
Maximum shaft cross-section for 130 mm diameter flue gas
pipe in the shaft:
–Angular: 230 x 230 mm
–Round: 280 mm
For the combustion air guiding through the external wall, the
air intake port must not be in any wind pressure area other
than the flue gas opening.

System conditions 5
0020058722_04 Air/flue gas system Installation manual 13
5.1.2 Flue gas pipe in the shaft, combustion air from the installation room
L2
L3
min. 1m
L1
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System
Shaft cross-sec-
tion:
At least
Maximum total pipe length (L1 + L2 + L3)
130 mm
diameter
Round: DN + 60 mm
Angular: DN + 40
mm
33.0 m
plus 3 x 87° diversions and support elbow ‒
160 mm
diameter
50.0 m
plus 3 x 87° diversions and support elbow ‒
200 mm
diameter ‒50.0 m
plus 3 x 87° diversions and support elbows
The horizontal flue gas pipe must have a maximum length of 6 m, minus the three 87° diversions.
5.1.3 Flue gas pipe in the shaft, combustion air through the external wall
L2
L1
L3
L4

5 System conditions
14 Installation manual Air/flue gas system 0020058722_04
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System
Shaft cross-sec-
tion:
At least
Maximum total pipe length (L1 + L2 + L3 + L4)
130 mm
diameter
Round: DN + 60 mm
Angular: DN + 40
mm
40.0 m
plus 1 x diversion 87° and
support elbow
38.0 m
plus 1 x
diversion 87°
and support
elbow
‒
160 mm
diameter
50.0 m
plus 1 x diversion 87° and support elbow ‒
200 mm
diameter ‒50.0 m
plus 1 x diversion 87° and support elbow
The horizontal lines must have a maximum length of 12 m, minus the two 87° diversions, of
which 6 m is for the air pipe and max. 6 m is for the flue gas pipe.
5.1.4 Flue gas pipe in the shaft, combustion air from the shaft
L3
L
1
L
2
L
2
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System
Shaft cross-sec-
tion:
At least
Maximum total pipe length (L1 + L2 + L3)
130 mm
diameter
Round: DN + 60 mm
Angular: DN + 40
mm
35.0 m
27.0 m 17.0 m
‒
Round: DN + 80 mm
Angular: DN + 60
mm
35.0 m
30.0 m
Round: DN + 100
mm
Angular: DN + 80
mm
35.0 m

System conditions 5
0020058722_04 Air/flue gas system Installation manual 15
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System
Shaft cross-sec-
tion:
At least
Maximum total pipe length (L1 + L2 + L3)
130 mm
diameter
Round: DN + 120
mm
Angular: DN + 100
mm
35.0 m 35.0 m 35.0 m ‒
160 mm
diameter
Round: DN + 70 mm
Angular: DN + 40
mm
50 m 50 m
39.8 m
‒
Round: DN + 90 mm
Angular: DN + 60
mm
50 m
Round: DN + 120
mm
Angular: DN + 80
mm
Round: DN + 140
mm
Angular: DN + 100
mm
200 mm
diameter
Round: DN + 70 mm
Angular: DN + 40
mm
‒50 m
38.6 m 26,3
Round: DN + 90 mm
Angular: DN + 60
mm
50 m 50 m
Round: DN + 120
mm
Angular: DN + 80
mm
Round: DN + 140
mm
Angular: DN + 100
mm
–plus 1 x diversion 87° and support elbow
–The horizontal lines must have a maximum length of 12 m, minus the 87° diversion, of which
max. 6 m is for the air pipe and max. 6 m is for the flue gas pipe.

5 System conditions
16 Installation manual Air/flue gas system 0020058722_04
5.1.5 Flue gas pipe through the roof, combustion
air from the installation room
min. 1m
L2
L
1
L3
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System Maximum total pipe length (L1 + L2 + L3)
130 mm
diameter ‒
160 mm
diameter
25.0 m
plus 3 diversions 87° ‒
200 mm
diameter
‒25.0 m
plus 3 diversions 87°
The horizontal flue gas pipe must have a max-
imum length of 6 m, minus the three 87° diver-
sions.
5.1.6 Flue gas pipe through the roof, combustion
air through the external wall
min.
1m
L2
L
1
L3
L4
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System Maximum total pipe length
(L1 + L2 + L3+ L4)
130 mm
diameter ‒
160 mm
diameter
25.0 m
plus 2 diversions 87° ‒
200 mm
diameter
‒25.0 m
plus 2 diversions 87°
The horizontal lines must have a maximum length
of 12 m, minus the two 87° diversions, of which
6 m is for the air pipe and max. 6 m is for the flue
gas pipe.

System conditions 5
0020058722_04 Air/flue gas system Installation manual 17
5.1.7 Flue gas pipe on the external wall,
combustion air from the installation room
L3
L1
L2
min. 1m
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System Maximum total pipe length (L1 + L2 + L3)
130 mm
diameter ‒
160 mm
diameter
50.0 m
plus 1 x diversion 87°
plus support elbow
‒
200 mm
diameter
‒50.0 m
plus 1 x diversion 87°
plus support elbow
The horizontal flue gas pipe must have a max-
imum length of 10 m, minus the 87° diversion.
5.1.8 Flue gas pipe on the external wall,
combustion air through the external wall
L4
L1
L
2
L3
min. 1m
ecoCRAFT VKK../3-E-HL
806 1206 1606 2006 2406 2806
System Maximum total pipe length
(L1 + L2 + L3 + L4)
130 mm
diameter ‒
160 mm
diameter
50.0 m
plus 1 x diversion 87°
plus support elbow
‒
200 mm
diameter ‒
50.0 m
plus 1 x diversion 87°
plus support elbow
The horizontal lines must have a maximum length
of 20 m, minus the 87° diversion, of which max.
10 m is for the air pipe and max. 10 m is for the
flue gas pipe.
5.2 General installation instructions
5.2.1 Technical properties of the air/flue gas
systems from Vaillant for calorific value
products
The air/flue gas systems from Vaillant demonstrate the fol-
lowing performance features:
Technical feature Description
Temperature resistance Adapted to the maximum
flue gas temperature of the
product.

6 Installing the 130 mm diameter system
18 Installation manual Air/flue gas system 0020058722_04
Technical feature Description
Leaks Adapted to the product for use
in buildings and outdoors
Condensate resistance For gas and oil fuels
Corrosion resistance Adapted to the gas and oil
condensing boiler
Clearance from combustible
materials
Not necessary
Installation location In accordance with the install-
ation instructions
Resistance to fire Normal level of flame resist-
ance (in accordance with EN
13501-1 Class E)
Fire resistance time None:
The external pipes of the
concentric system are not
flammable. A required fire
resistance time is provided by
shafts within the building.
5.2.2 Requirements for the shaft for the flue pipe
Flue pipes from Vaillant do not have any fire resistance (dir-
ection of operation from the outside to the inside).
If the flue pipe is guided through parts of a building that re-
quire a level of fire resistance, a shaft must be fitted. The
shaft must ensure the fire resistance (direction of operation
from the outside to the inside) that is required for the building
parts through which the flue gas installation is guided. The
required fire resistance must demonstrate a suitable classi-
fication (brick partition and heat insulation) and be sufficient
for the building's requirements.
Observe the national ordinances, regulations and standards.
An existing chimney that was used for the flue gas guiding
usually meets these requirements and can be used as a
shaft for the flue pipe.
The gas tightness of the shaft must comply with the test
pressure class N2 in accordance with EN 1443. An exist-
ing chimney that was used for the flue gas guiding usually
meets these requirements and can be used as a shaft for the
air guiding.
If the shaft is used to supply combustion air, this must be
designed and, in particular, insulated in such a way that no
moisture (caused by the cooling of the shaft by cold combus-
tion air penetrating from the outside) can penetrate the ex-
terior of the shaft. An existing chimney that was used for the
flue gas guiding usually meets these requirements and can
be used as a shaft for the supply of combustion air without
the need for additional heat insulation.
5.2.3 Route of the flue pipe in buildings
The route of the flue pipe should correspond to the shortest
and the most direct distance between the product and the
flue gas installation opening, and it should run as straight as
possible.
▶Do not arrange several diversions immediately after each
other.
As a result of standards relating to the hygiene of drinking
water, water pipes must be protected against impermissible
heating.
▶Lay the flue pipe separately from the drinking water
pipes.
It must be possible to check and, if required, clean the entire
length of the flue gas route.
It must be possible to remove the flue pipe again with a min-
imal amount of effort (no time-consuming mortising work in
the living area, but screwed-in cladding instead). If they are
arranged in shafts, they are usually easy to remove.
5.2.4 Location of the opening
The location of the flue gas installation opening must comply
with the relevant applicable international, national and/or
local regulations.
▶Align the opening of the flue gas installation in such a
way that ensures a secure outward flow and distribution
of the flue gases and prevents these gases from re-en-
tering the building through openings (windows, air intake
openings and balconies).
5.2.5 Disposing of condensate
Local regulations may stipulate the minimum quality of any
condensate that may enter the public waste-water system. If
required, a condensate neutraliser must be used.
▶When disposing of the condensate into the public waste-
water system, observe the local regulations.
▶Only use corrosion-resistant piping material for removing
condensate.
6 Installing the 130 mm diameter
system
To install the 130 mm diameter shaft system, the flue gas
pipe is installed in the shaft first. The flue gas connection and
the horizontal flue gas pipe are then installed and, finally, the
combustion air line is installed.
6.1 Installation instructions
▶For inspection purposes, install at least one inspection T-
piece in the flue gas pipe in the boiler installation room.
▶You must not immure the flue pipe.
▶Use the safety pipe contained in the scope of delivery for
the shaft opening.
The shaft dimensions for installing the basic set must be at
least:
–170 mm x 170 mm
–190 mm diameter

Installing the 130 mm diameter system 6
0020058722_04 Air/flue gas system Installation manual 19
6.2 Installing the basic set for shaft installation
6.2.1 Basic set for the shaft installation, article
number 0020042762
500
Ø130
220
220
250
300
250
180
207
Ø125
1
4
5
2
3
8
7
6
1 Shaft cover for PP, 130
mm (1 pc)
2 Spacer for PP, 130 mm (7
pcs)
3 Safety pipe for shaft open-
ing, DN 180, 300 mm
(1 pc)
4 Support elbow (PP) 130,
87° incl. mounting rail (1
pc)
5 Sealing tape
6 Flue pipe, aluminium (no
sleeve), 500 mm long
(1 pc)
7 Ventilation grille (1 pc)
8 Wall collar for PP 130
(1 pc)
6.2.2 Preparing the installation
1. Determine the installation site of the flue gas guiding in
the shaft.
2. Drill a sufficiently large opening to allow enough space
for installation.
3. Drill a hole in the rear side of the shaft.
–Diameter: 10 mm
6.2.3 Installing the support elbow and inserting
the flue pipes in the shaft
002.nim
1
2
3
4
5
1. Mortise a sufficiently large opening at the installation
site to allow enough space for installation.
2. Insert the support elbow with the mounting rail (5) so
that the flue pipe is positioned in the centre of the shaft.
3. Slide the spacer (3) onto the flue pipe.
–Distance between the spacers: ≤2 m
4. Use a line (2) to lower the first flue pipe (4) down far
enough until you can insert the next flue pipe (1).
–The sleeve side of the flue pipe must always point
upwards.
5. Continue joining the pipes together until you can insert
the lowest pipe into the support elbow.
6. If the flue gas pipe cannot be inspected from the shaft
opening, install an inspection T-piece in a suitable posi-
tion (article number 0020042764).
Conditions: Diversions required in the shaft
▶Install a 15° or 30° elbow (article number 0020042768
and 0020042767).
7. After every diversion, install an inspection T-piece as
close as possible to the diversion.

6 Installing the 130 mm diameter system
20 Installation manual Air/flue gas system 0020058722_04
6.2.4 Installing the shaft extension
1
2
3
4
min. 100 mm
min. 300 mm
1. Install the 130 mm diameter aluminium flue pipe (4) that
is included in the scope of delivery.
2. Remove the line from the shaft.
3. Slide the shaft extension (3) over the aluminium pipe
(4) and secure it to the shaft side using rawl plugs and
bolts.
4. Secure the top cover with rear ventilation (1) to the alu-
minium pipe using the safety line (2) that is included.
5. Lock the top cover into the shaft extension (3).
6.2.5 Installing the shaft connection
1
4
3
2
1. Insert the 500 mm flue pipe (2) into the support elbow.
2. Shorten the DN 180 safety pipe for the shaft opening
(1) to the shaft wall thickness.
3. Push the safety pipe over the flue pipe in the shaft until
it ends flush with the shaft's external wall.
4. Secure the safety pipe with mortar and leave it to
harden.
5. Fit the wall collar (4) that is contained within the scope
of delivery over the flue pipe. Only secure the wall collar
to the shaft after completing the installation work.
6. Create an opening at the foot of the shaft for rear ventil-
ation of the shaft.
Conditions: Rear ventilation of the shaft required
–Dimensions: 150 x 150 mm
7. Secure the ventilation grille (3).
8. Secure the pipe wall collar.
6.3 Flue gas connection and installing the
horizontal flue gas pipe
6.3.1 Scope of delivery article number
0020060589
1 Transition piece, 130 mm
diameter
2 Elbow 87°
3 Extension with measure-
ment opening