Vaillant Flue pipe User manual

For the heating engineer
Installation Manual
Flue pipe for ecoCRAFT
VKK GB 806/3-E-H
VKK GB 1206/3-E-H
VKK GB 1606/3-E-H
VKK GB 2006/3-E-H
VKK GB 2406/3-E-H
VKK GB 2806/3-E-H
GB
Modular gas condensing boiler

Installation manual flue pipe for ecoCRAFT 0020058722_032
Contents
Contents
1 Notes on the documentation.............................. 3
1.1 Lodging and storage of the documents..................3
1.2 Symbols used .................................................................3
1.3 Applicability of the manual.........................................3
2 Description of the appliance .............................. 3
2.1 CE label............................................................................3
2.2 Intended use...................................................................3
3 Safety instructions/regulations ........................ 3
3.1 Safety instructions .......................................................3
3.2 Regulations.....................................................................4
3.2.1 Regulations (Great Britain and Eire)........................4
4 Tested and approved air/
flue pipes - room-sealed....................................... 5
4.1 Description......................................................................5
4.2 Tested and approved air/flue pipes .........................5
4.3 Air/flue pipe – room sealed, combustion air
from the shaft................................................................6
4.4 Air/flue pipe – room sealed, combustion air
through the external wall .......................................... 8
4.5 Air/flue pipe – room sealed, combustion air
and flue gas evacuation via the roof .......................9
4.6 Air/flue pipe – room sealed, combustion air
through the external wall, flue pipe on
the facade ..................................................................... 10
5 Guarantee .............................................................11
6 Disposal.................................................................11
7 Customer service.................................................11

3Installation manual flue pipe for ecoCRAFT 0020058722_03
1 Notes on the documentation
The following information is intended to help you
throughout the entire documentation. Further docu-
ments apply in combination with this installation manu-
al.
We accept no liability for any damage caused by fail-
ure to observe these instructions.
Other applicable documents
For the heating engineer:
Installation instructions ecoCRAFT No. 0020055744
1.1 Lodging and storage of the documents
Pass this installation manual as well as any other appli-
cable documents and auxiliary material if necessary to
the system operator, who will store them so that the
manuals and auxiliary material are available when re-
quired.
1.2 Symbols used
Please observe the safety instructions in this installation
manual for the installation of the flue pipes!
dDanger!
Immediate risk of serious injury or death!
aCaution!
Potentially dangerous situation for the product
and environment.
hNote
Useful information and notes.
• Symbol for a necessary task
1.3 Applicability of the manual
This installation manual applies exclusively to the
Vaillant appliances listed in the other applicable docu-
ments.
2 Description of the appliance
2.1 CE label
The ecoCRAFT VKK GB 806/3-E-H, VKK GB 1206/3-E-H,
VKK GB 1606/3-E-H, VKK GB 2006/3-E-H,
VKK GB 2406/3-E-H and VKK GB 2806/3-E-H gas fired
condensing boilers have been certified in accordance
with the EU Gas Equipment Directive 90/396/EWG as
heating boiler systems with an associated flue gas in-
stallation and as a boiler of type C63.
2.2 Intended use
Vaillant gas-fired high efficiency boilers ecoCRAFT
VKK GB 806/3-E-H, VKK GB 1206/3-E-H, VKK GB
1606/3-E-H und VKK GB 2006/3-E-H,
VKK GB 2406/3-E-H and VKK GB 2806/3-E-H are con-
structed in accordance with state of the art technology
and recognised safety regulations.
The air/flue gas pipe is designed to remove exhaust gas
and to supply combustion air. In case of improper non-
conventional use of air and exhaust pipes in connection
with appliance types, damage can be caused to the
health and body of the user and others respectively
other devices or material assets can be affected.
The dimensioning of the air/flue gas pipes tested with
the respective high efficiency boiler must be carried out
by means of the tables in the following chapters.
Any other or additional use is considered to be improper
and will relieve the manufacturer or supplier of any re-
sponsibility or liability for damage that may result. In
such cases the risk is borne solely by the technician car-
rying out the work and the user. Intended use also in-
cludes the observance of the other applicable docu-
ments.
3 Safety instructions/regulations
3.1 Safety instructions
Before installing the flue pipes you must inform the
local gas supply company and the regional chimney
sweep.
dDanger!
Danger of poisoning from exhaust gas leakage if
installed incorrectly!
The flue gas system may only be installed by a
suitably qualified heating engineer. He will also
assume responsibility for proper installation.
Furthermore, the rules, regulations and guide-
lines mentioned in this installation manual are
to be observed.
Danger!
Risk to life from poisoning as a result of escap-
ing flue gases!
All openings in the flue pipe that can be opened
for inspection purposes must be closed before
start-up and during operation. The openings
may only be opened by a technician.
Danger!
Danger of suffocation!
The room in which the appliance is situated
shall be designed and the appliance installed
within it as specified in BS 6644.
Notes on the documentation 1
Description of the appliance 2
Safety instructions/regulations 3

Installation manual flue pipe for ecoCRAFT 0020058722_034
aCaution!
Risk of corrosion in the flue gas installation!
The combustion air fed to the unit must be free
of chemicals which contain, e.g. fluorine, chlo-
rine or sulphur. Sprays, release or cleaning
agents, paints and adhesives can contain such
materials which can, in certain circumstances,
lead to corrosion when operating the unit, in-
cluding the exhaust gas installation. The ex-
haust ducting may only be installed using the
corresponding parts from Vaillant.
Caution!
Electronic damage and danger of fire by
lightning strike!
If the building is equipped with a lightning con-
ductor system, the flue pipes must be incorpo-
rated in the lightning protection system. The
vertical ducting must be incorporated in the po-
tential balancing system if it contains metallic
components.
Caution!
Malfunction of the unit by obstruction of the
flue gas flow!
Make sure that, during the installation process,
no swarf, mortar remnants etc. are left in the
flue pipes.
Caution!
Malfunctions and water condensate escape as a
result of leaks in the exhaust gas route!
The gaskets are sensitive to mineral oil based
greases. They must therefore not be greased.
Only use water to facilitate the assembly, if re-
quired.
Caution!
Danger of fire!
Outside the ducting, the exhaust pipe must be
at least 5 cm away from combustible building
components.
3.2 Regulations
For installation of the appliance laws, regulations, tech-
nical rules and standards must be considered and ad-
hered to ensure the safe installation of your appliance.
3.2.1 Regulations (Great Britain and Eire)
Attention shall be made to the regulations, guidelines
and standards in force. In particular reference shall be
given to the following regulations, guidelines, standards
and rules:
- The electrical connections to the boiler MUST be in ac-
cordance with the I.E.E Wiring Regulations, and tested
accordingly.
- The Clean Air Act 1993 and the 3rd Edition of the 1956
Clean Air Act.
- The Building Regulations England and Wales,
The Building Standards Scotland and any require-
ments determined by the local authorities within.
- Water supply (water fittings) regulations 1999
Detailed recommendations are also contained in the fol-
lowing documents:
BS 5854 Code of practice for flues and flue structures
in buildings.
BS EN 12828 Design for water-based heating systems.
BS 6644 Specification for Installation of gas-fired hot
water boilers of rated inputs between 70 kW (net) and
1.8 MW (net) (2nd and 3rd familygases).
BS 6880 Code of practice for low temperature heating
systems of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS 6981 Installation of low pressure gas pipework of up
to 28 mm in domestic premises.
BS 7074 Application selection and installation of ex-
pansion vessels and ancillary equipment for sealed
water systems.
Part 1 Code of practice for domestic heating and hot
water.
Part 2 Code of practice for low and medium tempera-
ture hot water systems.
BS 6700 Specification for design, installation, testing
and maintenance of services supplying water for domes-
tic use within buildings and their curtilages.
Institute of Gas Engineers Publications
IGE/UP/1 Soundness testing and purging of industrial
and commercial gas installations.
IGE/UP/1A Soundness testing and purging of small low
pressure industrial and commercial natural gas installa-
tions.
IGE/UP/10 Installation of gas appliances in industrial
and commercial premises.
Part 1 Flued appliances
3 Safety instructions/regulations

5Installation manual flue pipe for ecoCRAFT 0020058722_03
4 Tested and approved air/flue
pipes - room-sealed
This chapter describes the peripheral conditions under
which the ecoCRAFT condensing gas boilers can be fit-
ted to flue pipes supplied by the manufacturers shown
in Table 4.1.
4.1 Description
- with flue pipes checked and approved for the gas con-
densing boiler
- room-sealed operation
4.2 Tested and approved air/flue pipes
The exhaust gas systems used must be clearly and un-
ambiguously identifiable and must be in agreement with
one of the certificate numbers given in Table 4.1.
The layout and installation of the flue pipes must be in
accordance with the specification and installation manu-
als provided by the manufacturer of the exhaust gas
system. When the exhaust gas system is completely in-
stalled it must be marked with the prescribed identifica-
tion plate.
Flue pipes tested and approved for ecoCRAFT appli-
ances (GB)
Manufacturer Material Product
designation Certificate number Address
GB
DW - Alkon 0432 - BPR - 119938/2004
Schiedel Rite
Vent Ltd
Stainless
steel Prima Plus
- EN 1856-2 T200 P1 W V2
L50060 O200
- TUV 0036 CPD 9195 018
Schiedel Rite Vent Ltd
Crowther Estate, Washington, Tyne & Wear NE 38 0AQ
Tel.: [phone]
www.schiedel.co.uk
Table 4.1 Manufacturers of air/flue pipes (GB)
System-certified flue pipe - open flued 4