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

Installation manual flue pipe for ecoCRAFT 0020058722_036
The following describes the four possibilities for flue
pipes:
- flue pipes for room sealed operation, combustion air
from the duct
- flue pipes for room sealed operation, combustion air
through the external wall
- flue pipes for room sealed operation, combustion air
and flue gas dispersal above the roof
- flue pipes for room sealed operation, combustion air
through the external wall, flue gas pipe on the facade
aCaution!
Observe the maximum pipe lengths given in the
individual sections. Pipe lengths which are too
long will lead to operational malfunction of the
condensing boiler.
Caution!
Note whether an increased heat transmission
resistance of the exhaust gas pipe is required
by running through the cold section. Otherwise
it may cause the formation of ice in the ex-
haust pipe at low temperatures.
Caution!
The air supply must be installed in such a way
that no rainwater can enter the boiler. Rainwa-
ter ingress can cause a short-circuit of electri-
cal components and can cause corrosion in the
unit.
Caution!
Danger of fire!
Outside the ducting, the exhaust pipe must be
at least 5 cm away from combustible building
components. This does not apply to exhaust
gas pipes which permit less separation distance
in accordance with their classification.
Caution!
The distance between the flue terminal and the
roof must be at least 1 m, to avoid combustion
problems caused by wind pressure.
4.3 Air/flue pipe – room sealed, combustion air
from the shaft
L
1
L
2
L
3
min. 1 m
Fig. 4.1 Air / flue pipe – room sealed, combustion air from the
shaft
4 System - certified flue pipe - open flued

7Installation manual flue pipe for ecoCRAFT 0020058722_03
Appliance type Minimum
shaft cross-section
Maximum total pipe length (L1+ L2+ L3)
DN 130 DN 140 DN 150 DN 200
ecoCRAFT VKK GB 806/3-E-H round: DN+60 mm
square DN+40 mm 27.2 34.7 43.6 -
round: DN+80 mm
square: DN+60 mm 30.0 30.0 50.0 -
ecoCRAFT VKK GB 1206/3-E-H round: DN+60 mm
square DN+40 mm 10.0 12.4 15.0 -
round: DN+80 mm
square: DN+60 mm 24.0 30.0 44.6 -
round: DN+100 mm
square: DN+80 mm 30.0 30.0 50.0 -
ecoCRAFT VKK GB 1606/3-E-H round: DN+60 mm
square DN+40 mm 8.0 9.8 11.8 -
round: DN+80 mm
square: DN+60 mm 18.2 24.3 31.3 -
round: DN+100 mm
square: DN+80 mm 28.4 30.0 50.0 -
ecoCRAFT VKK GB 2006/3-E-H
round: DN+60 mm
square DN+40 mm - - - 14.1
round: DN+80 mm
square: DN+60 mm - - - 44.9
round: DN+100 mm
square: DN+80 mm - - - 50.0
ecoCRAFT VKK GB 2406/3-E-H
round: DN+60 mm
square DN+40 mm - - - 9.3
round: DN+80 mm
square: DN+60 mm - - - 28.1
round: DN+100 mm
square: DN+80 mm - - - 50.0
round: DN+120 mm
square: DN+100 mm - - - 50.0
ecoCRAFT VKK GB 2806/3-E-H
round: DN+60 mm
square DN+40 mm - - - 6.5
round: DN+80 mm
square: DN+60 mm - - - 19.3
round: DN+100 mm
square: DN+80 mm - - - 43.4
round: DN+120 mm
square: DN+100 mm - - - 50.0
Maximum length of horizontal pipes: each 4 m air pipe plus 2 x 87° elbows and 4 m flue gas pipe plus 2x 87° elbows
Minimum diameter of the air supply pipe 150 mm
Table 4.2 Maximum total pipe length
(combustion air from the shaft)
System - certified flue pipe - open flued 4

Installation manual flue pipe for ecoCRAFT 0020058722_038
4.4 Air/flue pipe – room sealed, combustion air
through the external wall
L
1
L
2
L
4
L
3
min. 1m
Fig. 4.2 Air / flue pipe –room sealed, combustion air through the
external wall
Appliance type Minimum shaft
cross-section
Maximum total pipe length (L1+ L2+ L3 + L4)
DN 130 DN 140 DN 150 DN 200
ecoCRAFT VKK GB 806/3-E-H round: DN+60 mm
square DN+40 mm 30.0 30.0 50.0 -
ecoCRAFT VKK GB 1206/3-E-H round: DN+60 mm
square DN+40 mm 30.0 30.0 50.0 -
ecoCRAFT VKK GB 1606/3-E-H round: DN+60 mm
square DN+40 mm 30.0 30.0 50.0 -
ecoCRAFT VKK GB 2006/3-E-H round: DN+60 mm
square DN+40 mm - - - 50.0
ecoCRAFT VKK GB 2406/3-E-H round: DN+60 mm
square DN+40 mm - - - 50.0
ecoCRAFT VKK GB 2806/3-E-H round: DN+60 mm
square DN+40 mm - - - 50.0
Maximum length of horizontal pipes: each 4 m air pipe plus 2 x 87° elbows and 4 m flue gas pipe plus 2 x 87° elbows
Minimum diameter of the air supply pipe 150 mm
Table 4.3 Maximum total pipe length
(combustion air through the external wall)
4 System - certified flue pipe - open flued

9Installation manual flue pipe for ecoCRAFT 0020058722_03
4.5 Air/flue pipe – room sealed, combustion air
and flue gas evacuation via the roof
L
1
L
4
L
2
L
5
L
3
min. 1m
Fig. 6.3 Air / flue pipe –room sealed, combustion air and flue
gas evacuation via the roof
Appliance type Maximum total pipe length (L1+ L2+ L3 + L4)
DN 130 DN 140 DN 150 DN 200
ecoCRAFT VKK GB 806/3-E-H 20.0 20.0 20.0 -
ecoCRAFT VKK GB 1206/3-E-H 20.0 20.0 20.0 -
ecoCRAFT VKK GB 1606/3-E-H 20.0 20.0 20.0 -
ecoCRAFT VKK GB 2006/3-E-H - - - 20.0
ecoCRAFT VKK GB 2406/3-E-H - - - 20.0
ecoCRAFT VKK GB 2806/3-E-H - - - 20.0
Maximum length of horizontal pipes: each 4 m air pipe plus 2 x 87° elbows and 4m flue gas pipe plus 2 x 87° elbows
The air supply pipe has at least the same diameter as the flue gas pipe
Minimum thermal resistance of the flue gas pipe in the cold section 0.4 m2K/W
Table 4.4 Maximum total pipe lengths
(combustion air and flue gas evacuation via the roof)
The distance between the air pipe opening and the sur-
face of the roof must be at least 0.5 m in order to avoid
functional problems caused by snow.
The opening of the exhaust gas pipe must be at least
0.5 m above the air pipe to avoid functional problems
caused by exhaust gas re-circulation.
System - certified flue pipe - open flued 4

Installation manual flue pipe for ecoCRAFT 0020058722_0310
4.6 Air/flue pipe – room sealed, combustion air
through the external wall, flue pipe on the
facade
L
1
L
4
L
2
L
3
min. 1 m
Fig. 6.47 Air/flue pipe – room sealed, combustion air through
the external wall, flue pipe on the facade
Appliance type Maximum total pipe length (L1+ L2+ L3 + L4)
DN 130 DN 140 DN 150 DN 200
ecoCRAFT VKK GB 806/3-E-H 30.0 30.0 30.0 -
ecoCRAFT VKK GB 1206/3-E-H 30.0 30.0 30.0 -
ecoCRAFT VKK GB 1606/3-E-H 30.0 30.0 30.0 -
ecoCRAFT VKK GB 2006/3-E-H - - - 30.0
ecoCRAFT VKK GB 2406/3-E-H - - - 30.0
ecoCRAFT VKK GB 2806/3-E-H - - - 30.0
Maximum length of horizontal pipes: each 4 m air pipe plus 2 x 87° elbows and 4m flue gas pipe plus 2 x 87° elbows
Minimum diameter of the air supply pipe 150 mm
Minimum thermal resistance of the flue gas pipe in the cold section 0.4 m2K/W
Table 4.5 Maximum total pipe lengths (combustion air through
the external wall, flue pipe on the facade)
4 System - certified flue pipe - open flued

11Installation manual flue pipe for ecoCRAFT 0020058722_03
5 Guarantee
Vaillant warranty
Vaillant provide a full parts and labour warranty for this
appliance.
The appliance must be installed by a suitably competent
person in accordance with the Gas Safety (Installation
and Use) Regulations 1998, and the manufacturer's in-
structions. In the UK 'CORGI' registered installers under-
take the work in compliance with safe and satisfactory
standards.
All unvented domestic hot water cylinders must be in-
stalled by a competent person to the prevailing building
regulations at the time of installation (G3).
Terms and conditions apply to the warranty, details of
which can be found on the warranty registration card in-
cluded with this appliance.
Failure to install and commission this appliance in com-
pliance with the manufacturer's instructions may invali-
date the warranty (this does not affect the customer's
statutory rights).
6 Disposal
Make sure that the flue pipe is handed over to a proper
disposal organisation.
hNote
Please observe the applicable national statuto-
ry regulations.
7 Customer service
Vaillant Service
To ensure regular servicing, it is strongly recommended
that arrangements are made for a Maintenance Agree-
ment. Please contact Vaillant Service Solutions
(0870 6060 777) for further details.
Guarantee 5
Disposal 6
Customer service 7

0020058722_03 GB 052009 - Subject to alterations