Viessmann Flue gas system User 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: [email protected]

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
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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
nThe component overviews for the types
of routing also apply to the Vitocrossal
300 and the Vitoladens 300-T.
nKeep flue paths as short as possible with
the fewest number of bends possible.
nCheck the gaskets in all female
connections.
nUse only the special gaskets supplied
with the boiler.
Required tools/equipment
nRope for lowering the flue gas system
into a duct (length: chimney height plus 3
metres).
nSaw and file for trimming and chamfering
the pipe sections.
nPower drill for securing the duct cover and
the support rail.
nPlug-in fem. connections in the flue must
always point in the flow direction.
nOnly use the components supplied with
the PP flue gas system.
nTwist the pipes slightly whilst pushing
them in.
nInner and outer pipe can be trimmed to
the same length.
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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.
nPressurised 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
m2), relative to the internal surface area,
is considered as indication that the flue is
sound.
nIn pressurised flue gas systems that are
surrounded by combustion air (balance
flue), the soundness can be checked by
testing the O2content in the combustion
air (annular gap test).
The flue is reckoned to be sufficiently
sound if the O2content in the combustion
air deviates by no more than the following
values from the reference value. The
reference value results after the self-
adjustment 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
nBalanced flue roof outlet (C33x)
nBalanced flue external wall terminal (C13x)
nRouting over external walls (C53x)
nSeparate 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 CO2concentration in
the combustion air at the annular gap of the
balanced flue pipe. The flue pipe is deemed
to be sound if the CO2concentration in the
combustion air is no higher than 0.2% or
the O2concentration is at least 20.6%.
If higher CO2or lower O2values are
measured, check the flue system for
soundness.
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General installation instructions (cont.)
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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.
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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:
nThe 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.
nThe 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.
nDue consideration should be given to the
routing of the condensate drain from the
chosen position.
nIf 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.
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Flue terminal position
nIf 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.
nA 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.
nWhere 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
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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
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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
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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.
nIt is important that the position
of the terminal allows free
passage of air across it at all
times.
nIt 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.
nThe minimum acceptable dimensions
from the terminal to obstruction and
ventilation openings are specified above
(BS 5440 Part 1).
nIf 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.
nWhere 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.
nWhere 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.
nThe air inlet / flue outlet duct must not
be closer that 25 mm to combustible
material.
nDue 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.
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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
Minimum distance to car
parking space

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.
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Routing through a duct (cont.)
Rigid flue
Balanced flue operation
1Boiler flue connection
2Standard duct pack
Comprising:
n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)
3Flue Pipe
2 m long
1 m long
0.5 m long
Flue bend (for use in corbelled chimneys)
30° or 15°
4Inspection piece, straight
5Balanced flue inspection piece, straight
6Balanced flue wall bezel
7Balanced flue pipe
1 m long
0.5 m long
8Balanced flue bend
87° or 2 x 45°
or
Balanced flue inspection tee
or
Balanced flue inspection bend
9Balanced flue sliding coupling
Fixing clamp
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ACombustion air
BFlue gas
CInspection
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
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1Boiler flue connection
2Standard duct pack
Comprising:
n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)
3Flue Pipe
2 m long
1 m long
0.5 m long
Flue bend (for use in corbelled chimneys)
30° or 15°
4Inspection piece, straight
5Balanced flue bend
87° or 2 x 45°
or
Balanced flue inspection tee
87°
6Ventilation bezel
ASecondary ventilation
BFlue gas
CInspection aperture
DVentilation aperture
ECombustion 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 m3per kW
rated output
n Apertures in connection doors min.
150 cm2
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Routing through a duct (cont.)
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ACombustion air
BFlue gas
CSecondary ventilation
DRoom interconnection aperture
EInspection aperture
1Boiler flue connection
2Standard duct pack
Comprising:
n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)
3Flue Pipe
2 m long
1 m long
0.5 m long
Flue bend (for use in corbelled chimneys)
30° or 15°
4Inspection piece, straight
5Balanced flue inspection piece, straight
6Balanced flue room interconnection bezel
7Balanced flue pipe
1 m long
0.5 m long
8Balanced 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 ø12 mm hole centrally into the
rear duct wall to secure support rail 1.
2. Insert support rail 1into the drilled hole,
and secure with screws or mortar on the
front duct wall.
3. Position support bend 2and secure with
the pin in a hole in the support rail.
4. Secure installation rope 3externally on
the lowest vertical pipe section.
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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 9terminate
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
7as possible.
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Routing through a duct (cont.)
11. Push on weather collar 7and secure
safety rope 8on 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.
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Routing through a duct (cont.)
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Flexible flue
Balanced flue operation
ACombustion air
BFlue gas
CInspection aperture
1Boiler flue connection
2Standard duct pack
Comprising:
n Support bend
n Support rail
n Duct cover
n Spacers (3 pce.)
3Inspection piece, straight (for installation
into the flexible flue (optional))
4Flexible flue
5Connecting pipe
for the connection of residual length of the
flexible flue
Pipe lowering attachment with 20m rope
6Balanced flue inspection piece, straight
7Wall bezel
8Balanced flue pipe
1 m long
0.5 m long
9Balanced 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 1and retaining ring
2from the adaptor (from the standard
duct set).
2. Push union ring 1onto flexible flue 3.
3. Place retaining ring 2into the second
groove of flexible flue 3.
4. Fit union ring 1to pipe lowering
attachment 4and fit the rope.
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