Viessmann Vitocaldens 222-F User manual

Installation instructions
for contractors
VIESMANN
Flue system
for condensing boilers
Flue system
5780 223 GB 5/2016 Dispose after installation.

2
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
intended for authorised contractors.
■ Work on gas installations must only
be carried out by a registered gas fit-
ter.
■ Work on electrical equipment must
only be carried out by a qualified
electrician.
Regulations to be observed
■ National installation regulations
■ Statutory regulations for the preven-
tion of accidents
■ Statutory regulations for environmen-
tal protection
■ Codes of practice of the relevant
trade associations
■ All current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW-TR Gas,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
Working on the system
■ Isolate the system from the power
supply (e.g. by removing the sepa-
rate fuse or by means of a mains iso-
lator) and check that it is no longer
'live'.
■ Safeguard the system against recon-
nection.
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
Safety instructions
5780 223 GB

3
Installation sequence
General installation information............................................................................ 4
■ Design............................................................................................................... 4
■ Flue gas temperature protection....................................................................... 4
■ Installation information...................................................................................... 4
■ Required tools/equipment................................................................................. 5
■ Fitting the balanced flue slide coupling............................................................. 6
■ Tightness test.................................................................................................... 7
■ Certification of the balanced flue system.......................................................... 7
■ System certification........................................................................................... 8
Installations requirements.................................................................................... 9
■ Statutory requirements...................................................................................... 9
■ Gas safety (installation and use) regulations (current issue)............................ 9
■ Boiler position................................................................................................... 10
Routing through a shaft........................................................................................ 15
■ Installation information...................................................................................... 15
■ Rigid flue........................................................................................................... 16
■ Flexible flue....................................................................................................... 26
Installation in a disused chimney.......................................................................... 36
■ Installation requirements................................................................................... 36
■ Installation......................................................................................................... 38
Vertical outlet for pitched or flat roofs................................................................... 41
■ Maximum flue length......................................................................................... 42
■ Installation......................................................................................................... 44
External wall connection....................................................................................... 47
■ Installation......................................................................................................... 49
Routing over an external wall............................................................................... 51
■ Maximum flue length......................................................................................... 52
■ Installation......................................................................................................... 52
Plume kit............................................................................................................... 54
■ Routing options................................................................................................. 54
Index
5780 223 GB

4
Design
Prior to installation, check that the max-
imum possible pipe length will not be
exceeded.
Max. possible pipe lengths in relation to
the boiler used:
Flue systems technical guide
Flue gas temperature protection
The flue pipes are approved for flue
gas temperatures up to 120 °C.
With Viessmann condensing boilers,
internal safeguards ensure that the
maximum permissible flue gas temper-
ature is not exceeded.
Installation information
■ The component overviews for the dif-
ferent types of routing also apply to
floorstanding condensing boilers.
■ Keep flue gas routes short and with
the fewest number of bends possible.
■ Route horizontal connection pipes
with a fall of ≥ 3° (approx. 50 mm/m)
towards the boiler.
■ Support horizontal connection pipes
at intervals of approx. 1 m.
■ To avoid damage and leaks, isolate
the flue system from sources of vibra-
tion (e.g. ventilation systems).
■ Check the gaskets in all female con-
nections are correctly seated.
■ Prior to installation, lubricate all gas-
kets with the lubricating paste provi-
ded.
■ Only use the special gaskets sup-
plied with the boiler.
■ Female plug-in connections in the
flue gas path must always point in the
direction of flow.
■ Only use the components supplied
with the Viessmann flue system.
■ Push the pipes into each other with a
slight twist.
■ Balanced flue pipes can be trimmed
in their assembled state.
Do not carry out commissioning until
the following conditions are met:
■ Free passage through the flue gas
pipes.
■ Flue system with positive pressure is
gas-tight.
■ Apertures for ensuring sufficient com-
bustion air supply are open and can-
not be closed off.
■ Applicable regulations on installing
and commissioning flue systems
have been followed.
General installation information
5780 223 GB

5
Danger
Leaking or blocked flue systems
or an insufficient supply of com-
bustion air cause life threatening
poisoning due to carbon monox-
ide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able
to be closed off.
Required tools/equipment
■ Rope for lowering the flue system
into a shaft (length: chimney height
plus 3 m)
■ Saw and file for trimming and cham-
fering the pipe sections
■ Power drill for securing the shaft
cover and the support rail
General installation information (cont.)
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6
Fitting the balanced flue slide coupling
Note
The slide coupling enables a gap of
approx. 45 mm to be covered. Prior to
installation, compensate for surplus or
insufficient length on the incoming pipe.
1.
120
4.
3.
5.
6.
2.
1. Push the pipe section into the
female connection of the incoming
balanced flue component.
2. Shorten the ongoing balanced flue
pipe to create a gap of 120 mm
between the pipe section and the
balanced flue pipe.
3. Push the slide coupling onto the
ongoing flue pipe.
4. Open the collar and push it over the
ongoing balanced flue pipe.
5. Pull the slide coupling out and push
it onto the incoming flue pipe.
6. Align the collar and close the toggle
fasteners.
General installation information (cont.)
5780 223 GB

7
Tightness test
After installation, flue systems routed
through a shaft must be tested for tight-
ness by the flue gas inspector [check
local regulations].
■ Pressurised flues which are routed
inside buildings and which are not
surrounded by combustion air
(open flue) must be pressure-tested.
For the pressure test, a leak detector
is used to pump air into the flue,
which has been sealed at the top and
bottom, until a pressure of 200 Pa
has built. This pressure is maintained
while the volume of air leaking out is
established.
A leakage rate of up to
0.006 l/(s x m2), relative to the inter-
nal surface area, is permitted for
classifying a flue as sufficiently gas-
tight.
■ In pressurised flues that are surroun-
ded by combustion air (room sealed),
the tightness can be checked by test-
ing the O2 content in the combustion
air (annular gap test).
The flue is considered sufficiently
gas-tight if the O2 content in the com-
bustion air does not deviate from the
reference value by more than the fol-
lowing values. The reference value is
established following the self-adjust-
ment of the test meter:
– For flues with general Building
Regulations approval 0.4 % by vol.
– For other flues 0.2 % by vol.
Note
Observe country-specific regulations.
Certification of the balanced flue system
The balanced flue system is CE desig-
nated and approved in accordance with
EN 14471 (see flue systems technical
guide).
General installation information (cont.)
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8
System certification
System certification to EC Gas Applian-
ces Directive EU/2009/142/EC in con-
junction with PPs flues offered by
Skoberne.
Vitocaldens 222-F CE-0085CO0306
Vitocrossal 200, type CM2 CE-0085BQ0021
Vitocrossal 300, type CU3 CE-0085BN0570
Vitocrossal 300, type CM3 CE-0085BN0569
Vitocrossal 300, type CT3B, CT3U CE-0085AQ0257
Vitodens 050-T CE-0085CQ0290
Vitodens 050-W CE-0085CP0029
Vitodens 100-E CE-0085BT0029
Vitodens 100-W, 111-W CE-0085BT0029, CE-0063CQ3356
Vitodens 111-F CE-0085CN0050
Vitodens 200-W CE-0085BR0432, CE-0085CN0050
Vitodens 222-F CE-0085BU0051, CE-0085CN0050
Vitodens 222-W CE-0085BR0432, CE-0085CN0050
Vitodens 242-F CE-0085BU0051, CE-0085CN0050
Vitodens 300-W CE-0085BR0433, CE-0085CM0463
Vitodens 333-F CE-0085BU0052, CE-0085CM0463
Vitodens 343-F CE-0085BU0052, CE-0085CM0463
Vitoladens 300-C CE-0035BS104, CE-0035CO106
Vitoladens 300-T CE-0035BO107
Vitoladens 300-W CE-0035BM112, CE-0035CO107
Vitoladens 333-F CE-0035BM112, CE-0035CO107
Vitorondens 200-T CE-0035CL102
Vitorondens 222-F CE-0035CL102
Vitosolar 200-F CE-0085CM0184
Vitosolar 300-F CE-0035CO107
Vitosorp 200-F CE-0085CO0146
Vitotwin 300-W CE-0085CM0150
Vitovalor 300-P CE-0085CP0028
Note
Affix the "System certification" and
"Flue system ..." labels clearly visible
near the flue system or on the boiler.
The labels are supplied with the techni-
cal documentation.
General installation information (cont.)
5780 223 GB

9
Statutory requirements
The appliance is suitable only for instal-
lation 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 elec-
trical installation.
It should also be in accordance with the
relevant recommendations in the cur-
rent 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 Build-
ing Compliance Certificate (for England
and Wales) or a Declaration of Safety
(Scotland, Northern Island, Isle of Man
or appliances out of the scope of Build-
ing Regulations) to the homeowner,
which will confirm that the work has
been carried out by a competent Gas
Safe Registered Installer. This docu-
ment 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 statu-
tory obligations.
Installations requirements
5780 223 GB

10
Boiler position
The following limitations must be
observed when siting the boiler:
■ 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 appli-
ance and for air circulation around it.
■ 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.
■ Due consideration should be given to
the routing of the condensate drain
from the chosen position.
■ 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 Insti-
tute of Gas Engineers.
■ If the appliance is to be installed in a
room containing a bath or shower,
any electrical switch or control utilis-
ing mains electricity must be so situ-
ated that it cannot be touched by a
person using the bath or shower.
Attention is drawn to the require-
ments of BS 7671 (the current I.E.E
Wiring Regulations) and in Scotland
the electrical provisions of the Build-
ing Regulations applicable in Scot-
land.
■ A compartment used to enclose the
appliance must be designed and con-
structed 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.
■ Where installation will be in an
unusual location, special procedures
may be necessary. BS 6798 gives
detailed guidance on this aspect.
Installations requirements (cont.)
5780 223 GB