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
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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
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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.)
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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.)
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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
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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.)
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Flue terminal position
Horizontal flue system
a
g
f
h,i
d,n
j
b,c
km
e
g
a
f
f
k
b,c
k
ll
g
c
k
Position Minimum spacing
mm
a Directly below an opening window, air vent or
any other ventilation opening
300
b Below a gutter drain or soil pipe 75
c Below eaves 200
d Below a balcony 200
e From vertical drain or soil pipes 150
f From internal and external corners 300
g Above adjacent ground or balcony level/roof 300
h From a surface facing the terminal 600
i Facing terminals 1200
j From opening door/window 1200
k Vertically from a terminal on same wall 1500
l Horizontally from a terminal on same wall 300
m Adjacent to opening 300
n Below carport/roof not recommended
Installations requirements (cont.)
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Vertical flue systems
q
o
o
r
p
s
t
u
t
Position Minimum spacing
mm
o From adjacent wall 300
p From adjacent opening window 1000
q From another terminal 600
r Minimum height 300
s Minimum distance measured perpendicular to
roof covering
400
t Beside or above an opening rooflight 600
u Below an opening rooflight 2000
Installations requirements (cont.)
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Minimum distance from terminal
2.5 m
A
ABoundary
Not under a car port
Installations requirements (cont.)
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2.1 m
B
Avoid access routes and patios
BWalkway or patio
2.5 m
C
Minimum distance to car parking space
CCar space
Installations requirements (cont.)
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Installation information
Prior to installation, the local flue gas
inspector should check that the shaft to
be used is suitable and permissible
[where applicable].
Shafts that were previously connected
to oil or solid fuel boilers must be thor-
oughly cleaned by a chimney sweep.
Loose deposits comprising sulphur and
soot must not remain on the inside of
the chimney. Running a balanced flue
pipe through the shaft is then not
required. If thorough cleaning is impos-
sible, if chloride deposits are present or
if the shaft is silted up, a separate bal-
anced flue pipe must be used inside the
shaft. Alternatively, separate (on site)
routing for the ventilation air and the
flue gas may be used.
In the installation room, at least one
inspection port must be provided in the
flue system for inspection, cleaning and
for testing the pressure (if required). If
the flue is not accessible from the roof,
a second inspection port must be provi-
ded behind the chimney cleaning hatch
in the attic.
Provide an inspection port at the base
of the shaft for inspecting the secon-
dary ventilation. Safeguard condensate
drainage from the flue to the boiler with
a fall of at least 3° (approx. 50 mm/m).
The flue system must protrude above
the roof line. Observe 400 mm protru-
sion from the roof parallel to the roof
slope according to FeuVo [or local reg-
ulations].
Routing through a shaft
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Rigid flue
Room sealed operation
B5
2
A
3
2
3
2
4
3
2
2
6798 71
A
C
B
C
ASupply air
BFlue gas
CInspection port
1Boiler flue connection
2Standard shaft pack
Comprising:
■ Support bend
■ Support rail
■ Shaft cover
■ Spacers (5 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 slide coupling
Fixing clamp
Balanced flue adaptor
7 60/100 mm to 7 80/125 mm
Maximum flue length
Vitodens 100-W, type WB1B: 10 m
Routing through a shaft (cont.)
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17
Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W
Rated heating output kW 26.0 26.0 30.0 35.0
System size 60/100 m 15 15 15 15
System size 80/125 m 25 20 20 20
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size
60/100
m 20 20 20 15 — — — —
System size
80/125
m 25 25 25 25 20 15 — —
System size
100/150
m — — — — 25 20 20 20
Note
For alternative system sizes, a bal-
anced flue adaptor is required.
The following components are taken
into consideration for the maximum flue
lengths:
■ Balanced flue connection pipe 0.5 m
long
■ 1 balanced flue bend 87° and 1 sup-
port bend 87°
or
■ 2 balanced flue bends 45° and 1 sup-
port bend 87°
Subtract other bends, tees and straight
lengths from the maximum length using
the following values:
■ Balanced flue connection pipe 0.5 m
long: 1 m
■ Balanced flue connection pipe 1 m
long: 2 m
■ Balanced flue bends 45°: 0.5 m
■ Balanced flue bends 87°: 1 m
■ Balanced flue inspection tee: 1.5 m
Routing through a shaft (cont.)
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Open flue operation
3
2
3
4
3
2
2
2
2
1 65 4
A
B
A
D
E
C
3
ASecondary ventilation
BFlue gas
CInspection port
DSupply air vent
ESupply air
1Boiler flue connection
2Standard shaft pack
Comprising:
■ Support bend
■ Support rail
■ Shaft cover
■ Spacers (5 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
5Flue bend
87° or 2 x 45°
or
Inspection tee
87°
6Ventilation bezel
Adaptor 7 60 mm to 7 80 mm
Routing through a shaft (cont.)
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Maximum flue length
Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W
Rated heating output kW 19 26.0 30.0 35.0
System size 60 m 15 15 20 20
System size 80 m 20 20 20 20
Note
For system size 80, an adaptor is
required.
Vitodens 200-W, 222-F and 242-F
Rated heating
output
kW 13 19 26 35 45 60 80 100
System size 60 m 20 20 20 15 — — — —
System size 80 m 25 25 25 25 20 15 — —
System size 100 m — — — — 25 20 20 20
The following components are taken
into consideration for the maximum flue
lengths:
■ Connection pipe 0.5 m long
■ 1 flue bend 87° and 1 support bend
87°
or
■ 2 flue bends 45° and 1 support bend
87°
Subtract other bends, tees and straight
lengths from the maximum length using
the following values:
■ Connection pipe 0.5 m long: 0.5 m
■ Connection pipe 1 m long: 1 m
■ Flue bend 45°: 0.3 m
■ Flue bend 87°: 0.5 m
■ Inspection tee: 0.3 m
Open flue operation with combustion air supply via interconnected rooms
Only possible with system sizes 60 and
80.
The connection piece to the shaft is
constructed as part of the balanced flue
system. The combustion air is drawn
from the room via an opening immedi-
ately by the chimney entry (air inlet
adaptor).
An adequate combustion air supply, as
specified by the TRGI 2008, must be
ensured inside the room by means of
an interconnected combustion air sup-
ply:
■ Minimum volume of the interconnec-
ted rooms, 4 m3 per kW rated heating
output
■ Vents in the connecting doors min.
150 cm2
Routing through a shaft (cont.)
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3
3
2
4
3
2
2
578
6
C
1
C
B
A
E
D
ASupply air
BFlue gas
CSecondary ventilation
DAperture for interconnected air
supply
EInspection port
1Boiler flue connection
2Standard shaft pack
Comprising:
■ Support bend
■ Support rail
■ Shaft cover
■ Spacers (5 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 air inlet adaptor
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 shaft (cont.)
5780 223 GB