for contractors for condensing boilers Installation ... · PDF fileInstallation instructions...

Installation instructionsfor contractors

VIESMANN

Flue system

for condensing boilers

Flue system

5780 223 GB 3/2014 Dispose after installation.

2

Please follow these safety instructions closely to prevent accidents and mate-rial losses.

Safety instructions explained

DangerThis symbol warns against therisk of injury.

! Please noteThis symbol warns against therisk of material losses and envi-ronmental pollution.

NoteDetails identified by the word "Note" con-tain additional information.

Target group

These instructions are exclusively inten-ded for qualified contractors.■ Work on gas installations must only be

carried out by a registered gas fitter.■ Work on electrical equipment must

only be carried out by a qualified elec-trician.

Regulations

Observe the following when working onthis system:■ Statutory regulations regarding the

prevention of accidents■ Statutory regulations regarding envi-

ronmental protection

■ The Code of Practice of relevant tradeassociations

■ all current safety regulations asdefined by DIN, EN, DVGW, TRGI,TRF, VDE [and all local standards].a ÖNORM, EN, ÖVGW-TR Gas,

ÖVGW-TRF and ÖVEc SEV, SUVA, SVGW, SVTI,

SWKI, VKF and EKAS guideline1942: LPG, part 2

Working on the system

■ Isolate the system from the power sup-ply (e.g. by removing the separate fuseor by means of a mains isolator) andcheck that it is no longer 'live'.

■ Safeguard the system against recon-nection.

■ Where gas is used as the fuel, closethe main gas shut-off valve and safe-guard it against unintentional reopen-ing.

Safety instructions

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Installation sequenceGeneral installation information............................................................................ 4■ Planning............................................................................................................ 4■ Flue gas temperature protection....................................................................... 4■ Installation information...................................................................................... 4■ Required tools/equipment................................................................................. 5■ Fitting the balanced flue slide coupling............................................................. 6■ Removing the flue pipe from the balanced flue pipe (if required)..................... 7■ Tightness test.................................................................................................... 7■ Certification of the balanced flue system.......................................................... 8■ System certification........................................................................................... 8Installations requirements.................................................................................... 9■ Statutory requirements...................................................................................... 9■ Gas safety (installation and use) regulations (current issue)............................ 9■ Boiler position................................................................................................... 10Routing through a shaft........................................................................................ 15■ Installation information...................................................................................... 15■ Rigid flue........................................................................................................... 16■ Flexible flue....................................................................................................... 26Installation in a disused chimney.......................................................................... 36■ Installation requirements................................................................................... 36■ Installation......................................................................................................... 38Vertical outlet for pitched or flat roofs................................................................... 41■ Maximum flue length......................................................................................... 42■ Installation......................................................................................................... 44External wall connection....................................................................................... 47■ Installation......................................................................................................... 50Routing over an external wall............................................................................... 52■ Maximum flue length......................................................................................... 53■ Installation......................................................................................................... 53Plume kit............................................................................................................... 55■ Routing options................................................................................................. 55

Index57

80 2

23 G

B

4

Planning

Prior to installation, check that the max-imum possible pipe length will not beexceeded.Max. possible pipe lengths in relation tothe boiler used:

Flue systems technical guide

Flue gas temperature protection

The flue pipes are approved for flue gastemperatures up to 120 °C.

With Viessmann condensing boilers,internal safeguards ensure that the max-imum permissible flue gas temperatureis not exceeded.

Installation information

■ The component overviews for the dif-ferent types of routing also apply tofloorstanding condensing boilers.

■ Keep flue gas routes short and with thefewest number of bends possible.

■ Route horizontal connection pipeswith a downward slope of ≥ 3° (approx.50 mm/m) towards the boiler.

■ Support horizontal connection pipes atintervals of approx. 1 m.

■ To avoid damage and leaks, isolatethe 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 suppliedwith the boiler.

■ Plug-in female connections in the fluegas path must always point in the flowdirection.

■ Only use the components suppliedwith the PPs flue system.

■ Push the pipes into each other with aslight twist.

■ Balanced flue pipes can be trimmed intheir assembled state.

Do not carry out commissioning untilthe 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 cannotbe closed off.

■ Applicable regulations on installingand commissioning flue systems havebeen followed.

General installation information

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DangerLeaking or blocked flue systemsor an insufficient supply of com-bustion air cause life threateningpoisoning due to carbon monox-ide in the flue gas.

Ensure the flue system functionscorrectly. Apertures for combus-tion air supply must not be able tobe closed off.

Required tools/equipment

■ Rope for lowering the flue system intoa shaft (length: chimney height plus3 m)

■ Saw and file for trimming and cham-fering the pipe sections

■ Power drill for securing the shaft coverand the support rail

General installation information (cont.)

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Fitting the balanced flue slide coupling

NoteThe slide coupling enables a gap ofapprox. 45 mm to be covered. Compen-sate for greater or shorter lengths priorto installation by means of the incomingpipe.

1.

120

4.

3.

5.

6.

2.

1. Push the pipe section into the femaleconnection of the incoming balancedflue component.

2. Shorten the ongoing balanced fluepipe to create a gap of 120 mmbetween the pipe section and the bal-anced flue pipe.

3. Push the slide coupling onto theongoing flue pipe.

4. Open the collar and push it over theongoing balanced flue pipe.

5. Retract the slide coupling and push itonto the incoming flue pipe.

6. Align the collar and close the togglefasteners.


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Removing the flue pipe from the balanced flue pipe (if required)

System size 60/100 and 80/125

2.

1.

Tightness test

After installation, flue systems routedthrough a shaft must be tested for tight-ness by the flue gas inspector [checklocal regulations].■ Pressurised flues which are routed

inside buildings and which are not sur-rounded by combustion air (open flue)must be pressure tested.For the pressure test, a leak detectoris used to pump air into a flue that hasbeen sealed at the top and bottom,until a pressure of 200 Pa has built.This pressure is maintained while thevolume of air leaking out is estab-lished.A leakage rate of up to0.006 l/(s x m2), relative to the internalsurface area, is permitted for classify-ing a flue as sufficiently gas-tight.

■ In pressurised flues that are surroun-ded by combustion air (balanced flue),the tightness can be checked by test-ing the O2 content in the combustionair (annular gap test).The flue is considered sufficiently gas-tight if the O2 content in the combus-tion air does not deviate from the ref-erence value by more than the follow-ing values. The reference value isestablished following the self-adjust-ment of the test meter:– For flues with general Building Reg-

ulations approval 0.4 % by vol.– For other flues 0.2 % by vol.

NoteObserve country-specific regulations.


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Certification of the balanced flue system

The balanced flue system is CE-desig-nated and approved in accordance withEN 14471 (see flue systems technicalguide).

System certification

System certification to EC Gas Applian-ces Directive EU/2009/142/EC in con-junction with PPs flues offered by Sko-berne.

Vitocrossal 200, type CM2 CE-0085BQ0021Vitocrossal 300, type CU3 CE-0085BN0570Vitocrossal 300, type CM3 CE-0085BN0569Vitocrossal 300, type CT3B, CT3U CE-0085AQ0257Vitodens 050-W CE0085CP0029Vitodens 100-E, 100-W, 111-W CE-0085BT0029Vitodens 200-W CE-0085BR0432, CE-0085CN0050Vitodens 222-F CE-0085BU0051, CE-0085CN0050Vitodens 222-W CE-0085BR0432, CE-0085CN0050Vitodens 242-F CE-0085BU0051, CE-0085CN0050Vitodens 300-W CE-0085BR0433, CE-0085CM0463Vitodens 333-F CE-0085BU0052, CE-0085CM0463Vitodens 343-F CE-0085BU0052, CE-0085CM0463Vitoladens 300-C CE-0035BS104, CE-0035CO106Vitoladens 300-T CE-0035BO107Vitoladens 300-W CE-0035BM112, CE0035CO107Vitoladens 333-F CE-0035BM112, CE0035CO107Vitorondens 200-T CE-0035CL102Vitorondens 222-F CE-0035CL102Vitosolar 200-F CE-0085CM0184Vitosolar 300-F CE0035CO107Vitosorp 200-F CE0085CO0146Vitotwin 300-W CE-0085CM0150Vitovalor 300-P CE-0085CP0028


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NoteAffix "System certification" and "Fluesystem Skoberne GmbH" labels in aclearly visible position near the flue sys-tem or on the boiler.

The labels are supplied with the techni-cal documentation.

Installations requirements

Statutory requirements

The appliance is suitable only for instal-lation in GB and IE and should be instal-led in accordance with the rules in force.In GB a Gas Safe Registered Installermust carry out the installation. It must becarried out in accordance with the rele-vant requirements of the:

Gas safety (installation and use) regulations (current issue)

It is in your own interest and safety toensure that the law is complied with.In addition to the above regulations, thisappliance must be installed in accord-ance with the current IEE Wiring Regu-lations for electrical installation (BS7671), local Building Regulations, theBuilding Standards (Scotland) (Consoli-dation) Regulations, bye laws of the localwater undertaking and Health and SafetyDocument NO. 635, The Electricity atWork regulations 1989, In Ireland (IE),the installation must be carried out by aCompetent Person and installed inaccordance with the current edition if I.S.813 "Domestic Gas Installations", Thecurrent Building Regulations and refer-ences should be made to the currentETCI rules for electrical installation.

It should also be in accordance with therelevant recommendations in the currenteditions of the following British Stand-ards and Codes of Practice: BS 5449,BS 5546, BS 5440:1, BS 5440:2, BS6798, BS 7593, BS 6891, IGE/UP/7 andIS 813 for IE.All Registered installers are required tonotify building control when they haveinstalled or exchanged a gas appliancein a residential dwelling, this can be donevia Gas Safe.


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Gas Safe will then issue either a BuildingCompliance Certificate (for England andWales) or a Declaration of Safety (Scot-land, Northern Island, Isle of Man orappliances out of the scope of BuildingRegulations) to the homeowner, whichwill confirm that the work has been car-ried out by a competent Gas Safe Reg-istered Installer. This document will beused to form part of the Home Informa-tion Pack (HIP).

! Please noteManufacturers instructions mustnot be taken in any way as overriding statutoryobligations.

Boiler position

The following limitations must beobserved when siting the boiler:■ The boiler is not suitable for external

installation. The position selected forthe installation should be within thebuilding, unless otherwise protectedby a suitable enclosure and must allowadequate space for installation, serv-icing and operation of the applianceand for air circulation around it.

■ The position must allow for a suitableflue system and terminal position. Theboiler must be installed on a flat verti-cal wall capable of supporting theweight of the appliance and any ancil-lary equipment when full.

■ Due consideration should be given tothe routing of the condensate drainfrom the chosen position.

■ If the boiler is to be fitted in a timberframed building it should be fitted inaccordance with ige/up/7. If in doubtadvice must be sought from the Insti-tute of Gas Engineers.

■ If the appliance is to be installed in aroom containing a bath or shower, anyelectrical switch or control utilisingmains electricity must be so situatedthat it cannot be touched by a personusing the bath or shower. Attention isdrawn to the requirements of BS 7671(the current I.E.E Wiring Regulations)and in Scotland the electrical provi-sions of the Building Regulationsapplicable in Scotland.

■ A compartment used to enclose theappliance must be designed and con-structed specifically for this purpose.An existing cupboard or compartmentmay be used provided it is modifiedaccordingly. BS 7698:2000 givesdetails of the essential features of cup-board / compartment design, includingairing cupboards. The Vitodens rangedoes not require compartment ventila-tion.

■ Where installation will be in an unusuallocation, special procedures may benecessary. BS 6798 gives detailedguidance 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

k m

e

g

af

f

k

b,c

k

l l

g

c

k

Position Minimum spacingmm

a Directly below an opening window, air vent or anyother ventilation opening

300

b Below a gutter drain or soil pipe 75c Below eaves 200d Below a balcony 200e From vertical drain or soil pipes 150f From internal and external corners 300g Above adjacent ground or balcony level/roof 300h From a surface facing the terminal 600i Facing terminals 1200j From opening door/window 1200k Vertically from a terminal on same wall 1500l Horizontally from a terminal on same wall 300m Adjacent to opening 300n Below carport/roof not recommended


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Vertical flue systems

q

oo

r

p

s

t

u

t

Position Minimum spacingmm

o From adjacent wall 300p From adjacent opening window 1000q From another terminal 600r Minimum height 300s Minimum distance measured perpendicular to

roof covering400

t Beside or above an opening rooflight 600u Below an opening rooflight 2000


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Minimum distance from terminal

2.5 mA

A Boundary

Not under a car port


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2.1

m

B

Avoid access routes and patios

B Walkway or patio

2.5 m

C

Minimum distance to car parking space

C Car space


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Installation information

Prior to installation, the local flue gasinspector should check that the shaft tobe used is suitable and permissible[where applicable].In the installation room, at least oneinspection port must be provided in theflue system for inspection, cleaning andfor testing the pressure (if required). Ifthe flue is not accessible from the roof, asecond inspection port must be providedbehind the chimney cleaning hatch in theattic.

Provide an inspection port at the base ofthe shaft for inspecting the secondaryventilation. Safeguard the condensatedrainage from the flue to the boiler witha slope of at least 3° (approx.50 mm/m).The flue system must protrude clear ofthe roof. Observe 400 mm roof protru-sion parallel to the roof slope accordingto FeuVo (or local regulations).

Routing through a shaft57

80 2

23 G

B

16

Rigid flue

Balanced flue operation

B5

2

A

3

23

2

4

3

2

2

6798 71

A

C

B

C

A Ventilation airB Flue gasC Inspection port

1 Boiler flue connection2 Standard shaft pack Comprising: ■ Support bend ■ Support rail ■ Shaft cover ■ Spacers (5 pce)3 Flue pipe 2 m long 1 m long 0.5 m long Flue bend (for use in corbelled

chimneys) 30° or 15° 4 Inspection piece, straight5 Balanced flue inspection piece,

straight6 Balanced flue wall bezel7 Balanced flue pipe 1 m long 0.5 m long8 Balanced flue bend 87° or 2 x 45° or Balanced flue inspection tee or Balanced flue inspection bend9 Balanced 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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Vitodens 100-W, type WB1C, Vitodens 111-WRated heating output kW 26.0 26.0 30.0 35.0System size 60/100 m 15 15 15 15System size 80/125 m 25 20 20 20

Vitodens 200-W, 222-F and 242-FRated heatingoutput

kW 13 19 26 35 45 60 80 100

System size60/100

m 20 20 20 15 — — — —

System size80/125

m 25 25 25 25 20 15 — —

System size100/150

m — — — — 25 20 20 20

NoteFor alternative system sizes, a balancedflue adaptor is required.

The following components are taken intoconsideration for the maximum fluelengths:■ 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 straightlengths from the maximum length usingthe 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


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Open flue operation

3

23

4

3

2

2

2

2

1 65 4

A

B

A

D

E

C

3

A Secondary ventilationB Flue gasC Inspection portD Ventilation air apertureE Ventilation air


chimneys) 30° or 15°4 Inspection piece, straight5 Flue bend 87° or 2 x 45° or Inspection tee 87°6 Ventilation bezel Adaptor 7 60 mm to 7 80 mm

Maximum flue length

Vitodens 100-W, type WB1C, Vitodens 111-WRated heating output kW 19 26.0 30.0 35.0System size 60 m 15 15 20 20System size 80 m 20 20 20 20


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NoteFor system size 80, an adaptor isrequired.


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 intoconsideration for the maximum fluelengths:■ Connection pipe 0.5 m long■ 1 flue bend 87° and 1 support bend

87°or

■ 2 flue bends 45° and 1 support bend87°

Subtract other bends, tees and straightlengths from the maximum length usingthe 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 and80.The connection piece to the shaft is con-structed as part of the balanced flue sys-tem. The combustion air is drawn fromthe room via an opening immediately bythe chimney entry (air inlet adaptor).An adequate combustion air supply, asspecified by the TRGI 2008, must beensured inside the room by means of aninterconnected combustion air supply:

■ Minimum volume of the interconnec-ted rooms, 4 m3 per kW rated heatingoutput

■ Vents in the connecting doors min.150 cm2


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3

3

2

4

3

2

2

578

6

C

1

CB

A

E

D

A Ventilation airB Flue gasC Secondary ventilationD Aperture for interconnected air sup-

plyE Inspection port


chimneys) 30° or 15°4 Inspection piece, straight5 Balanced flue inspection piece,

straight6 Balanced flue air inlet adaptor7 Balanced flue pipe 1 m long 0.5 m long8 Balanced flue bend 87° or 2 x 45° or Balanced flue inspection tee or Balanced flue inspection bend


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Installation

Ø 1

2

D

C

B

A

01. Drill a 7 12 mm hole through thecentre of the rear shaft wall tosecure support rail A.

02. Insert support rail A into the drilledhole, and secure to the front shaftwall with screws or mortar.

03. Position support bend B and usethe pin to secure it in a hole in thesupport rail.

04. Attach installation rope C to theoutside of the lowest vertical pipesection.

05. Subject to shaft size, install aspacer D every 2 to 5 m and foreach profiled piece (e.g. inspectionpiece or bend). Bent ends facingup.

06. Apply lubricating paste and push thepipes into each other with a slighttwisting motion.

07. Lower the pipes into the shaft usinginstallation rope C.

08. Remove the rope and push the low-est pipe into support bend B.


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345

50+0 -2

0

G

K

H

F

E

System size 60 to 100 mm

09. Have highest pipe section E end-ing approx. 50 mm below the topedge of the shaft.

10. Secure the lower part of shaftcover F.

50+0 -2

0

≈ 36

0

G

HK

F

E

System size 125 to 200 mm

11. System size 60 to 100 mm:Push on terminal pipe G.

NoteFor weight reasons, never trim ter-minal pipe G.

System size 125 to 200 mm:Trim final pipe section G (withoutfemale connection). The pipeshould be as flush as possible withflue collar H when this is fitted.

50+0 -2

0

500

E

K

G

F

H

System size 250 mm

12. Push on flue collar H and fastensafety rope K to the lower part.


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Fitting the connecting pipe

M

L

1. Only for balanced flue operation:Trim final ventilation air pipe L of theconnecting pipe so that it ends levelwith the internal shaft wall surface.

N

O

2. Balanced flue operation:Slide balanced flue wall bezel Monto the pipe and push it against theshaft opening.Open flue operation:Slide ventilation bezel N onto thepipe and push it against the shaftopening.

NoteThe gap created is designed to pro-vide secondary ventilation for theshaft.No additional ventilation grille isrequired.

Open flue operation with combustionair supply via interconnected rooms:Push the flue pipe onto the supportbend. Slide on air inlet adaptor Oand secure it to the shaft.

Fitting the metal shaft cover

For routing the plastic flue inside a twinflue shaft, in conjunction with a solid fuelboiler.The metal end piece must protrude intothe shaft by a length that is equal to orgreater than the flue pipe diameter.

If necessary, use the stainless steelextension which is available as anaccessory.


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200

80±1

050 1. Have the highest pipe section end

approx. 80 mm below the top edge ofthe shaft.

B

A

2. Push on metal pipe section A. Ifrequired, use an extension (accesso-ries).

3. Position shaft cover B and secure tothe shaft with the fixing materials pro-vided.


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Stainless steel extension in conjunction with on-site shaft cover

≥ 2

x D

CA

B

Ø D

≥400

A Chimney extension made from sootfire resistant material

B Stainless steel extensionC Shaft cover (on-site)

The shaft cover as a common down-draught plate (chimney cowl) must beprovided on site.


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Flexible flue

Balanced flue operation

68qP91 72A

2

5

2

4

2

3

2

2

B

A

C

C

A Ventilation airB Flue gasC Inspection port

1 Boiler flue connection2 Standard shaft pack (flexible) Comprising: ■ Support bend ■ Connection pieces ■ Support rail ■ Shaft cover ■ Spacers (5 pce)3 Inspection piece, straight (for installation in the flexible flue)4 Flexible flue5 Connection piece for connecting residual lengths of

the flexible flue Pipe lowering attachment with 20 m rope6 Balanced flue inspection piece,

straight7 Wall bezel8 Balanced flue pipe 1 m long 0.5 m long9 Balanced flue bend 87° or 2 x 45° or Balanced flue inspection tee or Balanced flue inspection bendqP Balanced flue slide coupling Balanced flue adaptor

7 60/100 mm to 7 80/125 mm


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Maximum flue length

Vitodens 100-W, type WB1C, Vitodens 111-WRated heating output kW 19 26.0 30.0 35.0System size 80 m 20 20 20 20



kW 13 19 26 35 45 60 80 100

System size 60 m 18 18 — — — — — —System size 80 m 25 25 25 25 20 15 — —System size 100 m — — — — 22 17 20 20


long■ 1 flue bend 87° and 1 support bend

87°or




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Open flue operation

2

2

1 976 A

D

E

C

2

2

5

2

4

2

3

B

A

8

A Secondary ventilationB Flue gasC Inspection portD Ventilation air apertureE Ventilation air

1 Boiler flue connection2 Standard shaft pack (flexible) Comprising: ■ Support bend ■ Connection pieces ■ Support rail ■ Shaft cover ■ Spacers (5 pce)3 Inspection piece, straight (for installation in the flexible flue)4 Flexible flue5 Connection piece for connecting residual lengths of

the flexible flue Pipe lowering attachment with 20 m rope6 Inspection piece, straight7 Flue pipe 1 m long 0.5 m long8 Flue bend 87° or 2 x 45° or Inspection tee 87°9 Ventilation bezel Adaptor 7 60 mm to 7 80 mm


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Maximum flue length

Vitodens 100-W, type WB1C, Vitodens 111-WRated heating output kW 19 26.0 30.0 35.0System size 80 m 20 20 25 25



kW 13 19 26 35 45 60 80 100

System size 60 m 18 18 — — — — — —System size 80 m 25 25 25 25 20 15 — —System size 100 m — — — — 22 17 20 20

The following components are taken intoconsideration for the maximum fluelengths:■ Connection pipe 0.5 m long■ 1 flue bend 87° and 1 support bend

87°or



Installation

DangerTo ensure correct function, routethe flexible flue at a maximumangle of 45° from the vertical.Never pull the flexible flue pipeover sharp edges during installa-tion.

Note■ Always draw the flue pipe in from the

top downwards.■ Observe flow direction (arrow on com-

ponents).

■ Subject to shaft size, install spacers atintervals of max. 2 m.

■ Insert a spacer before and after anychange in direction and any inspectionpiece.

■ The flue must not come into contactwith the shaft wall.


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Fitting the support rail inside the shaft

Ø 1

2

A

1. Drill a 7 12 mm hole through thecentre of the rear shaft wall to securesupport rail A.

2. Insert support rail A into the drilledhole, and secure to the front shaft wallwith screws or mortar.

Fitting an inspection piece, connection piece or connector

123

1

A

B

C

D


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31

1. Trim flexible flue pipe A cleanly atright angles.

2. Click spacer tooth of mountingring B into the 3rd groove of flexibleflue A.

3. Insert gasket C into the 1st grooveof flexible flue A.

4. Push inspection piece, connectionpiece or connector D onto mountingring B until it clicks into position.

Fitting the pipe lowering attachment and drawing the flexible flue into the shaft

A

B

C

1. Compress the end of flexible flue Ainto a slightly oval shape. Insertplate B of the pipe lowering attach-ment into the 3rd groove of the fluepipe.

2. Push leading cone C onto flexibleflue A. The end of the flue pipe mustbe completely covered.

3. Secure the rope to the loop of thepipe lowering attachment.

E

DE

A

4. Push spacer D onto flue A (bentends in flue gas flow direction).

5. Position provided cable ties Earound the ring of spacers D andtighten.

6. Pull flexible flue A from the topdownwards into the shaft. Never pullthe flue over sharp edges.


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7. Remove the pipe lowering attach-ment from the flue.

G

F

8. Fit connector F to flue A (seepage 30).

9. Position support bend G and use thepin to secure it in a hole in the supportrail.

10. Coat connector F with lubricatingpaste and push into support bendG.


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Fitting the plastic shaft cover

200

H

G

F

E

D

C

B

A

1. Route flexible flue A through shaftcover B.

2. Trim flexible flue A 200 mm abovethe top edge of the shaft.

3. Position base of shaft cover B onthe shaft and secure.

4. Only for 7 60 and 80 mm:Position reducer ring C on the baseof shaft cover B.

5. Click spacer tooth of mountingring D into the 3rd groove of flexibleflue A. See page 30.

6. Insert gasket E into the 1st grooveof flexible flue A.

7. Push terminal pipe F onto mountingring D until it clicks into position.

8. Hook safety rope G into the drilledhole in shaft cover B.

9. Push cowl H over terminal pipe Fand click into place on shaft coverB.


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Fitting the metal shaft cover

~50

G

E

F

D

C

B

A

1. Route flexible flue A throughretainer B.

2. Position retainer B on the shaft.

3. Trim flue A approx. 50 mm abovethe retaining plate of retainer B.

4. Pull flexible flue A up far enough toallow mounting ring C to be fitted.Click mounting ring C into the 3rdgroove of flexible flue A. Seepage 30.

5. Insert gasket D into the 1st grooveof flexible flue A.

6. Push adaptor E onto mountingring C until it clicks into position.

7. Push terminal pipe F into adaptorE.

8. Push cowl G onto terminal pipe Fand secure.


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Fitting the connecting pipe

B

A

1. Only for balanced flue operation:Trim final ventilation air pipe A of theconnecting pipe so that it ends levelwith the internal shaft wall surface.

D

C 2. Balanced flue operation:Slide balanced flue wall bezel Bonto the pipe and push it against theshaft opening.Open flue operation:Slide ventilation bezel C onto thepipe and push it against the shaftopening.

NoteThe gap created is designed to pro-vide secondary ventilation for theshaft.No additional ventilation grille isrequired.

Open flue operation with combustionair supply via interconnected rooms:Push the flue pipe onto the supportbend, slide air inlet adaptor D ontothe pipe and secure it to the shaft.


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Installation requirements

190

150

1200

300

D

C

B

A90

A Disused chimneyB Balanced flue pipe for connecting

the flexible flue

C Chimney connection plateD Vitodens

Installation in recesses below disusedchimneys. Recess height min.1200 mm.

Installation in a disused chimney

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Maximum flue length

Vitodens 100-W, type WB1CRated heating output kW 19 26.0 30.0 35.0System size 80 m 20 20 20 20


Vitodens 200-WRated heating output kW 13 19 26 35System size 60 m 18 18 — —System size 80 m 25 25 25 25System size 100 m — — — —


long■ 1 flue bend 87° and 1 support bend

87°or



Installation in a disused chimney (cont.)

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Installation

A

B

140

1. Determine the position of the bal-anced flue terminal and create anaperture 7 approx. 140 mm A inthe bottom of the shaft.

2. Pull flexible flue B into the shaft fromthe top. See page 31.


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C

D

3. Secure flexible flue B to chimneyconnection plate C. See page 30.

4. Push chimney connection plate Cupwards and secure. Do not tightenthe screws at this stage, so the chim-ney connection plate can be alignedwhen the Vitodens is being fitted.

5. Push balanced flue pipe D in chim-ney connection plate C upwards byapprox. 40 mm.


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C

D

6. Install the Vitodens in the recess.

Vitodens installation and serv-ice instructions

7. Pull balanced flue pipe D down-wards and push it into the boiler flueconnection as far as it will go. Ensurethat the gasket is seated correctly inchimney connection plate C.


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8. Tighten the fixing screws of chimneyconnection plate C.

9. Secure balanced flue pipe D tochimney connection plate C with theself-tapping screw supplied.

10. Fit the shaft cover. See page 33.

Vertical outlet for pitched or flat roofs

If the balanced flue system is routedthrough roof spaces that are not used asaccommodation, run the flue through anadditional metal pipe as protectionagainst mechanical damage(TRGI 2008).

When several roof outlets are installedside by side: Observe a minimum clear-ance of 1.5 m between outlets and toother building structures (e.g. skylights)in accordance with TRGI 2008. Observethe clearance of the flue outlet above theroof (see diagram). If the rated heatingoutput is ≥ 50 kW, an above-roof exten-sion is required (see page 46).


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a

1

3

4

5

7

B

A

2

6

A Ventilation airB Flue gas

Rated heating out-put

kW ≤50 ≥50

a (min.) mm 400 1000

1 Boiler flue connection2 Balanced flue roof outlet3 Pipe outlets for Klöber roof

tilesProvide a suitable Klöber roof tileon site.orUniversal roof tile or Flat roof collar

4 Balanced flue inspection piece,straight

5 Balanced flue slide coupling6 Balanced flue bend 87° or 2 x 45° Balanced flue pipe 1 m long 0.5 m long7 Fixing clamp Balanced flue adaptor

7 60/100 mm to 7 80/125 mm

Maximum flue length


Vitodens 100-W, type WB1C, Vitodens 111-WRated heating output kW 19 26.0 30.0 35.0System size 60/100 m 10 10 8 8System size 80/125 m 13 13 11 11

Vertical outlet for pitched or flat roofs (cont.)

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kW 13 19 26 35 45 60 80 100

System size60/100

m 10 10 10 10 — — — —

System size80/125

m 13 13 13 11 10 6 — —

System size100/150

m — — — — 13 9 15 15


The following components are taken intoconsideration for the maximum fluelengths:■ 2 balanced flue bends 87°

Subtract other bends, tees and straightlengths from the maximum length usingthe following values:■ Balanced flue bend 45°: 0.5 m■ Balanced flue bend 87°: 1 m■ Balanced flue inspection tee: 0.5 m


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Installation

Balanced flue roof outlet

2

7

6

3

! Please noteEnsure the specified minimumlengths above the roof areobserved.Never trim roof outlets above theroof.

■ Install pipe outlets for Klöber roof tiles,universal roof tiles or flat roof collars inaccordance with manufacturer'sdetails.

■ Integrate the flat roof collar into theroof skin according to the flat roofguidelines.

■ Ceiling/roof penetration (min. diame-ter):– 105 mm (system size 60)– 130 mm (system size 80)– 160 mm (system size 100).

■ Secure the roof outlet to the roof struc-ture with a clamp only after installationhas been completed.

■ Position the roof outlet on the roof tilesor flat roof collar from above.

■ Connect the balanced flue connectionpipe from below.


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Roof construction in line with the flatroof directive

CDE

FD

G

B

H

A

A Flat roof collarB Gravel ballast layer

C Insulation layerD Aeration layerE Thermal insulationF InsulationG CeilingH Flue pipe


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Fitting the above-roof extension

System sizes 60 and 80

3x

3x

B

A

C

D

C

B

C

B

1. Push the internal pipe of above-roofextension A onto roof outlet B andsecure with 3 screws provided.

2. Push black pipe section C onto roofoutlet B and secure with 3 screwsprovided.

3. Push roof outlet B with above-roofextension A onto the balancedflue.

4. Secure the 1 m above-roof extensionwith clamp D provided and theropes.


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System size 100

A

B

1. Remove top section A of the roofoutlet.

2. Push above-roof extension B ontothe roof outlet.

3. Push top section A onto above-roofextension B.

NoteFor extensions ≥ 1 m, secure the roofoutlet with ropes. The ropes can befastened to the above-roof exten-sion.

External wall connection

NoteCannot be used with the Vitocrossal orVitoladens.

Install an inspection port in the balancedflue for inspection and cleaning.

Recommendation: Use the balancedflue slide coupling to facilitate installationof the balanced flue.Route the connection piece with a down-ward slope of at least 3° (approx.50 mm/m).


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651 7 4 42

B

A3

A Ventilation air B Flue gas

1 Boiler flue connection2 Balanced flue external wall con-

nection (incl. wall bezels)3 Grille4 Balanced flue pipe 1 m long 0.5 m long5 Balanced flue bend 87° or 2 x 45° or Balanced flue inspection tee or Balanced flue inspection bend6 Balanced flue inspection piece,

straight7 Balanced flue slide coupling Fixing clamp Balanced flue adaptor

7 60/100 mm to 7 80/125 mm

Maximum flue length


External wall connection (cont.)

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Vitodens 100-W, type WB1C, Vitodens 111-WRated heating output kW 19 26.0 30.0 35.0System size 60/100 m 10 10 8 8System size 80/125 m 13 13 11 11


kW 13 19 26 35 45 60 80 100

System size 60 m 10 10 10 8 — — — —System size 80 m 13 13 13 11 10 6 — —System size 100 m — — — — 13 9 15 15





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Installation

C B A

a bc

Balanced flue system 7 60/100 mm and 7 80/125 mm

Balanced flue sys-tem (7 mm)

60/100 80/125

a (mm) ≤ 475 ≤ 710b (mm) 155 165c (mm) 704 952

Telescopic balanced flue externalwall connectionBalanced flue sys-tem (7 mm)

60/100

a (mm) ≥373 - ≤ 533b (mm) 154c (mm) ≥617 - ≤ 777


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C B A

730

475 160

Balanced flue system 7 100/150 mm

1. Create an opening in the wall (min.diameter):■ 105 mm (system size 60)■ 130 mm (system size 80)■ 160 mm (system size 100)

2. Push external wall connection Awith wall bezel B into the wall open-ing.

3. Slide on internal wall bezel C.

4. If the external wall connection termi-nates ≤ 2 m above ground level nearpublic roads, fit a protective grille.

5. Connect the balanced flue connec-tion pipe from the inside and routewith a downward slope of min. 3°(approx. 50 mm/m) towards theboiler.


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21

6

7

8

9

qP

5

B

5

3

qQ

qW

43

A

2 m

:

qR

A

7

C

qE

qR

qP

A Flue gasB Ventilation airC Elbow in the external wall routing for

a short roof overhang

1 Boiler flue connection2 Balanced flue inspection tee,

87°

orBalanced flue inspection bend,87°

3 Balanced flue slide coupling4 Balanced flue pipe 1.95 m long 1 m long 0.5 m long5 Wall bezel6 Fixing clamp7 Balanced flue inspection piece,

straight External wall pack with8 Balanced flue bend, 87° or ex-

ternal wall bend, 87° 9 External wall air inlet sectionqP Balanced flue pipe or external

wall pipe 1.95 m long 1 m long 0.5 m longqQ Balanced flue roof outlet (for a large roof overhang)qW Universal roof tile or Pipe outlet for Klöber roof tiles Provide a suitable Klöber roof tile

on site.qE External wall terminal

(for a short roof overhang)qR Balanced flue bend, 45° or ex-

ternal wall bend, 45° orBalanced flue bend, 30° or ex-ternal wall bend, 30°

Balanced flue adaptor7 60/100 mm to 7 80/125 mm

Routing over an external wall

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Maximum flue length

Vitodens 100-WRated heating output kW 19.0 26.0 30.0 35.0System size 60/100 m 20 20 15 15System size 80/125 m 25 25 20 20


kW 13 19 26 35 45 60 80 100

System size60/100

m 20 20 20 15 — — — —

System size80/125

m 25 25 25 20 12 12 — —

System size100/150

m — — — — 17 17 20 20




Installation

1. Create an opening in the wall (min.diameter):■ 105 mm (system size 60)■ 130 mm (system size 80)■ 160 mm (system size 100).

2. Push external wall bend 8 with wallbezel 5 into the wall opening fromthe outside.

3. Fit air inlet section 9 as near as pos-sible to external wall bend 8.

4. Secure interior wall bezel 5.

5. Connect the balanced flue connec-tion pipe from the inside and routewith a downward slope of min. 3°(approx. 50 mm/m) towards theboiler.

6. Use external wall clamps 6 to fit theflue components to the external wallat a consistent distance.Position external wall clamps 6 inintervals of max. 2 m.

Routing over an external wall (cont.)

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7. ! Please noteEnsure the specified mini-mum lengths above the roofare observed.Never trim roof outlets abovethe roof.

Roof outlet■ Use universal tiles or air vent tiles

with pipe outlets.■ Position balanced flue slide cou-

pling 3 underneath the roof outlet.■ Install pipe outlets for Klöber or uni-

versal roof tiles in accordance withmanufacturer's directions.

■ Position the roof outlet onto the rooftiles from above.

■ Connect the external wall pipe frombelow.

Elbow in the external wall routingfor a short roof overhang■ Elbow with 45° bend qR: Fit bal-

anced flue inspection piece 7.■ Elbow with 30° bend qR: Balanced

flue inspection piece 7 notrequired.

■ Fit external wall terminal qE

Routing over an external wall (cont.)

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Routing options

A B C

A Plume kit standard deliveryB Plume kit standard delivery

plus:■ 2 bends 87°■ 1 pipe, 1 m long

C Plume kit standard deliveryplus:■ 2 bends 45°■ 1 pipe, 1 m long

Observe the max. length of the entirebalanced flue.For the standard plume kit, deduct 3 mfrom the max. possible pipe length.

When using an additional 87° bend ortwo 45° bends, reduce the max. lengthby 1 m.

Plume kit57

80 2

23 G

B

56

1.

2.

1. Disengage and remove the end pieceof the external wall connection.

2. Insert external wall connection intothe wall.

3.

3. Push the flue bend into the externalwall connection.

Plume kit (cont.)

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35

4.

3535

4. Insert screws into the wall in accord-ance with the pipe length.

Plume kit (cont.)

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6.

7.5.

5. Mount flue pipes and bends in linewith the chosen method of routing.

6. Position the supplied fixing clampsand secure with the screws.

7. Insert the rodent protection into theuppermost bend.

NoteThe rodent protection should beinserted into the end piece of theplume kit.

Plume kit (cont.)

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57

80 2

23 G

B

60

Viessmann LimitedHortonwood 30, TelfordShropshire, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040E-mail: [email protected]

Viessmann Werke GmbH&Co KGD-35107 AllendorfTelephone: +49 6452 70-0Fax: +49 6452 70-2780www.viessmann.com

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