Viessmann Vitocaldens 222-F Installation Instructions Manual
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Viessmann Vitocaldens 222-F Installation Instructions Manual

Flue system for condensing boilers
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VIESMANN

Installation instructions

for contractors

Flue system

for condensing boilers
Flue system
Dispose after installation.
5780 223 GB
5/2016

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Summary of Contents for Viessmann Vitocaldens 222-F

  • Page 1: Installation Instructions

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

  • Page 2: Safety Instructions

    Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained ■ Codes of practice of the relevant trade associations Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.

  • Page 3: Table Of Contents

    Index Installation sequence General installation information................■ Design....................... ■ Flue gas temperature protection............... ■ Installation information..................■ Required tools/equipment................. ■ Fitting the balanced flue slide coupling............. ■ Tightness test....................■ Certification of the balanced flue system............■ System certification................... Installations requirements..................■...

  • Page 4: General Installation Information

    ■ 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.

  • Page 5: Required Tools/Equipment

    General installation information (cont.) Danger Ensure the flue system functions Leaking or blocked flue systems correctly. Apertures for combus- or an insufficient supply of com- tion air supply must not be able bustion air cause life threatening to be closed off. poisoning due to carbon monox- ide in the flue gas.

  • Page 6: Fitting The Balanced Flue Slide Coupling

    General installation information (cont.) 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. Push the pipe section into the 4.

  • Page 7: Tightness Test

    General installation information (cont.) Tightness test After installation, flue systems routed ■ In pressurised flues that are surroun- through a shaft must be tested for tight- ded by combustion air (room sealed), ness by the flue gas inspector [check the tightness can be checked by test- local regulations].

  • Page 8: System Certification

    General installation information (cont.) 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...

  • Page 9: Installations Requirements

    Installations requirements 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...

  • Page 10: Boiler Position

    Installations requirements (cont.) Boiler position The following limitations must be ■ A compartment used to enclose the observed when siting the boiler: appliance must be designed and con- ■ The boiler is not suitable for external structed specifically for this purpose. installation.
  • Page 11 Installations requirements (cont.) Flue terminal position Horizontal flue system Position Minimum spacing Directly below an opening window, air vent or any other ventilation opening Below a gutter drain or soil pipe Below eaves Below a balcony From vertical drain or soil pipes From internal and external corners Above adjacent ground or balcony level/roof From a surface facing the terminal...
  • Page 12 Installations requirements (cont.) Vertical flue systems Position Minimum spacing From adjacent wall From adjacent opening window 1000 From another terminal Minimum height Minimum distance measured perpendicular to roof covering Beside or above an opening rooflight Below an opening rooflight 2000...
  • Page 13 Installations requirements (cont.) Minimum distance from terminal 2.5 m A Boundary Not under a car port...
  • Page 14 Installations requirements (cont.) Avoid access routes and patios B Walkway or patio Minimum distance to car parking space C Car space...

  • Page 15: Routing Through A Shaft

    Routing through a shaft Installation information Prior to installation, the local flue gas In the installation room, at least one inspector should check that the shaft to inspection port must be provided in the be used is suitable and permissible flue system for inspection, cleaning and [where applicable].

  • Page 16: Rigid Flue

    Routing through a shaft (cont.) Rigid flue Room sealed operation Boiler flue connection Standard shaft pack Comprising: ■ Support bend ■ Support rail ■ Shaft cover ■ Spacers (5 pce) Flue pipe 2 m long 1 m long 0.5 m long Flue bend (for use in corbelled chimneys) 30°...
  • Page 17 Routing through a shaft (cont.) Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W Rated heating output 26.0 26.0 30.0 35.0 System size 60/100 System size 80/125 Vitodens 200-W, 222-F and 242-F Rated heating output System size — — — — 60/100 System size —...
  • Page 18 Routing through a shaft (cont.) Open flue operation Boiler flue connection Standard shaft pack Comprising: ■ Support bend ■ Support rail ■ Shaft cover ■ Spacers (5 pce) Flue pipe 2 m long 1 m long 0.5 m long Flue bend (for use in corbelled chimneys) 30°...
  • Page 19 Routing through a shaft (cont.) Maximum flue length Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W Rated heating output 26.0 30.0 35.0 System size 60 System size 80 Note For system size 80, an adaptor is required. Vitodens 200-W, 222-F and 242-F Rated heating output System size 60...
  • Page 20 Routing through a shaft (cont.) Boiler flue connection Standard shaft pack Comprising: ■ Support bend ■ Support rail ■ Shaft cover ■ Spacers (5 pce) Flue pipe 2 m long 1 m long 0.5 m long Flue bend (for use in corbelled chimneys) 30°...
  • Page 21 Routing through a shaft (cont.) Installation 01. Drill a 7 12 mm hole through the centre of the rear shaft wall to secure support rail A. 02. Insert support rail A into the dril- led hole, and secure to the front shaft wall with screws or mortar.
  • Page 22 Routing through a shaft (cont.) 09. Have highest pipe section E end- ing approx. 50 mm below the top edge of the shaft. 10. Secure the lower part of shaft cover F. System size 60 to 100 mm 11. System size 60 to 100 mm: Push on terminal pipe G.
  • Page 23 Routing through a shaft (cont.) Fitting the connection pipe 1. Only for balanced flue operation: Trim final ventilation air pipe L of the connection pipe so that it ends level with the internal shaft wall sur- face. 2. Balanced flue operation: Slide balanced flue wall bezel M onto the pipe and push it against the shaft opening.
  • Page 24 Routing through a shaft (cont.) 1. Have the highest pipe section end approx. 80 mm below the top edge of the shaft. 2. Push on metal pipe section A. If required, use an extension (acces- sories). 3. Position shaft cover B and secure to the shaft with the fixing materials provided.
  • Page 25 Routing through a shaft (cont.) Stainless steel extension in conjunction with on-site shaft cover The shaft cover as a common down- draught plate (chimney cowl) must be provided on site. Ø D A Chimney extension made from soot fire resistant material B Stainless steel extension C Shaft cover (on-site)

  • Page 26: Flexible Flue

    Routing through a shaft (cont.) Flexible flue Room sealed operation Boiler flue connection Standard shaft pack (flexible) Comprising: ■ Support bend ■ Connection pieces ■ Support rail ■ Shaft cover ■ Spacers (5 pce) Inspection piece, straight (for installation in the flexible flue) Flexible flue Connection piece for connecting residual lengths of...
  • Page 27 Routing through a shaft (cont.) Maximum flue length Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W Rated heating output 26.0 30.0 35.0 System size 80 Note For system size 80, an adaptor is required. Vitodens 200-W, 222-F and 242-F Rated heating output System size 60 —...
  • Page 28 Routing through a shaft (cont.) Open flue operation Boiler flue connection Standard shaft pack (flexible) Comprising: ■ Support bend ■ Connection pieces ■ Support rail ■ Shaft cover ■ Spacers (5 pce) Inspection piece, straight (for installation in the flexible flue) Flexible flue Connection piece for connecting residual lengths of...
  • Page 29 Routing through a shaft (cont.) Maximum flue length Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W Rated heating output 26.0 30.0 35.0 System size 80 Note For system size 80, an adaptor is required. Vitodens 200-W, 222-F and 242-F Rated heating output System size 60 —...
  • Page 30 Routing through a shaft (cont.) Fitting the support rail inside the shaft 1. Drill a 7 12 mm hole through the centre of the rear shaft wall to secure support rail A. 2. Insert support rail A into the drilled hole, and secure to the front shaft wall with screws or mortar.
  • Page 31 Routing through a shaft (cont.) 1. Trim flexible flue pipe A cleanly at 4. Push inspection piece, connection piece or connector D onto mount- a right angle. ing ring B until it clicks into posi- 2. Click spacer tooth of mounting tion.
  • Page 32 Routing through a shaft (cont.) 04. Push spacer D onto flue A (bent ends in flue gas flow direction). 05. Position cable ties E provided around the ring of spacers D and tighten. 06. Pull flexible flue A from the top downwards into the shaft.
  • Page 33 Routing through a shaft (cont.) Fitting a plastic shaft cover 1. Route flexible flue A through shaft cover B. 2. Trim flexible flue A 200 mm above the top edge of the shaft. 3. Position base of shaft cover B on the shaft and secure.
  • Page 34 Routing through a shaft (cont.) Fitting a metal shaft cover 1. Route flexible flue A through retainer B. 2. Position retainer B on the shaft. 3. Trim flue A approx. 50 mm above the retaining plate of retainer B. 4. Pull flexible flue A up far enough to allow mounting ring C to be fit- ted.
  • Page 35 Routing through a shaft (cont.) Fitting the connection pipe 1. Only for balanced flue operation: Trim final ventilation air pipe A of the connection pipe so that it ends level with the internal shaft wall sur- face. 2. Balanced flue operation: Slide balanced flue wall bezel B onto the pipe and push it against the shaft opening.

  • Page 36: Installation In A Disused Chimney

    Installation in a disused chimney Installation requirements A Disused chimney C Chimney connection plate B Balanced flue pipe for connecting D Vitodens the flexible flue Installation in recesses below disused chimneys. Recess height min. 1200 mm.
  • Page 37 Installation in a disused chimney (cont.) Maximum flue length Vitodens 100-W, type B1HA and B1KA Rated heating output 26.0 30.0 35.0 System size 80 Note For system size 80, an adaptor is required. Vitodens 200-W Rated heating output System size 60 —...

  • Page 38: Installation

    Installation in a disused chimney (cont.) Installation 01. Determine the position of the bal- 02. Pull flexible flue B into the shaft anced flue terminal and create an from the top. See page 31. aperture 7 approx. 140 mm A in the bottom of the shaft.
  • Page 39 Installation in a disused chimney (cont.) 03. Secure flexible flue B to chimney 05. Push balanced flue pipe D in connection plate C. See page 30. chimney connection plate C upwards by approx. 40 mm. 04. Push chimney connection plate C upwards and secure.
  • Page 40 Installation in a disused chimney (cont.) 06. Install the Vitodens in the recess. Vitodens installation and service instructions...

  • Page 41: Vertical Outlet For Pitched Or Flat Roofs

    Installation in a disused chimney (cont.) 07. Pull balanced flue pipe D down- 09. Secure balanced flue pipe D to wards and push it into the boiler chimney connection plate C with flue connection as far as it will go. the self-tapping screw supplied.

  • Page 42: Maximum Flue Length

    Vertical outlet for pitched or flat roofs (cont.) Rated heating out- ≤50 ≥50 a (min.) 400 1000 Boiler flue connection Balanced flue roof outlet Pipe outlets for Klöber roof tiles Provide a suitable Klöber roof tile on site. Universal roof tile Flat roof collar Balanced flue inspection piece, straight...
  • Page 43 Vertical outlet for pitched or flat roofs (cont.) Vitodens 200-W, 222-F and 242-F Rated heating output System size — — — — 60/100 System size — — 80/125 System size — — — — 100/150 Note Subtract other bends, tees and straight For alternative system sizes, a bal- lengths from the maximum length using anced flue adaptor is required.

  • Page 44: Installation

    Vertical outlet for pitched or flat roofs (cont.) Installation Balanced flue roof outlet Please note Ensure the specified minimum lengths above the roof are observed. Never trim roof outlets above the roof. ■ Install pipe outlets for Klöber roof tiles, universal roof tiles or flat roof collars in accordance with manufac- turer's instructions.
  • Page 45 Vertical outlet for pitched or flat roofs (cont.) Roof construction in line with the flat C Insulation layer roof directive D Aeration layer E Thermal insulation F Insulation G Ceiling H Flue pipe A Flat roof collar B Gravel ballast layer...
  • Page 46 Vertical outlet for pitched or flat roofs (cont.) Fitting an above-roof extension System sizes 60 and 80 1. Push the internal pipe of above-roof extension A onto roof outlet B and secure with 3 screws provided. 2. Push black pipe section C onto roof outlet B and secure with 3 screws provided.

  • Page 47: External Wall Connection

    Vertical outlet for pitched or flat roofs (cont.) System size 100 1. Remove top section A of the roof outlet. 2. Push above-roof extension B onto the roof outlet. 3. Push top section A onto above- roof extension B. Note For extensions ≥...
  • Page 48 External wall connection (cont.) A Supply air B Flue gas Maximum flue length Boiler flue connection Balanced flue external wall Vitodens 100-W, type WB1B: 10 m connection (incl. wall bezels) Grille Balanced flue pipe 1 m long 0.5 m long Balanced flue bend 87°...

  • Page 49: Installation

    External wall connection (cont.) Vitodens 100-W, type B1HA and B1KA, Vitodens 111-W Rated heating output 26.0 30.0 35.0 System size 60/100 System size 80/125 Vitodens 200-W, 222-F and 242-F Rated heating output System size 60 — — — — System size 80 —...
  • Page 50 External wall connection (cont.) Telescopic balanced flue external Balanced flue sys- 60/100 80/125 wall connection Balanced flue sys- 60/100 (7 mm) a (mm) ≤ 475 ≤ 710 (7 mm) b (mm) c (mm) a (mm) ≥373 - ≤ 533 b (mm) c (mm) ≥617 - ≤...

  • Page 51: Routing Over An External Wall

    Routing over an external wall Balanced flue inspection bend, 87° Balanced flue slide coupling Balanced flue pipe 1.95 m long 1 m long 0.5 m long Wall bezel Fixing clamp Balanced flue inspection piece, straight External wall pack with Balanced flue bend, 87° or ex- ternal wall bend, 87°...

  • Page 52: Maximum Flue Length

    Routing over an external wall (cont.) Maximum flue length Vitodens 100-W Rated heating output 19.0 26.0 30.0 35.0 System size 60/100 System size 80/125 Vitodens 200-W, 222-F and 242-F Rated heating output System size — — — — 60/100 System size —...
  • Page 53 Routing over an external wall (cont.) Please note ■ Position the roof outlet onto the Ensure the specified mini- roof tiles from above. mum lengths above the roof ■ Connect the external wall pipe are observed. from below. Never trim roof outlets above the roof.

  • Page 54: Plume Kit

    Plume kit Routing options A Plume kit standard delivery C Plume kit standard delivery plus: B Plume kit standard delivery ■ 2 bends 45° plus: ■ 1 pipe, 1 m long ■ 2 bends 87° ■ 1 pipe, 1 m long Observe the max.
  • Page 55 Plume kit (cont.) 1. Disengage and remove the end piece of the external wall connec- tion. 2. Insert external wall connection into the wall. 3. Push the flue bend into the external wall connection.
  • Page 56 Plume kit (cont.) 4. Insert screws into the wall in accordance with the pipe length.
  • Page 57 Plume kit (cont.) 5. Mount flue pipes and bends in line with the chosen method of routing. 6. Position the supplied fixing clamps and secure with the screws. 7. Insert the rodent protection into the uppermost bend. Note The rodent protection should be inserted into the end piece of the plume kit.
  • Page 60 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

This manual is also suitable for:

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