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CI/SfB(59)

August 2008

Centrotherm Advanced plast ic & metal f lue system solut ions for condensing boi lers02

Introduction

This brochure describes Centrotherm’s plastic and

metal flue system solutions for condensing gas

and oil boilers and describes the principles,

design considerations and installation methods

for the systems.

Centrotherm’s range includes rigid and flexible

pipes in polypropylene and metal for constructing

flue systems for commercial or residential

applications. The wide range of components

enables extended flue runs to be constructed,

giving the designer greater flexibility for

positioning the boilers, whilst push-fit joints on

pipes and accessories ensure installation is rapid

and cost-effective.

About Centrotherm

Centrotherm is a division of Ubbink (UK) Ltd. and

part of Centrotec Sustainable AG.

As well as gas flue systems, Centrotec

manufactures and supplies ventilation systems to

promote a healthy internal climate, solar

technology to maximse energy gain from the sun,

and medical technology. Sustainability is at the

the heart of Centrotec’s business, with the

development of solutions to protect the earth’s

resources and limit environmental pollution.

Centrotec has been involved in flue systems since

1982, and through a continuing program of

investment in research and development, is now

a European leader in pioneering plastic gas flue

systems for condensing gas and oil boilers.

Centrotherm draws on this research and practical

experience, and offers proven plastic technology

for commercial flue systems as well as flue

solutions in stainless steel and aluminium.

Advanced flue system solutions

Contents Page

Introduction 02

About Centrotherm 02

The system 03

Requirements 04

Declaration of conformity for plastic systems 05for stainless steel systems 06for aluminium systems 07

Technical description and performance 08

Design 09

Flue system overview 10

Flue system 1 11

Flue system 2 12

Flue system 3 13

Flue system 4 14

Flue system 5 15

Flue system 6 16

Flue system 7 17

Sitework 18

Supply, technical supportand references 19

h e a l t h c o m f o r t e n e r g y

Advanced plast ic & metal f lue system solut ions for condensing boi lers Centrotherm 03

The system

The challenge of Part L

The changes to Part L of the Building Regulations

introduced in April 2006 (and comparable

changes made in Scotland in 2007) have had a

significant impact on heating strategies for

dwellings which, prior to 2006, would have been

heated by electric systems.

With the primary test for Part L being the

comparison of the dwelling’s carbon dioxide

emissions (the DER) with that of a ‘notional’

dwelling (the TER), the carbon dioxide emission

rate of the fuel used to provide space and water

heating has become a key factor in achieving

compliance.

Under the Building Regulations mains electricity

has the highest carbon dioxide emission rate of

any of the major fuel types; a dwelling heated

primarily by electricity therefore requires

substantial improvements to its fabric in order to

compensate for the heating CO2 emissions and

so meet the TER. Apartments offer little scope for

compensating measures, making it extremely

difficult for those with electric heating to comply

with Part L.

The use of condensing boilers fired by gas or oil

can result in substantially lower emission rates

than those possible with electric heating, making

it easier for dwellings to comply with the

emission targets of Part L and the Code for

Sustainable Homes. However, the provision of

boilers to individual apartments is expensive,

whilst arranging for the supply of gas or oil to

each apartment presents significant problems of

compartmentation and fire safety.

Centralised boiler flue systems

A safe, cost-effective and energy-efficient

solution for heating apartments is the use of a

centralised boiler system to provide heat for a

number of apartments.

With a communal heating system there is no

need to provide individual boilers, nor to supply

fuel to each apartment. Instead, a number of

boilers are installed in a purpose-built

boiler-house and the hot water circulated

throughout the block. Modern metering systems

enable occupiers to be charged accurately for the

amount of heat used.

The increasing use of condensing boilers - driven

by their improved efficiency compared to

conventional types - also has implications for the

flue system. Because heat is recovered from flue

gases, they leave the boiler at a lower

temperature than those from a conventional

boiler, which means the flue can be made of

plastic, rather than metal.

Centrotherm’s push-fit polypropylene gas flue

systems are a cost-effective means of providing

flues for centralised boiler systems for virtually

any configuration of boilers and terminals.

Centrotherm can also supply metal flue systems

where required.

04

European legislation

Flue systems must comply with the Construction

Products Directive with regard to testing and

classification, and must only be used within their

tested range. The classification system for flues is

set out in the box below.

Building regulations

Combustion appliances are covered by Part J of

the Building Regulations (in Scotland, section 3 of

the Technical Standards). Part J2 requires

appliances to be connected to suitable flues

which discharge to outside air. Factory made

components must be independently certified to

the standard required for the type of appliance

specified.

Pipework to condensing appliances must be

impervious to condensate.

Where multiple appliances are flued together the

system must follow the guidance of

BS 5440-1:2000 for gas appliances or

BS 5410-1:1997 for oil appliances.

Flues should be designed to give least resistance

to the passage of gases, by minimising bends

and the length of horizontal runs.

Flues must also be appropriately shielded from

combustible building materials.

Installation of gas appliances must be carried out

by persons qualified under the Gas Safety

(Installation and Use) Regulations 1998.

Requirements

Flues are classified according to EN 1443:2003: Chimneys. General requirements. The classification systemaddresses the main performance characteristics of chimneys and flues and assigns performance classesagainst them.

The Temperature class (nom. working temp): T080 to T600.

Pressure tightness class: N1, N2, P1, P2, H1, H2, (where N is negative pressure, P is positive pressure and H is high positive pressure and a lower numberindicates greater gas tightness).

Resistance to condensate: W - wet - D - dry.

Corrosion resistance: 1, 2 or 3 (with 3 being most resistant)

Sootfire resistance classes: G - flue with soot fire resistance, 0 - without soot fire resistance.

Distance to combustible materials (mm): This appears directly after the sootfire resistance.

Manufacturers may also declare:

Thermal resistance (in units of m2K/W x 100): R.

Installation:

I May be used inside buildings or enclosures

E May be used inside and outside buildings or enclosures.

Fire resistance class to EN 13501: e.g. D

Type of chimney:

L System chimney without enclosure (or external pipe)

L1 System chimney with flammable cladding (e.g. plastic external pipe)

L0 System chimney with non-flammable cladding (e.g. metallic external pipe)

Centrotherm Advanced plast ic & metal f lue system solut ions for condensing boi lers

05

Declarat ion of conformity for plast ic systems

EN 14471 Chimneys - System chimneys with plastic flue liners requirements and test methods

Centrotec Sustainable AG Am Patbergschen Dorn 9 59929 Brilon [email protected] www.centrotec.de

System - Chimney PP models: single walled

concentric

Pieter van der Poel director Centrotherm and Ubbink

TÜV Industrie Service GmbH Munich

0036 CPD 9169 003

0.1 PP

system chimney single walled

EN 14471 T120 H1 O W 2 O20 I D L single walled system chimney flue material: PP

0.2 PP

system chimney concentric

EN 14471 T120 H1 O W 2 O00 I D L1 concentric system chimney flue material: PP enclosure: plastic

0.3 PP


EN 14471 T120 H1 O W 2 O00 E D L0 concentric system chimney flue material: PP enclosure: steel, aluminium

0.4 PP


EN 14471 T120 H1 O W 2 O00 E D L0 concentric system chimney flue material: PP enclosure: stainless steel

product description

number of standard

temperature class

pressure class

soot fire resistance

condensate resistance

corrosion resistance

distance to combustible

location

reaction to fire

section / fittingof

PP – system chimney

compressive strength max. height (rigid): 50m

max. height (flexible): 30m

wind load max. height above last

support [1.5m]

thermal resistance 0.00 m²K/W

reaction to fire D

flexural tensile strength length of excursion

[1.5m] max. angle:

87°flow resistance

medium roughness 0.5mm

Certificate Number

enclosure class

Conformity Declaration and Product Information

Producer Identification

Product Description

Name, Function of the Responsible Employee

Notified Body

Advanced plast ic & metal f lue system solut ions for condensing boi lers Centrotherm

06

Declarat ion of conformity for stainless steel systems


EN 1856-1 Requirements for Metal Systems Part 1 Components for Prefabricated Chimney systems

Producer Identification Centrotec Sustainable AG Am Patbergschen Dorn 9 59929 Brilon [email protected] www.centrotec.de

Production Location Verhuellweg 9 6984AA Doesburg The Netherlands

Product Description Prefabricated Chimney System - Stainless Steel Versions: Single walled Double walled

Name, Function of the Responsible Employee Pieter van der Poel

Managing director Ubbink-Centrotherm Notified Body Kiwa Gastec Certification

Wilmersdorf 50 7327 AC Apeldoorn The Netherlands

Description of Documents in conformity with EN 1856

0.1 Stainless Steel

Chimney system Single walled

EN1856-1 T200 P1 W Vm-L50040 O(20) Chimney system single walled Flue gas components: Stainless Steel

0.2 Stainless Steel

Chimney system Double walled

EN1856-1 T200 P1 W Vm-L50040 O(00) Chimney system double walled Flue gas components: Stainless Steel Air inlet components: Metal

0.3 Stainless Steel


EN1856-1 T200 P1 W Vm-L50040 O(00) Chimney system double walled Flue gas components: Stainless Steel Air inlet components: Plastics

Producdescription

Norm-Nr.

Temperature class

Pressure class

Condensate resistance

Corrosion resistance

Soot fire resistance

Extension/Moulded component of a

Metal - Chimney system

System vertical load 27m

Gas flue flow resistance Average wall roughness: 1.0mm

�-Values moulded components in conformity with EN13384-1

Thermal transmittance 0.0W/m²K

Flexural Rigidity Tensile Strength: n.p.d.

Slanted Installation: n.p.d. Windload: n.p.d.

Freeze-Thaw resistance Yes

Certificate Number 0036 CPD 6874


07

Declarat ion of conformity for a luminium systems


EN 1856-1 Requirements for Metal Systems Part 1 Components for Prefabricated Chimney systems

Producer Identification Centrotec Sustainable AG Am Patbergschen Dorn 9 59929 Brilon [email protected] www.centrotec.de

Production Location Verhuellweg 9 6984AA Doesburg The Netherlands

Product Description Prefabricated Chimney System - Aluminium Versions: Single walled Double walled

Name, Function of the Responsible Employee

Pieter van der Poel Managing director Ubbink-Centrotherm

Notified Body Kiwa Gastec CertificationWilmersdorf 50 7327 AC Apeldoorn The Netherlands

Certificate Number

Description of Documents in conformity with EN 1856-1 Anex ZA

0.1 Aluminium

Chimney system Single walled

EN1856-1 T200 P1 W Vm-L13150 Vm-L10150 O(20) Chimney system single walled

Fluegas components: Aluminium

0.2 Aluminium


EN1856-1 T200 P1 W Vm-L13150 Vm-L10150 O(00)

Chimney system double walled Fluegas components: Aluminium Air inlet components: Metal

0.3 Aluminium


EN1856-1 T200 P1 W Vm-L13150 Vm-L10150 O(00)

Chimney system double walled Fluegas components: Aluminium Air inlet components: Plastics

Product description

Norm-Nr.

Temperature class

Pressure class

Condensate resistance

Corrosion resistance

Soot fire resistance

Extension/Moulded component of a

Metal - Chimney system

System vertical load 50m

Gas flue flow resistance Average wall roughness: 1.0mm

�-Values moulded components in conformity with EN13384-1

Thermal transmittance 0.0W/m²K

Flexural Rigidity Tensile Strength: n.p.d.

Slanted Installation: n.p.d. Windload: n.p.d.

Freeze-Thaw resistance Yes

0036 CPD 6874


08

System configurations

Single wall systems: exhaust gas flues available in

rigid or flexible polypropylene, aluminium or

stainless steel, and in a range of diameters from

60 - 315mm, with 400mm and 630mm diameter

sections available from 2009. Sections are

supplied in 250, 500, 1000 and 2000mm

lengths, with a range of bends and connectors.

Flexible polypropylene pipes are available in 12.5

and 25m rolls.

Flue sections are joined using high performance

H1 seals which are suitable for service pressures

up to 5000Pa and are resistant to corrosive

condensate. Once installation lubricants have

dried the seals provide firm junctions between

sections.

Concentric flue systems combining exhaustgas flue (inner) and air intake pipe (outer)

Available in combinations of:• polypropylene inner with plastic, aluminium or

stainless steel outer

• aluminium inner with polypropylene,aluminium or stainless steel outer

• stainless steel inner and outer.

Diameters (inner/outer) range from 60/100mm to

250/300mm. Some concentric flue systems are

suitable for external use.

Centrotherm systems can be used to convert

chimneys to balanced flues which incorporate an

air intake, enabling straightforward replacement

of an existing boiler by a fanned flue condensing

boiler in the same location.

AccessoriesA comprehensive range of terminals and intakes

for roofs & walls, as well as support brackets,

condensate traps and connectors.

Application guide

The flue pipe material must be matched to the

boiler type and the proposed fuel (see below).

Pipe materials

Polypropylene• 2mm thick rigid or flexible pipes

• 60 - 315mm diameter (single wall)

• Peroxide seals (H1 5000Pa)

• Translucent finish up to 250mm, but withsome diameters also available in black or grey

• Translucent finish not UV-stabilised so must notbe exposed to sunlight for prolonged periods.Black and grey are UV-stabilised.

Aluminium• 1.5 - 1.7mm thick (exhaust flue) or 0.8mm

thick (air intake)

• 80 - 130mm diameter (single wall).

• Silicon seals (P1 200Pa)

• Natural finish, but with some diameters alsoavailable in white (RAL 9016)

• May be left exposed to atmosphere.

Stainless steel• 0.4mm thick

• 80 - 200mm diameter (single wall)

• Silicon seals (P1 200Pa)

• Natural finish

• May be left exposed to atmosphere.

Technical descr ipt ion and performance

Flue material Boiler type

Polypropylene

Aluminium

Stainless steel

Condensing gas

��

Condensing oil

��

Non-condensing gas

��

Non-condensing oil

��

Solid fuel

��


09

Design

Overview

Centralised boiler systems are common in

commercial buildings, offering high levels of

efficiency and control. They also offer significant

benefits in residential projects where compliance

with Part L and Code for Sustainable Homes

cannot be achieved by means of electric heating

systems.

Whilst individual boilers may offer a theoretical

solution for appartments there are substantial

problems in supplying fuel for each occupancy

and arranging for discharge of exhaust gases,

both of which have substantial implications for

compliance with Part B of Building Regulations.

A centralised boiler house containing multiple gas

or oil boilers offers a means of complying with

the carbon emission requirements of Part L,

which is practical and cost-effective, and

minimises compliance issues.

Boiler location

Centrotherm flue systems offer designers

considerable flexibility in the location of the

boiler: they may be located within the main

building with an internal flue, or in a self-

contained annex with the flue running up the

exterior of the building.

Flue design

The flue must be rated for use with the specified

boiler type: use the CE declarations on pages

05 - 07 in conjunction with the guidance notes

on page 04 to determine the performance

requirement of the flue.

The flue must be sized for the specified boiler(s).

The optimum diameter depends on the layout,

boiler capacity, fuel and exhaust rate.

Centrotherm offers a flue sizing service and can

advise on optimum design of the flue for the

system configuration. The illustrations on pages

11 - 17 show flue configurations suitable for a

number of boiler and flue combinations.

In order to minimise resistance to the passage of

exhaust gases, flues should be designed to run

vertically, with the minimum number of bends.

The use of flexible polypropylene pipes enables

small variations in direction to be accommodated

without the need for rigid bends.

Positive pressure cascade systems which link

multiple boilers should be fitted with non-return

valves, to prevent exhaust gases from one boiler

affecting the operation of the others. The use of

non-return valves enables narrower flues to be

specified: the boilers must have been tested for

positive pressure applications. Alternatively,

positive/negative systems allow boilers to be used

without non-return values: this will allow a slight

reduction in flue diameter. Consult Centrotherm

for further guidance.

Fire

Flues carrying exhaust gases must be isolated

from combustible materials. Where flues

penetrate fire compartment floors or walls they

must not compromise the compartmentation.

The opening for the flue must be appropriately

fire stopped. (See Approved Document B

section 7 and the ASFP publication ‘Fire stopping

and penetration seals for the construction

industry’). Rigid and flexible polypropylene flues

can be fire stopped using intumescent collars

designed to collapse the pipe in the event of a

fire.

Termination

The wide range of Centrotherm terminals enables

flues to be terminated through pitched roofs, flat

roofs and walls. In order to ensure the well-being

of building occupants, flue terminals should not

be sited in close proximity to openings.

For limitations on siting of flue outlets of gas

appliances consult Approved Document J

diagrams 3.4 and 3.5 and the associated tables;

for oil appliances consult diagram 4.2; for solid

fuel appliances consult diagram 2.1.

Ubiflex flashings should be used to provide

weather protection at terminal penetrations.


10

Flue system overview

II I I II I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II I I I II IIIII I I I I I I IIIIIIIIIII

I

I

II

II

I

IIII

II

IIII

IIIIIIIIIIIIIIIIII I

II

II

1

2

3

4

5

6

7

Typical flue systems

The diagram above and the visuals shown on

pages 11 - 17 show some typical Centrotherm

flue systems for single and multiple condensing

boilers. The systems accommodate applications

where the flue pipes are required to run up the

internal wall, external wall, within straight

enclosures, angled enclosures and where air is

drawn into the boiler from internal rooms or the

outside air.

Other flue configurations including horizontal

terminations are available.

Flue configurations and sizing can be carried out

by our team using the KESA Aladin Design

Programme.

Air supply

Exhaust gas


11

Flue system 1Single wall flue (air supply from boiler room)

2

1

4

5

6

�� Boiler

�� Connector

�� Air supply

�� Pipe at 3˚ to horizontal

�� Vertical pipe supported at 2m intervals

�� Roof terminal

3


12

Flue system 2Single wall flue - flexible pipe in enclosure (air supply from boiler room)

2

1

4

5

6�� Boiler

�� Connector

�� Air supply


�� Flexible pipe


Installation constraints for flexible pipes

D

<45˚r >3D

r

3


13

Flue system 3Concentric flue (air supply via flue enclosure)

2

1

3

5

7

4

�� Boiler

�� Connector


�� Concentric - single wall adaptor


�� Air supply


6

6


14

Flue system 4Single wall flue (air supply by dedicated pipework from outside boiler room)

1

2

5

6

4

3

�� Boiler

�� Connector

�� Air supply





15

Flue system 5Concentric flue -external application (room-sealed appliance)

2

1

3

5

6

�� Boiler

�� Connector


�� Air supply



4


16

Flue system 6Cascade system for multiple boilers (air supply from boiler room)

3

6

7

5

2

1

�� Boiler

�� Condensate drain

�� Connector with non-return valve

�� Air supply




4


17

2

1

5

6

3

�� Boiler

�� Condensate drain


�� Air supply



Flue system 7Cascade system for multiple boilers (air supply by dedicated pipework from outside

boiler room)

4


18

Storage

Components should be stored in a clean, dry

environment and in their original packaging.

Non-UV stabilised plastic components must be

protected from prolonged exposure to UV light.

Health and safety

Where installation of a flue involves working at a

height a full risk assessment must be conducted

and appropriate safety measures put into place.

Workmanship

Installation of Centrotherm flues does not require

any special tools.

Do not work with components which are at a

temperature of less than 0°C.

Installation

Pipes are joined by push-fit connections, with

peroxide or silicon sealing rings located in the

sockets. Pipes and components must be installed

with their socket ends to the outlet and male

ends to the appliance.

Joining

1 Lubricate seals and male parts of pipes withCENTROCERIN lubricant (note: other lubricantsmay have an adverse effect on the seal).

2 Push male end of pipe into opening with lighttwisting movement.

The use of translucent pipes enables installers to

check that seals have been fitted correctly.

Cutting

Components should be selected to minimise

cutting. Where cutting is unavoidable, pipe

sections can be cut to length, but only at the

non-seal end. Any cuts must be made at right

angles to the pipe and the cut end bevelled for

insertion into the adjoining socket.

Bends and other pre-formed components must

not be cut.

Configuration

Flues should be

supported at a

maximum of 2m

intervals vertically and

1m horizontally.

Additional supports

may be required at

bends on flexible pipes.

Inspection openings

should be located on

the upper side of

horizontal pipes, but

condensate drains should

be located on the underside.

Connectors from appliance and subsequent pipes

must be installed at 3° to horizontal (56mm fall

per linear metre), to enable condensate to drain.

At any lower angle there is a risk of water being

drawn into the seal chamber by capillary action,

resulting in rapid deterioration of the seal.

Commissioning

Once installation is complete the boiler system

and flue should be commissioned following the

boiler manufacturer’s instructions.

Sitework

2m m

ax.


19

Supply

Centrotherm flue systems are distributed in the

UK by approved suppliers.

Technical support

Centrothem offers comprehensive technical

support to designers and contractors working

with Centrotherm flue systems, including:

• Copies of test certificates;

• On-site visits by technical representatives;

• Flue design and specification service

No matter what the size and location of the

project, Centrotherm can supply flue and

chimney systems, to meet the most exacting

requirements.

References

• Approved Documents to Building Regulations

B - Volume 1 Dwellinghouses: 2006

B - Volume 2 Buildings other than

dwellinghouses: 2006

J - Combustion appliances and fuel storage

systems: 2002

J - 2002 Edition: Guidance and supplementary

information on the UK implementation of

European standards for chimneys and flues.

• Building Standards Scotland:2007 TechnicalHandbook - Domestic

• Building Standards Scotland:2007 TechnicalHandbook - Non-domestic

• BS EN 1443:2003 Chimneys. General requirements.

• EN 13384 Chimneys - Thermal and fluiddynamic calculation methods

- Part 1 Chimneys serving one appliance

- Part 2 Chimneys serving more than one heating appliance

- Part 3 Methods for the development of diagrams and tables for chimneys servingone heating appliance

• BS 5410 Code of practice for oil firing.

- Part 1:1997 Installations up to 45kW outputcapacity for space heating and hot watersupply purposes

• BS 5440-1:2008 Flueing and ventilation for gasappliances of rated input not exceeding 70kWnet (1st, 2nd and 3rd family gases).Specification for installation of gas appliancesto chimneys and for maintenance of chimneys

• Fire stopping and penetration seals for theconstruction industry. Association of SpecialistFire Protection. 2008. (available fromwww.asfp.org.uk)

Supply, technical support & references

Every effort has been taken in the preparation of this brochure to ensure the accuracy of representations contained herein.

Recommendations as to the use of materials, construction details and methods of installation are given in good faith and relate to

typical situations. However, every site has different characteristics and reliance should not be placed on the foregoing

recommendations. Advice can be given as to specific applications of the products, upon request to Centrotherm.


EUROPE’S LEADING BOILER FLUE SYSTEMS

Centrotherm are a European leader in flue systems offering

advanced solutions for commercial and residential applications,

in both plastic and metal, for gas and oil boilers.

Ubbink (UK) Ltd., Borough Road, Brackley, Northants NN13 7TB

Tel: 0845 456 3499 • Fax: 01280 705 332 • Email: [email protected]

www.centrothermflues.co.uk