Chimney systems ICOPAL WULKAN C/CI/C-eko/CI-eko

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NOTE!

Read the installation manual carefully before starting chimney installation. During chimney installation pay special attention to the following:

Â build chimney according to the technical documentation and design respecting all

requirements of the construction law referring to chimneys;

Â connect certified heating unit in proper technical condition to the chimney; Â install complete and original accessories of ICOPAL WULKAN chimney system; Â comply with requirements included in the installation manual;

Â get the chimney approved by a recognized chimney inspector;

Â the distance between the external surface of the chimney block (outer element)

and flammable elements of the building construction should be minimum 50 mm;

Â mineral wool ofminimum thickness equaling 30 mm should be applied in places

of chimney penetration through the floors;

Â installation openings in floors and roof must be in perpendicular line;

Â mortar of minimum strength totaling 2,5 MPa should be used for joining chimney

blocks (outer elements);

Â acid resistant putty - Rudomal KV - should be used for joining internal chamotte

elements.

NOTE!

When storing chimney elements and later during construction work, the system elements should be protected against rain or snowfalls. Do not use damp or frozen elements. ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L I N ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L

INSTALLATION MANUAL

Chimney systems

ICOPAL WULKAN C/CI/C-eko/CI-eko

Ventilated

Notified entity

Building Technical and Research Institute Prague

notification no. 1020

This instruction refers to

double-layer chimney systems ICOPAL WULKAN C / C-eko

and three-layer chimney systems ICOPAL WULKAN CI / CI-eko.

The above mementioned systems are available

in diameters from 140 mm to 250 mm

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IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L I N ST A LL AT IO N M A N U A L I N ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L I N ST A LL AT IO N M A N U A L I N ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A N U A L IN ST A LL AT IO N M A

1

On the foundation made according to the building project we apply waterproofing layer (FOUNDATION SPEED PROFILE SBS MEMBRANE).

3

On the prepared base we place the element with condensation outlet KJ / KJZ, remembering that the outlet should face

the direction where the ventilating grid will be installed. Special attention should be paid to the correct perpendicular po-sition of the element as this is the initial element of the whole chimney chamotte flue.

2

On the mortar we apply the first chimney block (outer element) and fill it in with concrete, remembering that the level and perpendicular posi-tion should be carefully set. The base of the chimney can be made of other available materials on condition that its parameters are not worse than of the base made according to the method described above (blocks or con-crete screed).

4

In the first chimney block (outer element) placed on the chimney base

we cut a central opening of 20 cm x 14 cm where the ventilating grid will be installed. The ventilating grid must allow a free flow of the air. We use a grinder for concrete to cut a chimney block which we mount on mortar.

5

We make an opening in the next chimney blocks in order to mount the

cleaning door on the cleaning pipe tee (chimney pipe for attachment of cleaning door). The opening should be:

for ICOPAL WULKAN C / CI systems:

Â Ø140mm, Ø200mm - 160mm x 290mm opening (width x height) Â Ø250mm - 235mm x 310mm opening (width x height)

for ICOPAL WULKAN C-eko / CI-eko systems:

Â Ø140mm, Ø200mm - 130mm x 270mm opening (width x height)

6

We prepare acid resistant putty to bond chamotte elements according to the manual attached

to the package.

We need approx. 0,4 l of water per 3 kg of dry putty. The amount of prepared putty should be adju-sted to the progress of chimney installation work (at temperature 20o_{C the putty will be usable for 90}

min.). After thorough stirring of the amount of the putty that is needed, we wait 5 minutes and stir the content again to receive the uniform blend. Hardening time at temperature 20o_{C is 24 hours. The}

temperature of application: from +5o_{C to +25}o_C.

7

We placed the first chimney block (outer element) with the opening for

cleaning door on mortar. Next, on the prepared acid resistant putty we mount the cleaning pipe tee.

ATTENTION!

While joining chamotte elements with acid resistant putty, the surfaces which are to be adhered should be moistened.

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8

We mount another chimney block (outer element) with an opening for

the door on mortar - the opening should be in downward direction. For ICOPAL WULKAN CI / CI-eko supports should be placed in the joint un-der the chimney insulation (4 flats or bars). For ICOPAL WULKAN C / C-eko the upper part of the pipe tee should be stabilized using a steel stabilizer.

9

For ICOPAL WULKAN CI / CI-eko system we

stabili-ze internal pipes with chimney insulation, mainta-ining the order of installation: into the chimney block we insert the chimney insulation and then an internal pipe. For ICOPAL WULKAN C / C-eko system the internal pipes shoul be stabilized with a steel stabilizing element.

10

We mount the next chimney blocks (outer elements) and internal chamotte pipes remembering that:

Â while joining chamotte pipes, each time we smoothen the internal surface of the joint with a moist

sponge, removing the excess putty inside the pipeline;

Â we cannot allow for the mortar to get in between the chamotte pipe and the chimney block (outer

ele-ment) - there must be no permanent fixing of the chimney block and the internal pipe.

11

After reaching the assumed height, we make an opening in chimney blocks (outer elements), in

order to mount a pipe tee for flue gas (chimney pipe for attachment of flue gas). The openings in the chimney blocks should be made in such a way that the diameter of the opening would be 7 cm bigger than the pipe tee diameter. Next we mount the pipe tee for flue gas.

12

We fill in the empty space between the chimney block (outer element) and a pipe tee for flue

gas with mineral wool in order to provide an expansion joint.

14

In the part of the chimney above the roof

we recommend using the prefabricated elements imitating brick made of colour concre-te in brick colour. We join the elements using a thin-layer mortar for concrete elements (eg. frost resistant flexible glue).

13

Next we proceed as in point 9.

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18

After finishing chimney installation, the remains of the acid resistant putty should be removed from the bottom of the

flue gas pipeline and to enable the outflow of the condensate. The chimney should be left to dry up completely and to achieve full durability of the mortar joints.

19

After chimney installation and finishing of the external surface, we leave the chimney for approx. 2 weeks to have fully

cured mortar joints and all chimney elements totally dry. When firing up the boiler for the first time, make sure that the increase of temperature is even during longer time period and no sudden temperature changes occur. This will allow a slow process of initial chimney heating, which will have a positive impact on its later functioning.

Important notes concerning Ceramic Chimney Pipes (CCP)

1. Before mounting, check CCP carefully - do not use dama-ged CCPs.

2. To join CCP use only Rudomal KV.

3. Heat expansion of ceramic pipes should be taken into consi-deration (the higher the chimney and the higher the temper-ature of fumes, the larger expansion of the CCP). That is why proper expansion joints should be provided.

Â in the space around attachment pipe tee for flue gas (KS pipe

tee - pipe tee to which a pipe from a boiler is attached) and chimney lining block (outer element), a mineral wool expan-sion joint should be used;

Â in the place where the fumes conduit from the boiler is

atta-ched to KS pipe tee, a heat resistant ceramic cord should be ap-plied (the expansion joint should be approx. 5-10 mm);

Â the attachment pipe should be mounted axially to the KS

pipe tee;

Â the depth of the insertion of the attachment pipe from the

boiler to KS pipe tee should be max. 60 mm.

4. Direct exposure of CCP to flame (e.g. during provisional he-ating of the building site, when the boiler overheats or when it has faulty construction, or if the chimney pipeline is

inappro-priate) can lead to cracks for which the manufacturer does not take responsibility resulting from the guarantee.

The installation manual provided by the manufacturer and referring to the purchased chimney system is an insepara-ble element of the guarantee. The following recommenda-tions should be met:

Â transport and storage as recommended by the manufacturer; Â no defects of the chimney elements should be confirmed

when purchase takes place;

Â build chimney according to the technical documentation and

design respecting all requirements of the construction law re-ferring to chimneys;

Â connect certified heating unit in proper technical condition

to the chimney;

Â install complete and original accessories of ICOPAL WULKAN

chimney systems;

Â comply with requirements included in the installation manual; Â attach a filled in identification plate to the chimney;

Â get the chimney approved by a recognized chimney

inspec-tor.

15

If the outlet of fumes from the chimney is placed higher than 100 cm above the roof, the

chim-ney should be reinforced by applying steel rods in proper openings of the chimchim-ney blocks. In order to do this, during the chimney installation the openings in chimney block corners should be fil-led in and plugged minimum 100 cm below the roof. The special openings where reinforcement ste-el rods are inserted should be filled in with thin cement mortar.

16

On the last chimney block we mount the concrete cap on mortar. The chamotte pipe should

freely go through the opening in the cap and protrude sufficently to mount a diffuser (chim-ney pot) on it. The installed diffuser should be approx. 1-2 cm above the concrete cap. If necessary we cut the pipe to adjust its length and mount the diffuser using high temperature silicone.

17

After finishing the external surfaces of the chimney (e.g. using plaster or board finishing) we mount the remaining steel elements of the chimney system.

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Ventilated chimney systems – ICOPAL WULKAN C/CI/C-eko/CI-eko

Table of heat resistance

Chimney lining block (outer element) 46x46x20 cm. Weight: 23 kg.

Chimney lining block (outer element) 46x46x20 cm. Weight: 16 kg.

Chimney lining block (outer element) 36x36x24,5 cm. Weight: 15 kg.

Chimney lining block (outer element) 36x50x24,5 cm. Pv-20

Pv25T

Pv36-eko Pv50-eko

Description – size – weight SYMBOL

Condensation collecting sump (tank) with outlet ope-ning (the base element of the chimney chamotte flue). Height: 7 cm. Weight: 4 kg.

KJ-20

Condensation collecting sump (tank) with outlet pipe (the base element of the chimney chamotte flue). Height: 18 cm. Weight: 6 kg/12,5 kg.

KJZ-14 KJZ-25

Straight pipe element (chimney pipe). Height 328 mm, thickness of pipe wall 15 mm (KZ25 – 25 mm).

Weight: 5,3 kg / 7,7 kg / 17 kg. KZ-14

KZ-20 KZ-25

Cleaning door (cleanout door). Dimensions: 14x27 cm – DRS-200 18x25 cm – DRS-250. 13x27 cm – DRS-eko. DRS-200 DRS-250 DRS-eko

Acid resistant putty to connect internal chamotte pi-pes.

Packaging – 3 kg buckets. KV-3

Steel diffuser (chimney pot).

Diameter: Ø 140 mm / 200 mm / 250 mm. DF-140 DF-200 DF-250 Ventilation grid. Dimensions: 14 x 20 cm. KW

Mineral wool chimney insulation: – IK type – slates for WULKAN CI 140/200/250 – IKH type – harmonica for WULKAN CI-eko 140/200. IK-140

IK-200 IK-250 IKH-140 IKH-200

Steel stabilizing element for ICOPAL WULKAN C200. STC-200

Above the roof concrete element imitating brick (pre-fabricated stack) Dimensions: 48 x 48 x 6,5 cm / 48 x 72 x 6,5 cm / 42 x 42 x 8 cm / 42 x 56 x 8 cm. Weight: 19 kg / 29 kg. P-65 P-65 + W P-80 P-80+W

Chimney cap (prefabricated concrete end) - dye in the cake concrete. Dimensions: CZ-200 62x62x7,5 cm; CZ-200 + W 62x86x7,5 cm; CZ-eko 52 x 52 x 6; CZ+W-eko 52x66x6. Weight: 39 kg / 49 kg / 29 kg / 39 kg. CZ-200 CZ-200 + W CZ-eko CZ+W-eko

Cleanout pipe tee (pipe for attachment of cleaning door).

Height: 660 mm, thickness of pipe wall: 15 mm, (KC25 – 25 mm) cleanout opening (width x height) 130x260 mm, KC25 – 180x270 mm.

Weight: 16,20 kg / 30 kg. KC-14

KC-20 KC-25

Pipe tee for attachment of flue gas.

Height: 660 mm, thickness of pipe wall: 15 mm, (KS25 – 25 mm), cleanout opening diameter – 140 mm / 200 mm / 250 mm. Weight: 12,2 kg / 17,7 kg / 33 kg. KS-14 KS-20 KS-25 KS-20/45o KS-25/45o SYSTEM EXTERNAL DIMENSIONS (mm) INTERNAL DIAMETER (mm) INSULATION THICKNESS (mm) HEAT RESISTANCE (m2_{* K * W-1)} 460 x 460 140 0 R19 460 x 460 200 0 R26 360 x 360 140 0 R16 360 x 360 160 0 R17 360 x 360 180 0 R18 360 x 360 200 0 R19 460 x 460 140 33 R66 460 x 460 200 37 R75 360 x 360 140 55 R58 360 x 360 160 45 R53 360 x 360 180 35 R47 WULKAN C-140 WULKAN C-200 WULKAN C-140-eko WULKAN C-160-eko WULKAN C-180-eko WULKAN C-200-eko WULKAN CI-140 WULKAN CI-200 WULKAN CI-140-eko WULKAN CI-160-eko WULKAN CI-180-eko WULKAN CI-200-eko 360 x 360 200 25 R39

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Chimney height above the roof

(according to Polish construction law)

Chimney pipes must be let out above the roof to a height ensuring the correct chimney draught (stack effect). In order to achieve this effect, the following rules should be fulfilled:

Â_{on flat roofs with sloping angle of not more than 12°,}

inde-pendently of the construction of the roof and the roofing ma-terials used, the chimney outlets shoul be at least 60 cm abo-ve the leabo-vel of the roof ridge or the edges of buildings with sunken roofs.

Â on pitched roofs where the angle of slope exceeds 12° and

roof covering is:

a) flammable - the outlets should be at least 60 cm above the

roofs ridge

b) non-flammable, burn-resistant - the outlets should be at

least 30 cm above the roof surface and the distance from the top of the chimney to the roof measured horizontally should be at least 100 cm.

Â_{when the chimney is situated close to obstructing building}

elements (e.g. a roof with a slope over 12° can be considered an obstruction) - for the proper work of the chimney, their outlets should be placed above the roof according to the fol-lowing rules:

a) above the plane drawn at an angle of 12° downwards from

the obstruction or roof ridge for chimneys situated at a distan-ce of 3 to 10 m from the obstruction (in pitched roofs);

b) at least at the level of upper edge of the obstruction (roof

rid-ge) for chimneys situated 1,5 to 3 m from the obstruction

c) at lest 30 cm higher than upper edge of the obstruction

(ro-of ridge) for ro(ro-ofs situated at a distance (ro-of up to 1,5 m from this obstruction. ICOPAL S.A. ul. Łaska 169/197 98-220 Zduńska Wola tel. +48 43 823 41 11 fax +48 43 823 40 25 www.icopal.pl Product Manager mob. +48 691 519 242 e-mail: plmwa@icopal.com www.icopal.pl