For the installer

Installation instructions

Installation instructions

PFGHRD 60/100

Passive Flue Gas Heat Recovery Device

GB, IE

INSTALLATION

Explanation of symbols

a Symbol that denotes danger:

- Imminent danger to life

- Risk of severe personal injury

- Risk of minor personal injury

The PFGHRD is an integral part of the flue system and as such should be fitted in accordance with the manufacturer's flue instructions.

Product description

The PFGHRD (Passive Flue Gas Heat Recovery

Device) is designed as a complimentary energy saving system that can be connected to a

Contents of package

1. PFGHRD unit

2. Support bracket

3. Wall fixing screws

4. Unit fixing screws

5. Installation manual

6. SAP label (attached to product)

7. Wall template

8. Flue anchor bracket (attached to product)

Technical information

DHW system

Max. water pressure

Min. operating pressure

10.0* bar

0.2 bar

* Use a pressurereducing device to achieve this, if necessary.

Connections

Water connections

General dimensions

Height

Width

Depth

Weights

Empty

Full

15 mm

276 mm

376 mm

262 mm

6.6 kg

9.4 kg condensing combination boiler. This appliance recovers latent energy from flue gases produced by condensing combination boilers. The energy from flue gases is used to preheat incoming domestic cold water. The PFGHRD heat exchanger increases domestic hot water efficiency and therefore reduces gas consumption, CO emissions and waste of sanitary water.

2

The PFGHRD is included in SAP Appendix Q, under

Passive Flue Gas Heat Recovery Devices.

Vaillant - PFGHRD 60/100

Boiler applications

Condensing boilers only ecoTEC plus ecoTEC pro

Flue Connections (60/100)

Top

Bottom

General

DHW Heat exchanger

Inner casing

Outer casing

Water content

60 - 100 mm

60 - 100 mm

Stainless steel

PP According to

EN 14471-1

ABS

2.8 litres

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INSTALLATION

Maximum flue length ecoTEC exclusive 832/838

Vertical

Horizontal

Maximum flue length ecoTEC plus 824/pro 24

Vertical

Horizontal

Maximum flue length ecoTEC plus 831/pro 28

Vertical

Horizontal

Maximum flue length ecoTEC plus 837/937

Vertical

Horizontal

3 m

1 m + elbow

10 m

6 m + elbow

7 m

3 m + elbow

5 m

2 m + elbow

(Further flue lengths/bends may be used, but a loss in output of

1% is incurred for every additional metre).

General installation conditions

Assess the overall height of the installation including PFGHRD and choose the appropriate flue system arrangement (see 3. Installation diagram).

In situations where the water pressure exceeds

10 bar, it should be reduced to the permitted water pressure.

To allow pipework to be installed behind the boiler we recommend the use of the 308650 spacing frame.

No requirement for expansion vessel or mixing valve, see Commissioning page 7.

PFGHRD Installation

1. The hot and cold water pipes are positioned at the bottom of the PFGHRD near the water connections.

Inlet

Cold mains water

Outlet

Pre-heated water

NOTE: No soldering of joints should be undertaken in close vicinity to the PFGHRD or boiler as this may cause damage.

2. Dimensions.

A

Distance from the flue outlet centre line to inside wall face, A = 130mm, if using a spacing frame, A = XXmm.

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INSTALLATION

3. Installation diagram.

466 recoFLUE

35

Air intake

Flue adaptor

Trim ring

384

434

Measurement from top of air intake

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INSTALLATION

Installation sequence

1. Fix the PFGHRD template to the wall ensuring that there is sufficient clearance to the ceiling.

Ensure that the centre line of the template is vertical and at least 250mm from any side wall to allow for mounting of the boiler and pipework. Ensure there is at least 1320mm clearance from the flue centreline to any surface below to allow for installation of the boiler.

3. Secure the PFGHRD bracket and the boiler mounting bracket to the wall.

4. Fix boiler to wall according to manufacturers instruction.

2. Mark and drill holes for the PFGHRD and boiler mounting brackets, all as per the wall template. Mark the centre of the flue. Remove the wall template and drill the flue hole. Note that if you intend to use a spacing frame, use the information provided with the spacing frame to drill additional holes as required.

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INSTALLATION

5. Mount the PFGHRD onto the flue outlet of the boiler and onto the support bracket. Attach to the support bracket with the fixings provided and secure the flue clamp.

6. Connect the water pipes. Use the correct materials that can be combined with stainless steel.

7. Connect the flue system to the PFGHRD in accordance with the boiler installation instructions. Ensure the flue clamps are fitted and secured. Ensure that the flue anchor bracket attached to the PFGHRD is secured to the flue system by the screw provided.

8. Note that the overall flue length should not exceed the figures shown in the table on page

3, to allow for the additional resistance of the

PFGHRD.

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INSTALLATION

FLUE ANCHOR

BRACKET &

SCREW

9. The PFGHRD is ready for commissioning.

Commissioning

1. Complete installation and pipework of the boiler according to the installation instructions.

Ensure tightness of all flue joints.

2. Open the cold water supply and cold water inlet valve of the appliance and check all connections for water leaks.

3. Turn on hot water tap and flush the PFGHRD until it is completely filled with water and no noise is audible.

4. The PFGHRD is ready for use.

5. Commission the boiler in accordance with the installation instructions.

To prevent corrosion of the boiler or PFGHRD and also on the air/flue gas duct, note the following:

Do not use sprays, solvents, chlorinated cleaning agents, paint, adhesives or similar substances in the vicinity of the boiler. Under unfavourable circumstances, these substances may cause corrosion.

All mains water heated by the ecoTEC range of combination boilers will be classed as Category

2 fluid (potable water) and small expansion volumes created during warm up must be allowed to flow back into the supply pipe. No back flow prevention is necessary with this appliance as the very small expansion volume is unlikely to heat the incoming service pipe above

25 Deg C.

Note that where back flow prevention devices are fitted (this may include water meters) these can prevent the permitted expansion into the cold supply. This along with the effects of pumping and / or water hammer can result in a pressure build-up that may cause damage to the boiler (and other household devices such as showers). Vaillant cannot accept responsibility for damage caused to the boiler or its surroundings where an appliance has been fitted to supplies with mechanical back flow prevention. In these cases the requirement would be that a competent installer correctly installs a suitable shock arrestor / miniexpansion vessel adjacent to the boiler in the cold water supply pipe.

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Supplier

Manufacturer