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

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 and are to be used with boilers for all types of fuel. 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. INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL

INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL 1On the foundation made according to the building project we apply waterproofing layer (FOUNDATION SPEED PROFILE SBS MEMBRANE). 2On the mortar we apply the first chimney block (outer element) and fill it in with concrete, remembering that the level and perpendicular position 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 concrete screed). 3On 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 position of the element as this is the initial element of the whole chimney chamotte flue. 4In 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. 5We 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) 6We 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 adjusted to the progress of chimney installation work (at temperature 20 o 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 20 o C is 24 hours. The temperature of application: from +5 o C to +25 o C. 7We 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.

Next we proceed as in point 9. 13 8We 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 under 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. 9For ICOPAL WULKAN CI / CI-eko system we stabilize internal pipes with chimney insulation, maintaining 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. We mount the next chimney blocks (outer elements) and internal chamotte pipes 10 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 element) - there must be no permanent fixing of the chimney block and the internal pipe. After reaching the assumed height, we make an opening in chimney blocks (outer elements), in 11 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. We fill in the empty space between the chimney block (outer element) and a pipe tee for flue 12 gas with mineral wool in order to provide an expansion joint. In the part of the chimney above the roof 14 we recommend using the prefabricated elements imitating brick made of colour concrete in brick colour. We join the elements using a thin-layer mortar for concrete elements (eg. frost resistant flexible glue). INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL

INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL If the outlet of fumes from the chimney is placed higher than 100 cm above the roof, the chimney should be reinforced by applying steel rods in proper openings of the chimney blocks. In 15 order to do this, during the chimney installation the openings in chimney block corners should be filled in and plugged minimum 100 cm below the roof. The special openings where reinforcement steel rods are inserted should be filled in with thin cement mortar. On the last chimney block we mount the concrete cap on mortar. The chamotte pipe should 16 freely go through the opening in the cap and protrude sufficently to mount a diffuser (chimney 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. After finishing the external surfaces of the chimney (e.g. using plaster or board finishing) we 17 mount the remaining steel elements of the chimney system. After finishing chimney installation, the remains of the acid resistant putty should be removed from the bottom of the 18 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. After chimney installation and finishing of the external surface, we leave the chimney for approx. 2 weeks to have fully 19 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 damaged CCPs. 2. To join CCP use only Rudomal KV. 3. Heat expansion of ceramic pipes should be taken into consideration (the higher the chimney and the higher the temperature 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 expansion joint should be used; Â in the place where the fumes conduit from the boiler is attached to KS pipe tee, a heat resistant ceramic cord should be applied (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 heating of the building site, when the boiler overheats or when it has faulty construction, or if the chimney pipeline is inappropriate) 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 inseparable element of the guarantee. The following recommendations 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 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 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 inspector.

Ventilated chimney systems ICOPAL WULKAN C/CI/C-eko/CI-eko SYMBOL Pv-20 Pv25T Pv36-eko Pv50-eko KJ-20 KJZ-14 KJZ-25 KC-14 KC-20 KC-25 KS-14 KS-20 KS-25 KS-20/45 o KS-25/45 o KZ-14 KZ-20 KZ-25 DRS-200 DRS-250 DRS-eko KV-3 CZ-200 CZ-200 + W CZ-eko CZ+W-eko DF-140 DF-200 DF-250 P-65 P-65 + W P-80 P-80+W KW IK-140 IK-200 IK-250 IKH-140 IKH-200 STC-200 Description size weight 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. Condensation collecting sump (tank) with outlet opening (the base element of the chimney chamotte flue). Height: 7 cm. Weight: 4 kg. Condensation collecting sump (tank) with outlet pipe (the base element of the chimney chamotte flue). Height: 18 cm. Weight: 6 kg/12,5 kg. 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. 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. 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. Cleaning door (cleanout door). Dimensions: 14x27 cm DRS-200 18x25 cm DRS-250. 13x27 cm DRS-eko. Acid resistant putty to connect internal chamotte pipes. Packaging 3 kg buckets. 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. Steel diffuser (chimney pot). Diameter: Ø 140 mm / 200 mm / 250 mm. Above the roof concrete element imitating brick (prefabricated 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. Ventilation grid. Dimensions: 14 x 20 cm. Mineral wool chimney insulation: IK type slates for WULKAN CI 140/200/250 IKH type harmonica for WULKAN CI-eko 140/200. Steel stabilizing element for ICOPAL WULKAN C200. Table of heat resistance SYSTEM 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 EXTERNAL DIMENSIONS (mm) INTERNAL DIAMETER (mm) INSULATION THICKNESS (mm) HEAT RESISTANCE (m 2 * 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 CI-200-eko 360 x 360 200 25 R39 INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL

INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL INSTALLATION MANUAL 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, independently of the construction of the roof and the roofing materials used, the chimney outlets shoul be at least 60 cm above the level 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 following rules: a) above the plane drawn at an angle of 12 downwards from the obstruction or roof ridge for chimneys situated at a distance of 3 to 10 m from the obstruction (in pitched roofs); b) at least at the level of upper edge of the obstruction (roof ridge) for chimneys situated 1,5 to 3 m from the obstruction c) at lest 30 cm higher than upper edge of the obstruction (roof ridge) for roofs situated at a distance 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