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Version 3/ August 2018 Installing instructions DW-MAMMUT
1
INSTALLING INSTRUCTIONS
Double wall flue system with ceramic inner tube type DW-MAMMUT
Version 3/ August 2018 Installing instructions DW-MAMMUT
2
Double wall flue system with ceramic inner tube type DW-MAMMUT
Certification 0036 CPD 9174 039 nach EN 13063-1 (dry operation mode) Certification 0036 CPD 9174 040 nach EN 13063-2 (wet operation mode)
Building authority approval Z-7.1-3351 (W3G)
(For further information see Declaration of Performance or Building authority approval of system DW-MAMMUT)
Version 3/ August 2018 Installing instructions DW-MAMMUT
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Double wall flue system with ceramic inner tube type DW-MAMMUT
Version 3/ August 2018 Installing instructions DW-MAMMUT
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Double wall flue system with ceramic inner tube type DW-MAMMUT
Contents: 1. System overview .............................................................. Page 5
2. Mounting and regulations .............................................. Page 6
3. Mounting heights ……………………………………………..…….... Page 6
4. Minimum distance to combustible materials .………... Page 8
5. Installation of the vertical part of flue system
5.1 Construction of pipes ……………………..………………. Page 9
5.2 Application of the acid-resistant paste ………….. Page 9
5.3 Wall brackets made of stainless steel ……………. Page 12
5.4 Telescopic support …………………………………….……. Page 12
5.5 Concrete socket ………………………………………….…… Page 12
5.6 Base plate …………………………………………………………. Page 13
5.7 Clean-out element .………………………..……………….... Page 13
5.8 Connection element to the upright part ………... Page 13
5.9 Supports …………………………………………………..…….. Page 13
5.10 Intermediate support ………………………………………. Page 14
5.11 Flashing kit ………….…………………………………………... Page 15
5.12 Mounting above the roof ………………………………… Page 15
5.13 Protection against accidental contact …………... Page 16
5.14 Lightning protection …………………………………..…... Page 16
5.15 Inside applications ……….………………………………..... Page 16
5.16 Inclined run …..………………………………………………….. Page 17
6. Condensate drain
6.1 General notes ………………………………………….……..… Page 18
6.2 Neutralization of condensate ..……………………….. Page 18
6.3 Condensate return to the heat generator ……... Page 18
6.4 Condensation guide at the bottom …………….….. Page 18
7. Example ………………….…………………………………………………. Page 19
8. Final notes …………………….……………………………………..…... Page 20
9. Labeling after installation …………….…………………..…...... Page 20
Version 3/ August 2018 Installing instructions DW-MAMMUT
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SYSTEM OVERVIEW
CE-Certification 0036 CPD 9174 039
Multi wall exhaust system with ceramic inner tube for all standard fireplaces (oil-, gas- and solid fuel1) in negative pressure for dry operation mode. Possible fields of application: open fireplaces, ovens, oil- and gas boilers, pellet boilers etc. The diameter calculation according to EN 13384 must ensure, that the temperature of the interior wall at the chimney top in steady-state conditions remains above the water vapor dew point temperature of the exhaust gas. Classification acc. to EN 13063-1: Exhaust gas system EN 13063-1 T400 - N1 - D - 3 - G50
CE-Certification 0036 CPD 9174 040
Multi wall exhaust system with ceramic inner tube for all fireplaces (oil- and gas) in negative pressure for wet operation mode. Possible fields of application: oil- and gas boilers, ventilating systems, ovens, air heaters, industrial facilities etc. The proof that the temperature of the interior wall of the system’s upper end is above the water vapor dew point temperature of the exhaust gas at a constant temperature can be abandoned. Classification acc. to EN 13063-2: Exhaust gas system EN 13063-2 T400 - N1 - W - 2 - O20
Building authority approval Z-7.1-3351 (only in Germany)
Multi wall exhaust system with ceramic inner tube for all standard fireplaces (oil-, gas- and solid
fuel1) in negative pressure for wet operation mode, also after soot fire. Possible fields of application: open fireplaces, ovens, oil- and gas boilers, Pellet boilers etc. The proof that the temperature of the interior wall of the system’s upper end is above the water vapor dew point temperature of the exhaust gas at a constant temperature can be abandoned. Classification acc. to DIN V 18160-1: Exhaust gas system DIN V 18160-1 T400 - N1 - W - 3- G50 - L00 1 excluding anthracite coal from Ibbenbüren, Germany
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Version 3/ August 2018 Installing instructions DW-MAMMUT
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MOUNTING AND REGULATIONS
The installing has to be performed professionally according to the installing instructions
respectively according to the valid national regulations.
In Germany in particular DIN V 18160-1, as well as the applicable rules of regional building
(LBauO), firing regulations (FeuVO), relevant DIN standards and all other building- and safety
regulations.
The required cross section has to be determined according to DIN EN 13384 and has to be
rechecked by the executing specialist firm.
Before the installation the design of the system has to be clarified with the concerned
district chimney sweeper. The suitability and safe usability of the exhaust system is to
be certified by a competent district chimney sweeper before commissioning.
MOUNTING HEIGHTS
Measure a max.
distance between
wall supports
Measure b free
standing height
above last support
Measure c height above
support
Measure d height above
pipe tee connection /
clean-out element
Clamp Inside – Ø in mm
dw 21 dw21
120 4 3 37 30
140 4 3 35 30
160 4 3 32 30
180 4 3 27 30
200 4 3 24 30
Figure 1: Mounting heights
c
Table 1: Mounting heights (in mm)
2
3
2
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STRENGTH OF THE DOWEL CONNECTION in kN
Important advice to the Table of dowel-connection strength:
The dowel-connection strength in the Table is the angular tensile force per dowel.
The wall space of the chimney system is allowed to be up to 40 cm.
The dowel strengths for the wall spacers are valid at heights above territory up to 20 m.
For heights above territory up to 8 m a reduction factor of 0.63 is valid.
For heights above territory between 20 m and 100 m an extension factor of 1.38 has to be
observed.
At wall spaces >40 cm special attachments / wall brackets are to be used according to the static
confirmatory test.
Wall brackets dwm 01 Wall spacer dwm 21
Inner pipe Ø in mm
Wall space Wall space Length of cantilever
50 – 120 mm
250 mm
400 mm
50 – 120 mm
250 mm
400 mm
m
120 0,93 1,34 1,84 1,27 1,99 2,82 3,00
140 1,03 1,446 1,97 1,48 2,22 3,09 3,00
160 1,03 1,446 1,97 1,48 2,22 3,09 3,00
180 0,88 1,18 1,56 1,37 2,00 2,75 3,00
200 0,96 1,27 1,66 0,88 1,27 1,71 3,00
Number of dowel per support
6 6 6 2 2 2
Table 2: Strength of the dowel connection
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MINIMUM DISTANCE TO COMBUSTIBLE MATERIALS in the vertical
part
When used as exhaust gas line (oil, gas) a minimum distance to combustible materials of 20 mm
(T400) to a max. nominal diameter of inner tube up to 200 mm, is valid. Bei Anschluss von For
solid fuel fireplaces T400 a minimum distance to combustible materials of 50 mm to a max.
nominal diameter of inner tube up to 200 mm applies (see Table 3)!
The distance to combustible materials refers to a ventilated installation throughout the
whole length (see Figure 2)!
Note:
For wall ducts the local resp. national regulations apply, you can also use the Jeremias certificated
wall-, ceiling-, roof penetration LUX-ECO and LUX-NOVA. These wall ducts are only approved in
Germany, Austria and Switzerland.
Please also note the installing instructions of the above mentioned penetrations!
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Ap
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0036 CPD 9174 039 T400 N1 D 3 G50 (= 50 mm) Ø120- 200 Oil, gas and solid fuel firing installations for
dry operation mode
0036 CPD 9174 040 T400 N1 W 2 O20 (= 20 mm) Ø120- 200 Oil & gas firing installations for wet and dry
operation mode
Z-7.1-3351 T400 N1 W 3 G50 (= 50 mm) Ø120- 200 Oil, gas and solid fuel firing installations for
wet and dry operation mode
Figure 2
XX
XX
Distance ventilated along the whole length incl. roof penetration
Distance dimension xx see Table 3
Combustible material e.g. wood wall
Exhaust gas system DW-MAMMUT
Table 3: Distances to combustible materials
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Version 3/ August 2018 Installing instructions DW-MAMMUT
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INSTALLATION OF THE VERTICAL PART OF FLUE SYSTEM 5.1 CONSTRUCTION OF PIPES
All components have to be mounted in a way, that the nozzle of the inner pipe is above or rather
in flow direction of the exhaust gas, while the nozzle of the outer pipe has to show converse to
the flow direction of the exhaust gas.
Every surge is protected by a locking band (see Figure 5, 6, 7, 8, 11 and 12).
You can choose between elements with a length of 1000 mm (usable length 940 mm)
720 mm (usable length 660 mm) and 390 mm (usable length 330 mm).
5.2 APPLYING THE ACID RESISTANT PASTE 2010 AND CONNECTING THE ELEMENTS
The under sides of the ceramic elements (insertion ends see Figure 4) are to be moistened. The
acid-resistant cement is properly mixed and then applied wedge-shaped on the under sides of the
elements. Then, the elements must be joined together, the excess acid-resistant paste, on the
inside of connection is smoothened with a sponge. This operation must be repeated for each
element.
Also note the product data sheet of the acid resistant paste!
Figure 3: Detail Straight pipe element
overa
ll len
gth
usa
ble
len
gth
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Version 3/ August 2018 Installing instructions DW-MAMMUT
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Notes for mixing the acid resistant paste:
Please note the hazard warnings and the product data of the acid resistant paste!
Mix:
Put 7 cups of putty powder and a cup of water in a clean container and mix to a homogeneous
mass (prescribed mixing ratio = 100g putty powder: 12g water)
Attention note waiting time:
After proper mixing, a soil-moist, crumbly mass is produced, which, after a maturing time (waiting
period) of 5 minutes and by mixing again becomes a supple homogeneous putty and only then is
it ready for usage.
Never re-use a hardened acid-resistant paste by adding water!
Processing time (open time):
Blended Nisott-acid putty 2010 is usable for approx. 1 hour.
Processing:
Do not prepare Nisott acid putty 2010 at temperatures below 5°C.
Moisten the fireclay pipes under side surface, apply Nisott acid cement 2010 with a suitable
spatula or trowel.
After fitting the fireclay pipe, smooth it out at the butt joint of the pipes with a suitable sponge.
Freshly fitted pipes should be protected from rain and frost until the Nisott acid cement 2010
hardens.
Curing time:
The acid resistant paste has a hardening time of 24 hours at 20°C. The complete hardening is
achieved after approx. 10 days. To shorten the hardening time, heated water can be used approx..
40 – 50°C.
Storage:
Nisott acid resistant paste 2010 should be stored away from moisture. In cool seasons, it is
necessary to store the acid resistant paste in warm place.
Note:
Element joints must be processed very carefully to avoid possible complaints!
Version 3/ August 2018 Installing instructions DW-MAMMUT
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Acid resistant paste 2010 – approval number - Z-7.4-1587
Important information for the operator of the exhaust system:
Commissioning of the exhaust system DW-MAMMUT:
• The used acid resistant paste requires at least 10 days to bind the ceramic inner tubes.
Only after this time the exhaust system may put into operation.
Only fireplaces with a maximum exhaust temperature of 400°C may be connected. Please
check the details of the stove manufacturer.
• First commissioning:
So as to expel the building moisture, please heat slowly, an increase of 50°C / minute must not
be exceeded. This is especially true in temporary fireplaces with poor efficiency and
correspondingly high exhaust gas temperatures. Quick heating up can lead to cracking and/or
flaking of the inner tubes, which could jeopardize the operational safety of the system.
• In the ceramic connecting piece, the flue pipe (connecting piece) must never be plugged in
force-fitting manner. The existing annular gap must be filled with a ceramic fibre cord or
mineral fibre so that there is no pressure or drag on the ceramic smoke pipe socket, otherwise
there is a risk that the smoke pipe socket will be blown up.
Please note in your own interest the above points,
so as not to endanger the operational and fire safety of your exhaust system!
After moistening the bead surfaces of the elements, the acid cement is applied in a wedge shape to the mating ends of the element
Figure 4: Applying the acid-resistant paste
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Figure 7: Mounting with telescopic support
5.3 WALL BRACKETS MADE OF STAINLESS STEEL
When chimney is supported at a load-bearing wall,
mounting is possible blade upwards (Figure 5) and
blade downwards (Figure 6).
Please note the strength of the dowel connection.
For the installation wall brackets have to be used which
stable enough for the mentioned mounting heights in Table 1!
5.4 TELESCOPIC SUPPORT
If chimney is supported at bottom –
the height of the support is adjustable (see Figure 7).
5.5 CONCRETE SOCKET
If mounted on a concrete socket a
base plate for socket mounting has to be used (see Figure 8).
Figure 5: mounting base plate with lateral condensate drain and “upward wall bracket”
Figure 6: mounting base plate with condensate drain at bottom and “downward wall bracket”
Figure 8: Setup with base plate for socket mounting
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5.6 BASE PLATE
The insulated base plate with condensate drain below or laterally for connection to the drainage
pipe has to be armed on the support. The open base plate is used as base plate for intermediate
support or as direct bonnet of the chimney system on a support (e.g. open fireplace, industrial
plant).
5.7 CLEAN-OUT ELEMENT
The element with clean-out opening is set on the base plate.
The position of the clean-out and inspection opening has to be planned
according to the valid standards or rather the local regulations.
Note:
In order to be able to carry out cleaning and inspection work from the bottom of
the exhaust system more easily, it is recommended to install the cleaning
element offset by approx. 90° to the T connection (see Figure 9).
5.8 CONNECTION ELEMENT TO THE UPRIGHT PART
The connection of the connection line to the exhaust gas system
can be realised with the pipe tee connection 87° (see Figure 10).
If the storm collar has to be placed on a locking band, then the assembly is only possible with a specially produced storm collar made according to customer specifications!
Figure 10: Connecting to a vertical exhaust gas system
Pipe tee 87°
Figure 9: Cleaning element offset to the T-connection
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5.9 SUPPORTS
The wall spacers act as fixation of the exhaust gas system at the wall or at steel-support
constructions. Die einzuleitenden Kräfte in das Gebäude, sind bauseits zu prüfen.
The rigid wall spacer has a wall space of 50 mm (DWM21). Bei größeren Wandabständen werden
verstellbare Wandabstandshalter verwendet.
Grundsätzlich ist über jedem T-Anschluss direkt ein Wandabstandshalter anzubringen.
The maximum distances between the single attachments and the dowel-connection strengths
have to be observed at all wall attaching bands (see Table 1).
The supports should always be mounted near to an element surge.
5.10 INTERMEDIATE SUPPORT
If the maximum mounting heights are
exceeded (see Figure 1 and Table 1),
intermediate supports should be considered,
which are stable enough to absorb the static
load. This is ensured through the stainless steel
wall brackets and the base plate for
intermediate support (see Figure 11).
It’s advisable to put a wall spacer after the
last intermediate support to dervive the
expected wind loads before.
Figure 11: mounting with intermediate support
wall spacer
end cap
base plate for intermediate support
wall brackets
straight pipe element 1000/ 720 / 480 / 390 mm wall spacer
pipe tee 87°
inspection element
base plate
wall brackets
Version 3/ August 2018 Installing instructions DW-MAMMUT
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cantilever
5.11 FLASHING KIT
Flashing kits are available for all slopes (with grading of
10°, with sealing zones made of stainless steel or lead). These
guarantee the temperature-independent linear expansion
of the chimney.
The storm collar (included in scope of delivery) has to be
screwed to the chimney element and to be sealed
(see Figure 12). To achieve a suffice ventilation in the roof
area the storm collar has to be fixed about 3 cm above
of the stainless steel flashing kit.
The storm collar must be sealed accordingly.
Note:
Please also note the installing instructions of the flashing kit
for DW-systems.
However the storm collar must not be mounted
on the locking band above the roof flashing!
5.12 MOUNTING ABOVE THE ROOF
During planning of the exhaust gas system the minimum height above
the roof has to be considered. The double wall systems of Jeremias can
be executed freestanding up to 3.0 m (see Table 1) from the last attachment.
Due to the bonded ceramic inner tubes, a greater height above the last
Clamped connection can be only realized with a cantilever arm (see Figure 13).
Figure 13: Mounting with cantilever
Figure 12: Flashing kit
end cap
storm collar
flashing kit
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5.13 PROTECTION AGAINST ACCIDENTAL CONTACT
At an exhaust gas temperature above 200°C, a surface temperature of more than 70°C can be
expected and therefore a contact protection in the accessible area (except the installation area) is
required up to a height of 2 m above the floor e.g. one also needs to have contact protection in
public places.
The contact protection must not obstruct the rear ventilation.
5.14 LIGHTNING PROTECTION
Lightning protection has to be performed according to the relevant technical regulations.
Requirements result in Germany from DIN EN 62205-3 (VDE 0185-305-3) (Protection of structural
works with persons), DIN VDE 0100-410 (Construction of low-voltage systems: protective
measures; Protection against electric shock) and DIN VDE 0100-540 (Construction of low-voltage
systems part 5 to 54: Selection and erection of electrical equipment – earth termination service
and protective conductors)
Execution has to be done by a specialised firm!
5.15 INSIDE APPLICATIONS
For applications installed inside ventilated elements
with integrated exhaust air leading can be mounted
as penetration (see Figure 14). If the height above
the last support exceeds 3m,
the 3-point-guy wire bracket can achieve a higher mounting.
Figure 14: Setup ventilated element with Integrated exhaust air leading
Version 3/ August 2018 Installing instructions DW-MAMMUT
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max.
3000m
m
max. 3000
mm
max. 3000
mm
max. 3000 mm
2
2
1
1
11
11
1
2
2
2
1
1
5.16 INCLINED RUN
If the exhaust gas system is to be moved, the maximum dimensions of the following drawing (see
Figure 15) should be observed. Please also note that after an offset intermediate supports with
wall brackets have to be used (see Figure 15).
After an inclined run the weight of the elements must be intercept with a base plate for
intermediate support and cantilevers & cross rail or wall brackets.
Please note that during high exhaust gas temperatures and/ or great lengths, ahead of
an inclined run appropriate actions have to be taken to compensate the thermal
elongation e. g. with a compensator
Please consider that the clean-out openings have to be according to the national regulations
(in Germany according to DIN V 18160-1).
Figure 15: Structure inclined run
Attachment with wall spacer dw 20-24
Intermediate support and wall bracket
Inclined run 87°
Inclined run 15° / 30° / 45°
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CONDENSATE DRAIN 6.1 GENERAL NOTES
The discharge of condensation and rainwater to the sewage is to be provided by the customer
(connect sewage connection point to the exhaust system)!
Especially when solid fuel burners are connected, the condensate drain should be cleaned
regularly and the deposits must be cleared in order to ensure the discharge of rainwater and
condensate.
Note:
If there is no or slight accumulation of condensate and rainwater then dust can be removed from
the condensate drain during cleaning work on the exhaust system.
It is advisable to take measures which prevent the freezing of outdoor condensate drain or
siphon, in particular if regular condensation is expected.
6.2 CONDENSATE NEUTRALISATION
Please observe the national as well as the local regulations.
If condensation neutralization is necessary then our neutralization units are available.
6.3 CONDENSATE RETURN TO THE HEAT GENERATOR
In case of a humid operation in the connection line, at least 3° slope to the heat generator is to be
laid. The resulting condensate can be dissipated via this, if this is suitable, otherwise measures
must be taken to ensure to complete drainage of the condensate, e. g. by a condensation trap
with siphon.
6.4 CONDENSATION GUIDE AT THE BOTTOM
Condensate and rainwater from the vertical part of the exhaust system flows into the base plate
with condensate drain via the inner wall and from there into the condensate discharge or in the
neutralization unit, which can be drained via the house drain.
Note:
If the exhaust system is intended for wet operation then the closing cap must be removed from
the condensate drain in order to ensure complete drainage of accumulated condensate and
rainwater. In this way a possible moisture penetration of the insulation as well as the freezing of
bottom in the winter can be avoided.
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Version 3/ August 2018 Installing instructions DW-MAMMUT
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EXAMPLE
End cap DWM32
Straight pipe element e.g. 1000mm DWM1246
Flashing kit with storm collar e. g. with stainless steel cover frame for roof pitch 36°-45° DW83
Adjustable wall spacer e.g. 50-150mm DWM22
Base plate for intermediate support DWM07 and wall brackets adjustable e.g. 50-150mm DWM01
Pipe tee 87° DWM11
Inspection length with expansion compensation DWM10
Base plate with ½“ nozzle, cover cap and condensate drain below DWM05
Adjustable wall brackets e.g. 50-150mm DWM01
7
Figure 16: Example
Version 3/ August 2018 Installing instructions DW-MAMMUT
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GENERAL NOTES
The exhaust gas system DW-MAMMUT was developed and tested for gas leaks, corrosion
resistance and secure installation. Therefore, only original parts of the system Jeremias DW-
MAMMUT must be used. In addition the manufacturer’s specifications and installation instructions
have to be met.
Technical changes are reserved!
LABELING AFTER INSTALLATION
The installed exhaust gas system has to be fitted depending on the application with the following
nameplate: Figure 17: System label DW-MAMMUT
Opfenrieder Str. 11-14 · 91717 Wassertrüdingen Tel.: 09832 68 68 50 · Fax: 09832 68 68 68 [email protected] · www.jeremias.de
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