flue installation instructions

For the installer

Flue installation instructions

ecoMAX 613/2 E

ecoMAX 618/2 E

ecoMAX 622/2 E

ecoMAX 635/ E

ecoMAX 824/2 E

ecoMAX 828/2 E

ecoMAX 835/ E

ecoMAX pro 18 E

ecoMAX pro 28 E

ecoTEC plus 612

ecoTEC plus 615

ecoTEC plus 618

ecoTEC plus 624

ecoTEC plus 824

ecoTEC plus 630

ecoTEC plus 831

ecoTEC plus 637

ecoTEC plus 837

ecoTEC pro 28

GB

Air flue duct for use with ecoMAXand ecoTEC boilers

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 1

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 2

OVERVIEW

PART

2 C

ONC

ENTR

IC 8

0/12

5

PART 1 Pages 4 - 38

Standard Concentric Systems Ø 60/100(Galvanized steel air duct/plastic flue duct)

PART 2 Pages 39 - 61

Optional Concentric System Ø 80/125(Galvanized steel air duct/plastic flue duct)

PART

2 C

ONC

ENTR

IC 8

0/12

5PA

RT 1

CO

NCEN

TRIC

60/

100

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 3

4

CONTENTS: PART 1 CONCENTRIC 60/100

Page

The air/flue duct must be installed by a suitablyqualified service provider, which is responsiblefor observing the relevant specifications,regulations and standards.

Requirements

Planning the air/flue duct layout

Regulations and standards to be observed 5

Alternative termination accessories available 6Maximum flue lengths for ecoMAX 11Maximum flue lengths for ecoTEC 12

§

Installation of the vertical air/flue duct 31

Installation of the horizontal air/flue duct 15

Installation of the black terminal kit 24

Fitting air/flue duct extensions

Installing the air/flue duct sliding sleeve

How to add extensions 34How to install elbows 35

14

Installation of the variable termination kit 26

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 4

5

PART

1 C

ONC

ENTR

IC 6

0/10

0

REQUIREMENTS

Regulations andstandards to beobserved

§

☞ Vaillant ecoMAX/ecoTEC boilersare certified as heating boilerswith corresponding flue systems according to EC Directive90/396/EEC on gas-fired devi-ces. This installation manual iscovered by this certification and isreferred to in the design approvaltest certificate.

☞ These instructions should be readin conjunction with the instructionsfor installation and servicing supplied with the boiler.

☞ Ensure also that all legislation,rules, regulations and directivesmentioned in the installationinstructions are observed.

☞ The installation of the boiler andits flue must be carried out by acompetent person who is registered with CORGI (TheCouncil for Registered GasInstallers).

☞ The installation of the boiler andflue must be in accordance withthe Gas Safety (Installation andUse) Regulations 1998 and theBuilding Regulations and BS 5440 Part 1.

☞ The requirements for flue termination detailed in the boilerinstallation instructions must beobserved.

☞ Two types of flue system are available for ecoMAX/ecoTECboilers. The standard concentricflue system (100 mm outsidediameter) and a larger diameterconcentric system (125 mmoutside diameter) which allowslonger air/flue duct lengths to beachieved.

☞ The air/flue duct operates at verylow temperatures therefore noclearance is necessary betweenthe air duct and adjacent services.

☞ Ensure while installation work isbeing carried out that no debrissuch as swarf, filings or fragmentsof mortar are allowed to remainin the air/flue duct.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 5

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

303 936Optional connection accessories

Telescopic offset section

Telescopic extension440 mm - 690 mm Ø 60/100

6

PLANNING THE AIR/FLUE DUCT LAYOUT

Alternative termination accessories available

Air/flue duct extensions, concentric470 mm - Ø 60/100



Bends (PP), concentric (pack of 2)45° - Ø 60/100

Elbow, concentric87° - Ø 60/100

Flue support clips (pack of 5), Ø 100

Sliding sleeve (PP) Ø 60/100

Adjustable roof tiles for pitched roof

303 900 = Vertical air/flue duct (black)

Accy. No.303 900

303 919

303 906

303 902

303 903

303 905

303 911

x

303 910

303 821

303 915

009076 black

x

x

x

x

x

x

x

x

x

303 930 303 933

Black terminal kit for horizontal air/flue duct 303 934

Adjustable flue support clips (pack of 3); Ø 100 303 935 x

Variable termination kit - black *) 303 942

Extension pipe for variable termination kit VTKØ 60 mm 1 m - black *) 303 943

87° elbow for variable termination kit - black *) 303 944

45° bend for variable termination kit - black (2 pieces) 303 945�

Variable termination kit - white *) 303 946

Extension pipe for variable termination kit VTKØ 60 mm 1 m - white *) 303 947

87° elbow for variable termination kit - white *) 303 949

45° bend for variable termination kit - white (2 pieces) 303 948�

Flexible pitched roof seal 303 980 x

Flat roof penetration collar 009 056 x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

*) delivered with support clips

303 930 = Horizontal air/flue duct (only ecoMAX)303 933 = Horizontal air/flue duct303 936 = Horizontal telescopic air/flue duct

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 6

7

PART

1 C

ONC

ENTR

IC 6

0/10

0


Fig. 1.1: Extensions, Ø 60/100

13

65

Fig. 1.3: Elbow joints, Ø 60/100

Elbow, 87°, Ø 60/100Only Part of:Vaillant Accy. No.: 303 933Vaillant Accy. No.: 303 936

18

2718

27

18

27


Elbow, 87°, Ø 60/100Vaillant Accy. No.: 303 910

Bends, 45° (pack of 2), Ø 60/100Vaillant Accy. No.: 303 911

Air/flue duct extension 470 mm Ø 60/100Vaillant Accy. No.: 303 902

Air/flue duct extension 970 mm, Ø 60/100Vaillant Accy. No.: 303 903

Air/flue duct extension 1970 mm, Ø 60/100 Vaillant Accy. No.: 303 905

GU

_LA

Z 70

/0

GU

_LA

Z 72

/0

Fig. 1.4: Flue support clips, Ø 100/Ø 80

Flue support clips, Ø 100 (pack of 5)Vaillant Accy. No.: 303 821

☞ Use one clip per extension to support the air/flue duct.

GU

_LA

Z 72

/0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 7

8


155

Fig. 1.8: Sliding sleeve, Ø 60/100

Sliding sleeve (PP), Ø 60/100 Vaillant Accy. No.: 303 915

290 – 374

33 –

56

Fig. 1.7: Offset section, Ø 60/100

Offset section, Ø 60/100Vaillant Accy. No.: 303 919

3039

19_I

Ax

440 – 690

Fig. 1.6: Telescopic extension, Ø 60/100

Telescopic extension (PP), Ø 60/100440 mm - 690 mmVaillant Accy. No.: 303 906

250

Fig. 1.5: Flue support clips, Ø 100

Adjustable flue support clips, Ø 100(pack of 3)Vaillant Accy. No.: 303 935

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 8

9

153

130

390

Fig. 1.11: Flat roof penetration collar

Flat roof penetration collarVaillant Accy. No.: 009 056

498

132

255

Fig. 1.9: Adjustable roof tile for pitched roof

Adjustable roof tile for pitched roofVaillant Accy. No.: 009 076 (black)

GU

_LA

Z 41

/0


Fig. 1.12: Black terminal kit

Black terminal kit for horizontalair/flue ductVaillant Accy. No.: 303 934For 303 933 and 303 936 only

PART

1 C

ONC

ENTR

IC 6

0/10

0

495

132

495

Fig. 1.10: Flexible pitched roof seal

Flexible pitched roof seal (black)Vaillant Accy. No.: 303 980

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 9

10


�

Fig. 1.16: 45° bend

45° bend for variable termination kit- blackVaillant Accy. No.: 303 945

45° bend for variable termination kit- whiteVaillant Accy. No.: 303 948

Fig. 1.15: 87° elbow

87° elbow for variable termination kit- blackincluding 1 support clipVaillant Accy. No.: 303 944

87° elbow for variable termination kit- whiteincluding 1 support clipVaillant Accy. No.: 303 949

Fig. 1.14: Extension Ø 60 1 m pipe

Extension pipe for variabletermination kit Ø 60 mm 1 m - black

including 1 support clipVaillant Accy. No.: 303 943

Extension pipe for variabletermination kit Ø 60 mm 1 m - whiteincluding 1 support clipVaillant Accy. No.: 303 947

Fig. 1.13: Variable termination kit

Variable termination kit - blackVaillant Accy. No.: 303 942For 303 933 and 303 936 only

Variable termination kit - whiteVaillant Accy. No.: 303 946For 303 933 and 303 936 only

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 10

11

Fig. 1.17: Flue support clip, Ø 60 mm

60

Flue support clip, Ø 60 mmdelivered with kits

Maximum flue lengths for use with ecoMAX


Vertical flue systems

303 900 Max. permitted concentric flue lengthFig. 1.18

12.0 m 10.0 m 7.0 m 10.0 m9.0 m

Variable termination kit

303 942303 946

only incombina-tion with 303 933

Max. permittedconcentricflue lengthFig. 1.19

Horizontal flue systems

303 930303 933


8.0 mincl.

1 elbow 87°

8.0 mincl.

1 elbow 87°

4.0 mincl.

1 elbow 87°

10.0 mincl.

1 elbow 87°

7.0 mincl.

1 elbow 87°

Accessories Accy. No. 828/2 E 635/ E835/ E

pro 18 Epro 28 E

824/2 E613/2 E618/2 E622/2 E

ecoMAX

Maximum length of flue is reduced by 1.0 m for each additional 87° elbow


The maximum permitted concentric flue length given above is reduced asfollows:

- Reduced by 0.5 m for the variable terminal- Reduced by 0.5 m for every 1 m VTK pipe- Reduced by 0.5 m for every 87° bend- Reduced by 0.5 m for 2 x 45° bend



PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 11

Max. permitted concentric flue lengthFig. 1.18

12.0 m 12.0 m 12.0 m 8.0 m 12.0 m

12


Variable termination kit

303 942303 946

only incombina-tion with 303 933


Accessories Accy. No.


303 933 Max. permittedconcentricflue lengthFig. 1.17

8.0 mincl.

1 elbow 87°

8.0 mincl.

1 elbow 87°

5.5 mincl.

1 elbow 87°

8.0 mincl.

1 elbow 87°

8.0 mincl.

1 elbow 87°

ecoTEC




303 900

Maximum flue lengths for use with ecoTEC

The maximum permitted concentric flue length given above is reduced asfollows:

- Reduced by 0.5 m for the variable terminal- Reduced by 0.5 m for every 1 m VTK pipe- Reduced by 0.5 m for every 87° bend- Reduced by 0.5 m for 2 x 45° bend

plus 624plus 824

plus 612plus 615plus 618

plus 630plus 831

plus 637plus 837

pro 28



834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 12

13

PART

1 C

ONC

ENTR

IC 6

0/10

0

Maximum flue length

Max

imum

flue

leng

th

LAS

Euro

B/S

074

/0

LAS

Euro

B/S

074

/0

Fig. 1.18: Horizontal flue systems Fig. 1.19: Vertical flue systems


Concentric flue length

Flue

leng

th o

utsi

de

Fig. 1.20: Horizontal flue system installed with vertical termination kit

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 13

14

INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE

Fig. 2.0: Installing the sliding sleeve

1

34

675

2

Schi

ebem

uffe

_neu

INSTALLING THEAIR/FLUE DUCT SLIDINGSLEEVE☞ NOTE:

For installations where there is in-sufficient movement to allow fittingof the flue into flue outlet, a slid-ing sleeve (Accy. No. 303 915) isavailable. When using the slidingsleeve both the air and flue ductsof the last extension must beshortened by a further 95 mm.

• Push the sliding sleeve (1) over thecut end of the flue duct (2).

• Place the air duct clamp (7) overthe air duct.

• Pull back the sliding sleeve so thatit engages into the socket (3) ofthe boiler (4). Ensure that thesliding sleeve penetrates thesocket such that there is at least20 mm engagement at both endsof the sliding sleeve.

• Fit the air duct clamp over the airducts (5 and 6) of theextension/terminal and boileroutlet. Close the snap clamp.

• Drill two holes 3 mm diameterthrough the air duct clamp (thecentre of the holes should be 6mm from the edge of the clamp).Ensure that the drill does notpenetrate the inner flue duct.Screw the air duct clamp to theair duct of the sleeve using thescrews provided.

• Complete the installation of theflue as detailed in theseinstructions.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 14

15

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT

Horizontal air/flue duct

Accy No.: 303 930for ecoMAX only(Length 0.8 m)

Contents of the accessory:• Horizontal air/flue duct• 87° elbow• 1 x 70 mm air duct clamp• 1 x 40 mm air duct clamp• Internal trim ring Ø 100• External wall seal

Fig. 3.1: Horizontal air/flue conduit

IMPORTANT:The flue hole should be cut with aslight rise to outside if 3° ± 1°(equivalent to 50 mm ± 20 mm riseper metre length).

Preparation• Determine the installation site for

the boiler with reference to theinstallation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.

• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of the template is vertical using a plumbline or spirit level.

Top outlet flue exiting to rear• For installations where the air/flue

duct is to be installed directly tothe rear of the boiler, the installation template details theposition of the flue exit hole forhorizontal top outlet installation.

Top outlet flue exiting to side• For installations where the air/flue

duct is to be installed to the side,the position of the flue exit holecan be determined by carefullylevelling across the wall from thecentre line of the air/flue duct holemarked on the template (fig. 3.3).

• The position of the flue exit holeshould allow the flue to be installed with a slight upwardslope of about 3° ± 1° (equivalentto 50 mm ± 20 mm per metre offlue duct). Calculate the requiredrise according to the flue lengthand mark the position of the flueexit hole.

4013

70

800

95

LAS

Euro

B/S

037

/0

3

* 150

2

4

1

5

Fig. 3.2

LAS

Euro

B/S

072

/0G

B

*

* = 190 mm ecoMAXcombination and system boilers

* = 176 mm ecoMAX pro

☞ Observe the maximum fluelengths as detailed in table onpage 11.

PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 15

16

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)

• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 125 mmdiameter.Note: If access can be gained tothe proposed flue exit point fromoutside the dwelling, the hole canbe cut with a 107 mm core drilland the flue external wall seal fitted from outside the dwelling.

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 3.4).

This is dimension A.

• Cut the air duct and flue duct tothe lengths shown in (fig. 3.5).

• All flue sockets should pointtowards the terminal.

• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.Care should be taken not toscratch the white surface of the airduct.

• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 34 - 38.

• Secure the air duct sectionstogether by drilling a 3 mmdiameter hole through the locationhole in the end of the outer airduct. (Ensure that the drill doesnot pierce the inner flue duct).Secure the air ducts together usingthe screw provided.

*

Fig. 3.3 LAS

Euro

B/S

077

/1

150

A

A

150

Fig. 3.4 LAS

Euro

B/S

078

/0

A + 45 mm

13 mm

Fig. 3.5 LAS

Euro

B/S

076

/0

Rear exit

Side exit

* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro


* = 176 mm ecoMAX pro

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 16

17


• Push the air/flue duct assembly(1) including the flexible externalseal through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall (fig. 3.2 and fig. 3.6).

• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom(fig. 3.2).

• Slide the internal trim ring (2) overthe air duct until it is flush with thewall (fig. 3.2).

• At this stage it is necessary to prepare and fit the boiler onto thehanging bracket – refer to the boiler installation instructions.

• Fit the elbow (3) to the boiler by inserting the spigot of the flueelbow into the flue socket on theboiler and secure using the 40mm air duct clamp (4) provided(fig. 3.2).

• Pull the air/flue duct back throughthe wall such that the flue ductfully engages into the flue elbowsocket.

• Fit the 70 mm air duct clamp (5)ensuring that it is positionedcentrally (fig. 3.2).

• Drill two holes 3 mm Ø throughthe air duct of both the elbow/flueand elbow/boiler clamps at themost convienient holes on the airduct clamps. (Ensure that the drilldoes not penetrate the inner flueduct). Screw the clamps to the airducts of the flue assembly, theelbow and boiler using the screws supplied.

• Slide the internal trim ring back tothe wall, securing in position witha small amount of sealant if required.

Caution!If installed near a light, insects mayfly into the opening. Tell thehomeowner to clean the openingregularly.

150

13

3°

1

Fig. 3.6 LAS

Euro

B/S

001

/0G

B

PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 17

18



Accy No.: 303 933(Length 0.75 m)

Contents of the accessory:• Horizontal air/flue duct• 87° elbow• 1 x 48 mm air duct clamp• 1 x 30 mm air duct clamp• Internal trim ring Ø 100• External wall seal.











3013

754

4865

3

* 87

5

4

2

1

Fig. 3.8

LAS

Euro

B/S

072

/0G

B

*


* = 176 mm ecoMAX pro* = 125 mm ecoTEC

IMPORTANT:The air/flue duct is not concentricand the air duct has a slope of 1.5°(if the air flue duct is not cut). Thehole through the wall can thereforebe drilled horizontally with no slope.

Where extensions are used, thesemust be installed with a slope at 3° ±1° (equivalent to 50 mm ± 20 mmrise per metre length) to ensure thatcondensate dows not remain in thesleeve.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 18

19





• Cut the air duct and flue duct tothe lengths shown in (fig. 3.11).


• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.Care should be taken not toscratch the white surface of the airduct.


• Secure the air duct sectionstogether by drilling a 3 mmdiameter hole through the locationhole in the end of the outer airduct. (Ensure that the drill doesnot pierce the inner flue duct).Secure the air ducts together usingthe screw provided.

*

Fig. 3.9 LAS

Euro

B/S

077

/187

A

87

A

*

Fig. 3.10 LAS

Euro

B/S

078

/0

13 mm

A + 22 mm

Fig. 3.11 LAS

Euro

B/S

076

/0

Rear exit

Side exit

* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro* = 125 mm ecoTEC PA

RT 1

CO

NCEN

TRIC

60/

100



834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 19

20


• Push the air/flue duct assembly(1) including the flexible externalseal through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall (fig. 3.8 and fig 3.12).

• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom(fig 3.8 and fig 3.12).









13

87

1

Fig. 3.12 LAS

Euro

B/S

001

/0G

B

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 20

21

INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT

Horizontal telescopic air/flue duct

Accy No.: 303 936(Length 0.4 - 0.61 m)

Contents of the accessory:• Horizontal telescopic air/flue duct• 87° elbow• 1 x 48 mm air duct clamp• 1 x 30 mm air duct clamp• Internal trim ring Ø 100• External wall seal.











3013

405 - 610

4865

LAS

Euro

B/S

037

/0

3

* 87

5

4

2

1

Fig. 3.14

LAS

Euro

B/S

072

/0G

B



PART

1 C

ONC

ENTR

IC 6

0/10

0



*

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 21

22

INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)




• Adjust the air duct and flue ductto the lengths shown in (fig.3.17).

• Secure the air duct sectionstogether by drilling a 3 mmdiameter hole through the locationhole in the end of the outer airduct (1). (Ensure that the drill doesnot pierce the inner flue duct).Secure the air ducts together usingthe screw (1) provided. Place theadhesive tape (2) across the gapin the telescopic extensions.(fig. 3.17)


• Care should be taken not toscratch the white surface of the airduct.


*

Fig. 3.15 LAS

Euro

B/S

077

/1

87

A

87

A

*

Fig. 3.16 LAS

Euro

B/S

078

/0

1 2

A + 22 mm

Fig. 3.17

Rear exit

Side exit

* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro* = 125 mm ecoTEC



834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 22

23

INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT(TOP OUTLET)

• Push the air/flue duct assembly(1) including the flexible externalseal through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall (fig. 3.14 and fig. 3.18).

• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom(fig. 3.14 and fig. 3.18).









13

87

1

Fig. 3.18 LAS

Euro

B/S

001

/0G

B

PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 23

24

INSTALLATION OF THE BLACK TERMINAL KIT

Black terminal kit Accy. No.: 303 934

Contents of the accessory:• Black terminal• External wall seal

Fig. 3.19: Black kit

AssemblyBefore installing the flueduct• Use an 8 mm screwdriver to bend

the catches inwards (fig. 3.20).• Pull the terminal together with the

flue duct out of the air duct (fig.3.21).

• Unlock the catch between theterminal and the flue duct bytwisting them against each other(fig. 3.22).

• Pull the terminal off the flue duct.• Push the new terminal into the flue

duct and click to lock.

☞ Please note: The catch on the topof the terminal must lock firmlyinto the notch in the flue duct(fig. 3.23).

☞ Please note: Make sure the sealfits tightly.

• Push the flue duct and the terminalback into the air duct and lock thetwo catches (fig. 3.24).

Caution!The seam of the air duct must be atthe top.

• Fit the horizontal air/flue duct asdescribed on pages 18 and 21.

Fig. 3.22: Unlocking the catch

Fig. 3.21: Pulling out the terminal

Fig. 3.20: Releasing the catches

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 24

25

PART

1 C

ONC

ENTR

IC 6

0/10

0

INSTALLATION OF THE BLACK TERMINAL KIT

Fig. 3.24: Locking the catch

Fig. 3.23: Flue duct

AssemblyAfter installing the flueduct

Danger!Before starting work, shut down theappliance and prevent it from beingswitched on unintentionally.

• Remove the wall seal from theterminal.

• Use an 8 mm screwdriver to bendthe catches inwards (fig. 3.20).

• Pull the terminal together with theflue duct out of the air duct (fig.3.21).

Caution!Do not twist the flue duct, becausethis might detach the following flueduct behind the terminal from thespacer.


• Pull the terminal off the flue duct.• Push the new terminal into the flue

duct and click to lock.

☞ Please note: The catch on the topof the terminal must lock firmlyinto the notch in the flue duct (fig.3.23).


• Push the flue duct with theterminal back in the air duct.Carefully push the flue duct backinto the sleeve of the pipe or bendbehind it. Lock the two catches(fig. 3.24).

• Fit the wall seal.

Danger!Before starting up the appliance,check that the entire flue pipe isfirmly seated and sealed.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 25

26

INSTALLATION OF THE VARIABLE TERMINATION KIT

Variable termination kitAccy. No.: 303 942 (black)303 946 (white)

Contents of the kit:• Variable terminal• 2 x 1m pipe• 3 x pipe support clips• 87° bend with bird protection

grille

Important: The flue outlet of the variable termi-nation must face directly upwards.

Fig. 4.1: Variable termination kit

Assembly

Before installing the fluepipe• Use an 8 mm screwdriver to bend

the catches inwards (fig. 4.3).• Pull the terminal with the flue duct

out of the air duct (fig. 4.4).

Fig. 4.4: Pulling out the variable terminal

Fig. 4.3: Releasing the catch

55

Fig. 4.2

Flue Terminal ClearancesMinimum flue terminal clearancesare defined in BS5440, and thesemust apply unless the boiler manu-facturer has received approval toquote smaller clearances that arenot safety critical. Vaillant have re-duced flue terminal clearancesapproved and these are given in theboiler installation instructions. Theseare the minimum clearances thatmust apply to all installations, exceptwhen a Variable Termination Kit(VTK) is fitted.

When a VTK is fitted to the horizon-tal flue, the terminal clearances forthe air inlet are reduced. The termi-nal clearances for the ‘new’ flueoutlet at the end of the VTK do notchange.

The minimum terminal clearances A,B & C for the air inlet of the VTK arereduced to 50 mm from an openingsuch as a window, and 25mm froman opening such as an airbrick. Thismeans that the terminal on thehorizontal flue becomes the air inletwhen a VTK is fitted, and hence canbe located less than 300mm froman opening window or airbrick.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 26

27

PART

1 C

ONC

ENTR

IC 6

0/10

0


• Pull the terminal out of the flueduct.

• Push the variable terminal onto theflue duct.

☞ Please note: The catch on the topof the variable terminal must lockfirmly into the notch in the flueduct (fig. 4.6).

Caution!Make sure the seal fits tightly.

• Push the flue duct and the variableterminal back into the air ductand lock the two catches(fig. 4.7).

☞ Please note: The seam of the airduct must be at the top.

• Fit the horizontal ait/flue duct asdescribed on pages 18 and 21.

Caution!It cannot be fitted from inside.

• Fit the rest of the variabletermination kit as described onpage 28.


Fig. 4.7: Locking the catch

Fig. 4.6: Flue pipe

Fig. 4.5: Unlocking the catch

AssemblyAfter installing the flueductDanger!Before starting work, shut down theappliance and prevent it from beingswitched on unintentionally.

• Remove the wall seal from theterminal.

• Use an 8 mm screwdriver to bendthe catches inwards (fig. 4.3).

• Pull the terminal with the flue ductout of the air duct (fig. 4.4).

Caution!Do not twist the flue duct, becausethis might detach the following flueduct behind the terminal from thespacer.• Unlock the catch between the

terminal and the flue duct bytwisting them against each other(fig. 4.5).

• Pull the terminal out of the flueduct.

• Push the new variable terminalonto the flue duct.

☞ Please note: The catch on the topof the variable terminal must lockfirmly into the notch in the flueduct (fig. 4.6).


• Push the flue duct with thevariable terminal back in the airduct. Carefully push the flue ductback into the sleeve of the duct orbend behind it. Lock the twocatches (fig. 4.7).

• Fit the wall seal on the variableterminal.

• Fit the rest of the VTK asdescribed on page 28.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 27

28


• Fit the pipes and bends, workingfrom the variable terminal to theselected location for the flue exitusing support clips supplied fig4.8, 4.9, 4.10 or 4.11.

Caution!Pipe extensions must be fixed to thewall using pipe clamps. Use oneclamp for each extension directlybeside the sleeve. Fit another clampto the extension after each 87° bend (fig. 4.9).

Caution!The extension pipe expands whenheated. Leave 1 cm expansion space in eachsleeve.

☞ Please note: The maximum fluelengths where the variabletermination kit is installed areshown in the tables on pages 11and 12.

☞ Please note: The parts are simplypushed together (not bolted).

Caution!Fasten the 87° bend with birdprotection grille using a separatepipe clamp (fig. 4.9).


Danger!Before starting up the appliance,check that the entire flue pipe isfirmly seated and sealed.

Caution!During annual maintenance, checkthe flue system for- visible defects, such as

embrittlement or damage- tight connection of the pipes- dirt in the air intake and flue exits

due to leaves, insects etc.

Fig. 4.9: Bird protection grille

Fig. 4.8: Installation of basic kit showing position of support clips

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 28

29

PART

1 C

ONC

ENTR

IC 6

0/10

0�

Fig. 4.11: Installation of basic kit with two additional 45° bends showing position of support clips


Fig. 4.10: Installation of basic kit with two additional 87° bends showing position of support clips

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 29

Routing around roofeavesWhen routing the variabletermination kit around the roof eaves,additional lengths of M8 threadedbar will be required for the supportbrackets. Threaded bar can bepurchased from most local merchants.

• Change the bird protection grillefrom the 87° elbow to theextension installed at the end.

☞ If using the 87° elbow, use theseal from the pipe extension.

• The final pipe extension must befixed to the wall using two supportclips with a minimum distance of400 mm.

• Additional 45° bends may berequired.

min

400

mm

min

100

mm

Fig. 4.12: Routing around roof eaves

30


834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 30

31

40

1435

550

880

Vertical air/flue duct Accy. No.: 303 900 (black)

Contents of the accessory:• Vertical air/flue duct and terminal

assembly• 40 mm air duct clamp• Fixing bracket

☞ See page 6 et seq. for details ofair/flue duct elements.


Fig. 5.1: Vertical roof duct

The air/flue duct assembly may beconnected directly to the flue outleton top of the boiler.

In addition to the vertical air/flueduct and terminal accessory, air/flueduct extensions can be added toincrease the length of the flue.

Preparation

• Determine the installation site forthe boiler with reference to theinstallation and servicinginstructions supplied with theboiler.

• Ensure that all installation andservice clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.

• Determine the point where thevertical air/flue duct and terminalassembly will penetrate the roof.

☞ Please note: The vertical air/flueduct and terminal accessory(Accy. No. 303 900) may beshortened. The outer ‘white’ ductshould be shortened first, then theinner flue duct cut so that itprotrudes 13 mm out of the airduct. In case of installationdirectly to the boiler withoutelbows or bends, it is essentialthat the roof tile/collar is verticallyaligned with the air/flue duct ofthe boiler.

☞ Please note: If a 87° elbow isconnected directly to the boiler,use the 40 mm air duct clampsupplied with the vertical air flueduct at this position.

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 31

32


Pitched roof installation• Determine the point where the

vertical air/flue duct and terminalassembly will penetrate the roof.

• Fit the flexible pitched roof (Accy.No. 303 980) tile (1).

• Working from above, insert thevertical roof duct (5) through theroofing tile and push it firmly intoplace.

• Vertically align the roof duct andattach it to the roof structure withthe fixing bracket (6) supplied.

• Fit the boiler hanging bracket (2).• Install the appliance (3) with

reference to the installation andservicing instructions supplied withthe boiler.

☞ See pages 34 et seq. for furtherdetails on the installation ofextensions and elbows.

• Push the sliding sleeve (4) firmlyinto place on the extension.

• Join the vertical roof duct (5) tothe extension (7).

• Join the sliding sleeve (4) to theappliance’s connection piece (8).

☞ Using the sliding sleeve allows theappliance to be easily removedand replaced without dismantlingthe flue.

• Drill two holes 3 mm Ø throughthe air duct of the flue/boilerclamp at the most convienientholes on the air duct clamp.(Ensure that the drill does notpenetrate the inner flue duct).Screw the clamp to the air ductsof the flue assembly and the boilerusing the screws supplied.

• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.

• Note: The air/duct clamp must notbe screwed to the bottom of thevertical air/flue duct and terminalaccessory to allow for any slightmovement in the roof structure.

• Ensure that at least one pipeclamp supports the air/flue ductat each extension fitted.

750

2

3

550

885

Ø100

20 –

50

6

7

8

1

0 - 5

8

4

100-

110

5

Fig. 5.2: Fitting the appliance and the vertical roof duct to a building with a pitched roof

*



750

mm

eco

MA

Xco

mbi

natio

n an

d sy

stem

boi

lers

530

mm

eco

MA

X pr

o (to

p ho

les

of b

rack

et)

622

mm

eco

TEC

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 32

33


885

warm roofcold roof

550

Ø100

≥120

2

1

6

7

750

5

7

410

0- 1

10

Fig. 5.3: Fitting the appliance and vertical flue duct to a building with a flat roof

Flat-roof installation• Determine the point where the


• Fit the flat roof penetration collar(1).

• Stick the flat roof penetrationcollar firmly into place withadhesive in accordance with thecodes of practice for flat roofs (CP 144) to ensure a watertightseal.

• Working from above, insert thevertical roof duct (5) through theflat roof collar and push it firmlyinto place.







• Join the sliding sleeve (4) to theappliance’s connection piece (8).This permits easy separationbetween the air/flue duct and theappliance.





750

mm

eco

MA

Xco

mbi

natio

n an

d sy

stem

boi

lers

530

mm

eco

MA

X pr

o (to

p ho

les

of b

rack

et)

622

mm

eco

TEC

PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 33

34

FITTING AIR/FLUE DUCT EXTENSIONS

How to add extensions

Use a saw, tin-snips, etc. to cut tubesto size.

☞ No tools are required whenseparating extensions for cutting tosize air and flue tubes separately.When doing so, the flue conduitshould be twisted into a positionwhere the shoulders on the plastictube can be pushed through thespacer-piece. After cutting to size,refit the flue conduit and secure itto the air conduit.

Tip:Start by measuring the requiredlength of air conduit* (Lair), and thencalculate the corresponding length offlue conduit (Lexhaust) as follows:

Lexhaust = Lair + 40 mm

Lexhaust = length of flue conduitLair = length of air conduit

* Minimum length of air-conduitextension: 80 mm.

1

2

13

2

70L air

Lexhaust

1.

2.

+ 40 mm

27

1

Fig. 6.1: Cutting tubes to size

☞ The seals are sensitive to mineraloil-based grease products. For thisreason, the seals must not begreased. If the seals need wettingto aid in installation, use wateronly.

☞ De-burr and file down any roughedges on the tubes before fitting inorder to prevent damage to theseals. Remove all metal filings andother debris.

☞ Do not use damaged or dentedtubes, as they will not form anadequate seal.

☞ Ensure that the seals remaincorrectly aligned when installingthe tubes. Do not fit damagedseals.

☞ Secure the exhaust conduit withthe fixing device in order to ensurethat it is correctly centred relativeto the air conduit.

Fig. 6.2: Loosening the flue conduit

Important:You must fasten extensions to theceiling or wall using pipe clamps.Use one clamp for each extension.

Important:Where extensions are used, thesemust be installed with a slope of 3°±1° to ensure that condensate doesnot remain in the sleeve (equivalentto 50 mm ± 20 mm rise per metrelength).

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 34

35

How to install 2x 87° elbows• When using 2 x 87° elbows

follow fig. 6.1 to fig. 6.3 to avoidobstructions on outer wall.Note: The elbows must becorrectly aligned to avoid unduestress on the joints and risk ofleakage.The elbow fitted to the top of theboiler (1) should be twisted by 3°to ensure that the second 87° el-bow (2) exits the wall perpen-dicular.

• When using elbows for long flueruns in a corner follow fig. 6.4and fig. 6.5 to avoid obtrsuctions.

☞ Note: The elbows must becorrectly aligned to avoid unduestress on the joints an risk ofleakage.The elbow fitted to the top of theboiler (1) should be twisted by 3°to ensure that the second 87° el-bow (2) exits the wall perpendi-cular. When using 87° elbow install witha slope of 3° between wall andair-flue pipe (fig. 6.4) or use 2 x45° elbows (fig. 6.5).

1 2

* = 3°

*

1

2

* = 3°

*1

2

Fig. 6.1: Arrangement of 2 x 87° elbows – View from above

Fig. 6.2: Arrangement of 2 x 87° elbows – View from front

Fig. 6.3: Arrangement of 2 x 87° elbows – View from side


PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 35

36

12

max

. 5 m

max. 5 m* = 3°

*

90°

1

max

. 5 m

max. 5 m

90°

Fig. 6.4: Long flue runs – using 87° elbow

Fig. 6.5: Long flue elbow – Using 45° elbows




834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 36

37

PART

1 C

ONC

ENTR

IC 6

0/10

0


Offset Length of[in mm] air conduit

[in mm]


[in mm]


[in mm]

630 420635 425640 430645 435650 440655 445660 450665 455670 460675 465680 470685 475690 480695 485700 490705 495710 500715 505720 510725 515730 520735 525740 530745 535750 540755 545760 550765 555770 560775 565780 570785 575790 580795 585800 590

440 230445 235450 240455 245460 250465 255470 260475 265480 270485 275490 280495 285500 290505 295510 300515 305520 310525 315530 320535 325540 330545 335550 340555 345560 350565 355570 360575 365580 370585 375590 380595 385600 390605 395610 400615 405620 410625 415

Table 6.1: Length of surplus with 87° elbows

> 190 to< 210 mm 0

> 215 to not< 265 mm possible

> 270 to< 290 mm 80

295 85300 90305 95310 100315 105320 110325 115330 120335 125340 130345 135350 140355 145360 150365 155370 160375 165380 170385 175390 180395 185400 190405 195410 200415 205420 210425 215430 220435 225

How to install 87° elbowsAccy. No.: 303 910

☞ Note: The elbow delilvered withthe flue kits 303 933 and 303 936 is not the samedimension as shown here.

Example:

An offset of 400 mm is measured.This value is then used, along with thetable below, to determine the lengthof the air conduit ( = 190 mm in thiscase).

Important:This gives a correspondingexhaust-conduit length of 190 + 40 = 230 mm.

Fig. 6.3: Installation of 87° elbows

190

Offset

Length of air conduit95 95

1010

GU

_LA

Z 10

2/2G

B

PART

1 C

ONC

ENTR

IC 6

0/10

0

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 37

38


90 0 21095 0 215

100 0 220


160 86 280165 93 285170 100 290175 107 295180 115 300185 122 305190 129 310195 136 315200 143 320205 150 325210 157 330215 164 335220 171 340225 178 345230 185 350235 192 355240 199 360245 206 365250 214 370255 221 375260 228 380265 235 385270 242 390275 249 395280 256 400285 263 405290 270 410295 277 415300 284 420305 291 425310 298 430315 306 435320 313 440

Offset Length of Height[in mm] air conduit [in mm]

[in mm]


[in mm]

Table 6.2: Length of surplus with 45° bends


[in mm]

How to install 45° elbowsAccy. No.: 303 911Example:

An offset of 400 mm is measured.This value is then used, along with thetable below, to determine the lengthof the air conduit (= 284 mm) and theheight (= 420 mm).


GU

_LA

Z 10

3/2G

B

Fig. 6.4: Installation of 45° bends

325 320 445330 327 450335 334 455340 341 460345 348 465350 355 470355 362 475360 369 480365 376 485370 383 490375 390 495380 397 500385 404 505390 412 510395 419 515400 426 520405 433 525410 440 530415 447 535420 454 540425 461 545430 468 550435 475 555440 482 560445 489 565450 496 570455 503 575460 511 580465 518 585470 525 590475 532 595480 539 600485 546 605490 553 610495 560 615500 567 620505 574 625510 581 630515 588 635520 595 640

525 602 645530 610 650535 617 655540 624 660545 631 665550 638 670555 645 675560 652 680565 659 685570 666 690575 673 695580 680 700585 687 705590 694 710595 701 715600 709 720605 716 725610 723 730615 730 735620 737 740625 744 745630 751 750635 758 755640 765 760645 772 765650 779 770655 786 775660 793 780665 800 785670 808 790675 815 795680 822 800

Hei

ght

Offset

Length

of ai

r con

duit 10

10

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 38

39

CONTENTS: PART 2 CONCENTRIC 80/125

Page

The air/flue duct must be installed by a suitablyqualified service provider, which is responsiblefor observing the relevant specifications,regulations and standards.

Requirements

Planning the air/flue duct layout

Regulations and standards to be observed 40

Alternative termination accessories available 41Maximum flue lengths for ecoMAX 44Maximum flue lengths for ecoTEC 45

Changing the applianceconnection piece

§

47

Installation of the vertical air/flue duct 54

Installation of the horizontal air/flue duct 49

Fitting air/flue duct extensions

Installation of the sliding sleeve

How to add extensions 57How to install elbows 58

48

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 39

40

REQUIREMENTS

Regulations andstandards to beobserved

§

☞ Vaillant ecoMAX/ecoTEC boilersare certified as heating boilerswith corresponding flue systems according to EC Directive90/396/EEC on gas-fireddevices. This installation manual iscovered by this certification and isreferred to in the design approvaltest certificate.

☞ These instructions should be readin conjunction with the instructionsfor installation and servicing supplied with the boiler.

☞ Ensure also that all legislation,rules, regulations and directivesmentioned in the installationinstructions are observed.

☞ The installation of the boiler andits flue must be carried out by acompetent person who is registered with CORGI (TheCouncil for Registered GasInstallers).

☞ The installation of the boiler andflue must be in accordance withthe Gas Safety (Installation andUse) Regulations 1998 and theBuilding Regulations and BS 5440 Part 1.

☞ The requirements for flue termination detailed in the boilerinstallation instructions must beobserved.

☞ The air/flue duct operates at verylow temperatures therefore noclearance is necessary betweenthe air duct and adjacent services.

☞ Ensure while installation work isbeing carried out that no debrissuch as swarf, filings or fragmentsof mortar are allowed to remainin the air/flue duct.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 40

41

PART

2 C

ONC

ENTR

IC 8

0/12

5


Alternative terminationaccessories available

303 200 = Vertical air/flue duct (black)

303 209 = Horizontal air/flue duct

303 907 = Appliance connection piece for ecoMAX only303 926 = Appliance connection piece for ecoTEC and ecoMAX

Optional connection accessories Accy. No.303 200

Air/flue duct extensions (PPs), concentric470 mm - Ø 80/125 303 202 x



Bends (PPs), concentric (pack of 2)45° - Ø 80/125 303 211 x

Elbow (PPs), concentric87° - Ø 80/125

303 210 x

Flue support clips (pack of 5), Ø 125 303 616 x

Sliding sleeve (PPs) Ø 80/125 303 215 x

Adjustable roof tiles for pitched roof 009076 black x

Flat roof penetration collar 009 056 x

303 209

x

x

x

x

x

x

x

x

x

Flexible pitched roof seal 303 980 x

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 41

42


Fig. 1.2: Extensions, Ø 80/125

Fig. 1.4: Flue support clips, Ø 125 or Ø 80

Flue support clips, Ø 125 (pack of 5)Vaillant Accy. No.: 303 616

☞ Use one clip per extension to support the air/flue duct.

15

25

15

25

15

25


Elbow (PPs), 87°, Ø 80/125Vaillant Accy. No.: 303 210

Bends (PPs), 45° (pack of 2), Ø 80/125Vaillant Accy. No.: 303 211

Air/flue duct extension (PPs) 470 mm, Ø 80/125Vaillant Accy. No.: 303 202

Air/flue duct extension (PPs) 970 mm,Ø 80/125Vaillant Accy. No.: 303 203

Air/flue duct extension (PPs) 1970 mm,Ø 80/125 Vaillant Accy. No.: 303 205

GU

_LA

Z 70

/0

GU

_LA

Z 72

/0

GU

_LA

Z 71

/0

5825

18

Fig. 1.1: Appliance connection piece

Appliance connection pieceØ 80/125Vaillant Accy. No.: 303 926(with 2 measuring apertures)

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 42

43

PART

2 C

ONC

ENTR

IC 8

0/12

5


498

132

255

Fig. 1.6: Adjustable roof tile for pitched roof

Adjustable roof tiles for pitched roofVaillant Accy. No.: 009 076 (black)

GU

_LA

Z 41

/0

164

120

Fig. 1.5: Sliding sleeve, Ø 80/125

Sliding sleeve (PPs), Ø 80/125 Vaillant Accy. No.: 303 215

GU

_LA

Z 76

/0

153

130

390

Fig. 1.8: Flat roof penetration collar GU

_LA

Z 42

/0

Flat roof penetration collarVaillant Accy. No.: 009 056

495

132

495

Fig. 1.7: Flexible pitched roof seal

Flexible pitched roof seal (black)Vaillant Accy. No.: 303 980

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 43

44


Maximum flue lengths for use with ecoMAX



303 200 Max. permitted concentric flue length


303 209 Max. permittedconcentricflue length

14.0 m

13.0 mincl.

1 elbow 87°

31.0 m 20.0 m

30.0 mincl.

1 elbow 87°

20.0 mincl.

1 elbow 87°

27.0 m

25.0 mincl.

1 elbow 87°

613/2 E 618/2 E 622/2 E pro 18 Epro 28 E

ecoMAX

Maximum length of flue is reduced by 2.5 m for each additional 90° elbow.









26.0 m

25.0 mincl.

1 elbow 87°

22.0 m

21.0 mincl.

1 elbow 87°

29.0 m

30.0 mincl.

1 elbow 87°

824/2 E 828/2 E 635/ E835/ E

ecoMAX





834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 44

45


Maximum flue lengths for use with ecoTEC

PART

2 C

ONC

ENTR

IC 8

0/12

5






14.0 m

13.0 mincl.

1 elbow 87°

27.0 m

25.0 mincl.

1 elbow 87°

plus 612plus 615

ecoTEC










21.0 mincl.

1 elbow 87°

23.0 m 27.0 m

25.0 mincl.

1 elbow 87°

plus 637plus 837

pro 28

ecoTEC





plus 618plus 624plus 630plus 824plus 831

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 45

46


Maximum flue length

Max

imum

flue

leng

th

LAS

Euro

B/S

074

/0LA

S Eu

ro B

/S 0

74/0

Fig. 1.10

Fig. 1.9

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 46

47

CHANGING THE APPLIANCE CONNECTION-PIECE

1

2

Fig. 2.0: Fitting the appliance connection-piece

InstallationAccy No.: 303 907 for ecoMAXonlyAccy No.: 303 926 for ecoTEC andecoMAX

The appliance is supplied ready-fittedwith the connection-piece for the60/100 air/flue duct system.

• Loosen the four screws (2) andpull the appliance connection-piece (1) upwards to remove it.

• Push the appliance connection-piece with the selected connectiondiameter down from above,inserting the push-in end onto thesleeve of the flue collectingchamber. Now push theappliance connection-piecedownwards until the flange comesinto contact with the low-pressurechamber.

• Refit the fixing screws (2).

The seals are sensitive tomineral oil-based greaseproducts. For this reason, the seals mustnot be greased. If the sealsneed wetting to aid ininstallation, use water only.

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 47

48

INSTALLATION OF THE SLIDING SLEEVE

Fig. 3.0: Installing the sliding sleeve

1

34

675

2

Schi

ebem

uffe

_neu

INSTALLING THEAIR/FLUE DUCT SLIDINGSLEEVE☞ NOTE:

For installations where there is in-sufficient movement to allow fittingof the flue into flue outlet, a slid-ing sleeve (Accy. No. 303 215) isavailable. When using the slidingsleeve both the air and flue ductsof the last extension must beshortened by a further 85 mm.

• Push the sliding sleeve (1) over thecut end of the flue duct (2).

• Place the air duct clamp (7) overthe air duct.

• Pull back the sliding sleeve so thatit engages into the socket (3) ofthe boiler (4). Ensure that thesliding sleeve penetrates thesocket such that there is at least20 mm engagement at both endsof the sliding sleeve.

• Fit the air duct clamp over the airducts (5 and 6) of theextension/terminal and boileroutlet. Close the snap clamp.

• Drill two holes 3 mm diameterthrough the air duct clamp (thecentre of the holes should be 6mm from the edge of the clamp).Ensure that the drill does notpenetrate the inner flue duct.Screw the air duct clamp to theair duct of the sleeve using thescrews provided.

• Complete the installation of theflue as detailed in theseinstructions.

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 48

49



70

1103

70

15


Vaillant Accy No.: 303 209

Contents of the accessory:• Horizontal air/flue duct• 87° elbow• 2 x 70 mm air duct clamps • 1 x internal plastic ring Ø 125• 1 x external metal plate



GU

_LA

Z 82

/0

Fig. 4.2: Example of installation with horizontal air/flue duct



PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 49

50

Side flue installations• For installations where the air/flue

duct is to be installed to the side,the position of the flue exit holecan be determined as follows:

• Identify the correct measurementas shown in fig. 4.3, carefullymeasure the distance from the bottom centre of the boiler hanging bracket (centreline of thetwo lower hanging bracket fixingholes). This gives the position ofthe centreline of the 127 mm flueelbow and adaptor when installed.

• The position of the flue exit holecan be determined by carefullylevelling across the wall from thismark.

• The position of the flue exit holeshould allow the flue to be installed with an upwards slopetowards the terminal of approximately 3° ± 1°, equivalentto 50 mm ± 20 mm rise per metreof flue length. Calculate therequired rise according to the fluelength and mark the position ofthe flue exithole (fig 4.4).

Note: Due to the long lengths of fluepossible and the slope required, itmay be necessary to adjust the location of the boiler installation template. Please check that both theboiler installation site and flue termination are in accordance withthese instructions prior to drilling anyholes for the boiler hanging bracket.• Once the position of the flue exit

hole has been determined, thehole should be cut through thewall using a core drill of 127 mmdiameter. The flue exit hole shouldbe cut with a rise towards outsideof 3°.

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 4.5).This is dimension A.

• For installations where the measured distance dimension A(fig. 4.5) is greater than 960 mm,an air/flue extension accessorywill be required. The number ofair/flue duct extensions which canbe used depends on the boiler.




• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of thetemplate is vertical using a plumbline or spirit level.

*

Fig. 4.3 LAS

Euro

B/S

077

/1

253

Fig. 4.4 LAS

Euro

B/S

083

/1

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITHEXTENSIONS

* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro* = 125 mm ecoTEC

*


* = 210 mm ecoMAX pro(from top holes on bracket)

* = 238 mm ecoTEC



834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 50

51


• Taking each extension to be used,fit the flue duct into the air ductand secure using the 3 screwsprovided.

• For ease of measuring and marking the air/flue duct extensions, assemble them looselytogether with the air/flue duct andterminal assembly as shown(fig. 4.6).

Note: The joints between the flue ductsections are of a push-fit type, withthe flue duct spigot inserted into asocket containing a sealing ring. Forease of installation lubricate the sealusing soap solution prior to assembling.• Assemble the flue such that there

is a gap of about 10 mm betweeneach air duct, which will ensurethe correct flue duct penetrationinto the flue sockets of 30 mm. All flue sockets should pointtowards the flue terminal.

• Measure from the flue terminaland mark the air duct to a lengthof:Dimension A + 60 mm

• Take the extension(s) to be shortened and remove the3 screws. Separate the ducts.

Note: For assembly reasons do notshorten any air duct to a length ofless than 100 mm. If necessary shorten two adjacent extensions toachieve the overall required length.• Cut the air duct square and

remove any burrs.• Refit the flue duct into the air duct

and secure using the 3 screws.• Cut the flue duct as detailed in

fig. 4.7.• When cutting the air and flue

ducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.

• Care should be taken not toscratch the white surface of the airduct.


• At this stage it is necessary toprepare and fit the boiler onto thehanging bracket – refer to theboiler installation instructions.

• Fit the appliance flue outletadaptor to the boiler.

A

Fig. 4.5 LAS

Euro

B/S

082

/0

10 mm

Mark air duct here

Dimension A + 20 mm

Fig. 4.6 LAS

Euro

B/S

084

/0

25 mm

Mark flue duct here

15 mm

Fig. 4.7 LAS

Euro

B/S

080

/0

Dimension A + 60 mm

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 51

52

220

15

3°

1

Fig. 4.8: Installing the horizontal wall duct LGU

_LA

Z 38

4/0_

IT

• Push the assembled air/flue ductand terminal assembly through theflue exit hole until it protrudes 220 mm out from the outsidewall.

• Ensure that the terminal is correctly positioned with the airinlet grille at the bottom.

• Slide one of the two trim ringsover the air duct until it is flushwith the internal wall face.


834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 52

53

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (80/125 Ø)

8

82 - 90

253

7

4

2

3

6

750

Fig. 4.9: Indirect installation

Indirect installation• Fit the wall mounting (2).• Install the appliance (3) with


• Change the appliance connection-piece (4) as described onpage 47.

• Join the 87° elbow to theappliance connection piece.

• Push the sliding sleeve (7) firmlyinto place on the appropriateextensions (6).

• Install the extensions and join thesliding sleeve to the 87° elbow.

☞ This section functionssubsequently as a separationpoint.

• Join all separation points with theair-conduit fixing collars (8).


☞ For horizontal flue installationsthrough sloping roofs, please order the Horizontal Flue Flashingfrom Ubbink (Nothants, Tel: 01280 700211)

**

*


* = 530 mm ecoMAX pro(from top holes on bracket)

* = 622 mm ecoTEC

** = 253 mm ecoMAXcombination and system boilers

** = 210 mm ecoMAX pro(from top holes on bracket)

** = 238 mm ecoTEC

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 53

54

1530

880

70

650

Vertical air/flue duct Accy. No.: 303 200 (black)

Contents of the accessory:• Vertical air/flue duct and terminal

assembly• Adapter (air) for Ø 110/125• 70 mm air duct clamp• Fixing bracket



Fig. 5.1: Vertical roof duct GU

_LA

Z 81

/0

The air/flue duct assembly may beconnected directly to the flue outleton top of the boiler.

In addition to the vertical air/flueduct and terminal accessory, air/flueduct extensions can be added toincrease the length of the flue.

Preparation

• Determine the installation site forthe boiler with reference to theinstallation and servicinginstructions supplied with theboiler.

• Ensure that all installation andservice clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.

• Determine the point where thevertical air/flue duct and terminalassembly will penetrate the roof.

☞ Please note: The vertical air/flueduct and terminal accessory (Accy.No. 303 200) may be shortened.The outer ‘white’ duct should beshortened first, then the inner flueduct cut so that it protrudes 15 mmout of the air duct. In case ofinstallation directly to the boilerwithout elbows or bends, it isessential that the roof tile/collar isvertically aligned with the air/flueduct of the boiler.


834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 54

55


750

2

3

790

740

Ø125

20 –

50°

5

6

8

*

7

1

0 - 5

8

4

82 -

90

Fig. 5.2: Fitting the appliance and the vertical roof duct to a building with a pitched roof

Pitched roof installation• Determine the point where the


• Fit the flexible pitched roof seal (1).• Working from above, insert the

vertical roof duct (5) through theroofing tile and push it firmly intoplace.






• Join the vertical flue duct (5) to theextension (7).

• Join the sliding sleeve (4) to theappliance’s connection piece (8).

☞ Using the sliding sleeve allows theappliance to be easily removedand replaced without dismantlingthe flue.







750

mm

eco

MA

X co

mbi

natio

n an

d sy

stem

boi

lers

530

mm

eco

MA

X pr

o(to

p ho

les

of b

rack

et)

622

mm

eco

TEC

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 55

56


880

warm roofcold roof

650

Ø125

≥120

2

1

5

6

7

750

7

4

82 -

90

Fig. 5.3: Fitting the appliance and vertical flue duct to a building with a flat roof

Flat-roof installation• Determine the point where the


• Fit the flat roof penetration collar(1).

• Stick the flat roof penetrationcollar firmly into place withadhesive in accordance with thecodes of practice for flat roofs (CP 144) to ensure a watertightseal.

• Working from above, insert thevertical flue duct (5) through theflat roof collar and push it firmlyinto place.







• Join the sliding sleeve (4) to theappliance’s connection piece (8).This permits easy separationbetween the air/flue duct and theappliance.





750

mm

eco

MA

X co

mbi

natin

and

syste

m b

oile

rs53

0 m

m e

coM

AX

pro

(top

hole

s of

bra

cket

)62

2 m

m e

coTE

C

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 56

57


How to add extensions

Use a saw, tin-snips, etc. to cut tubesto size.

☞ No tools are required whenremoving previously-fittedextensions for cutting to size airand flue tubes separately. Whendoing so, the flue conduit shouldbe twisted into a position wherethe shoulders on the plastic tubecan be pushed through the spacer-piece. After cutting to size, refitthe flue conduit and secure it tothe air conduit.

Tip:Start by measuring the requiredlength of air conduit* (Lair), and thencalculate the corresponding length offlue conduit (Lexhaust) as follows:

Lexhaust = Lair + 40 mm

Lexhaust = length of flue conduitLair = length of air conduit

* Minimum length of air-conduitextension: 100 mm.

1

2

15

1 2

70

L air

Lexhaust

1.

2.

+ 40 mm

25

Fig. 6.1: Cutting tubes to size

☞ The seals are sensitive to mineraloil-based grease products. For thisreason, the seals must not begreased. If the seals need wettingto aid in installation, use wateronly.

☞ De-burr and file down any roughedges on the tubes before fitting inorder to prevent damage to theseals. Remove all metal filings andother debris.

☞ Do not use damaged or dentedtubes, as they will not form anadequate seal.

☞ Ensure that the seals remaincorrectly aligned when installingthe tubes. Do not fit damagedseals.

☞ Secure the exhaust conduit withthe fixing device in order to ensurethat it is correctly centred relativeto the air conduit.

Fig. 6.2: Loosening the flue conduit GU

_LA

Z 29

0/1

Important:You must fasten extensions to theceiling or wall using pipe clamps.Use one clamp for each extension.

Important:Where extensions are used, thesemust be installed with a slope of 3°±1° to ensure that condensate doesnot remain in the sleeve (equivalentto 50 mm ± 20 mm rise per metrelength).

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 57

58

How to install 2x 87° elbows• When using 2 x 87° elbows

follow fig. 6.1 to fig. 6.3 to avoidobstructions on outer wall.Note: The elbows must becorrectly aligned to avoid unduestress on the joints and risk ofleakage.The elbow fitted to the top of theboiler (1) should be twisted by 3°to ensure that the second 87° el-bow (2) exits the wall perpen-dicular.

1 2

* = 3°

*

1

2

* = 3°

*1

2

Fig. 6.1: Arrangement of 2 x 87° elbows – View from above

Fig. 6.2: Arrangement of 2 x 87° elbows – View from front

Fig. 6.3: Arrangement of 2 x 87° elbows – View from side


834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 58

59

12

max

. 5 m

max. 5 m* = 3°

*

90°

1

max

. 5 m

max. 5 m

90°

Fig. 6.4: Long flue runs – using 87° elbow

Fig. 6.5: Long flue elbow – Using 45° elbows


PART

2 C

ONC

ENTR

IC 8

0/12

5



834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 59

60



[in mm]


[in mm]


[in mm]

730 520735 525740 530745 535750 540755 545760 550765 555770 560775 565780 570785 575790 580795 585800 590805 595810 600815 605820 610825 615830 620835 625840 630845 635850 640855 645860 650865 655870 660875 665880 670885 675890 680895 685900 690905 695910 700915 705920 710925 715930 720935 725940 730

505 295510 300515 305520 310525 315530 320535 325540 330545 335550 340555 345560 350565 355570 360575 365580 370585 375590 380595 385600 390605 395610 400615 405620 410625 415630 420635 425640 430645 435650 440655 445660 450665 455670 460675 465680 470685 475690 480695 485700 490705 495710 500715 505720 510725 515

Table 6.1: Length of surplus with 90° elbows

200, 205 0210, 0


310 100315 105320 110325 115330 120335 125340 130345 135350 140355 145360 150365 155370 160375 165380 170385 175390 180395 185400 190405 195410 200415 205420 210425 215430 220435 225440 230445 235450 240455 245460 250465 255470 260475 265480 270485 275490 280495 285500 290


An offset of 400 mm is measured.This value is then used, along with thetable below, to determine the lengthof the air conduit (= 190 mm in thiscase).


190

Offset

Length of air conduit95 95

1010Fig. 6.3: Installation of 90° elbows G

U_L

AZ

102/

2GB

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 60

61

90 0 21095 0 215100 0 220


170 100 290175 108 295180 115 300185 122 305190 129 310195 136 315200 143 320205 150 325210 157 330215 164 335220 171 340225 178 345230 185 350235 192 355240 199 360245 207 365250 214 370255 221 375260 228 380265 235 385270 242 390275 249 395280 256 400285 263 405290 270 410295 277 415300 284 420305 291 425310 298 430315 306 435320 313 440325 320 445330 327 450



[in mm]


[in mm]

Table 6.2: Length of surplus with 45° bends


[in mm]

Hei

ght

Offset

Length

of ai

r con

duit 10

10


An offset of 400 mm is measured.This value is then used, along with thetable below, to determine the lengthof the air conduit (= 284 mm) and theheight (= 420 mm).


GU

_LA

Z 10

3/2G

B

Fig. 6.4: Installation of 45° bends

335 334 455340 341 460345 348 465350 355 470355 362 475360 369 480365 376 485370 383 490375 390 495380 397 500385 405 505390 412 510395 419 515400 426 520405 433 525410 440 530415 447 535420 454 540425 461 545430 468 550435 475 555440 482 560445 489 565450 496 570455 504 575460 511 580465 518 585470 525 590475 532 595480 539 600485 546 605490 553 610495 560 615500 567 620505 574 625510 581 630515 588 635520 596 640525 603 645530 610 650

535 617 655540 624 660545 631 665550 638 670555 645 675560 652 680565 659 685570 666 690575 673 695580 680 700585 687 705590 695 710595 702 715600 709 720605 716 725610 723 730615 730 735620 737 740625 744 745630 751 750635 758 755640 765 760645 772 765650 779 770655 786 775660 794 780665 801 785670 808 790675 815 795680 822 800685 829 805690 836 810695 843 815700 850 820705 857 825710 864 830715 871 835720 878 840

PART

2 C

ONC

ENTR

IC 8

0/12

5

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 61

62

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 62

63

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 63

83

44

49

_08

GB

02

20

06

834449_08GB_022006.qxd 27.02.2006 15:13 Uhr Seite 64

flue installation instructions

Documents