Vaillant Air flue duct Installation Instructions Manual

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For the installer

Flue installation instructions

Air flue duct for use with ecoTEC boilers

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

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

Contents

1 Notes on the documentation ........................... 3

1.1 Storage of documents ............................................. 3

1.2 Symbols used ............................................................. 3

1.3 Applicability of the manual ..................................... 3

2 Standard Concentric Systems Ø 60/100 ...... 3

2.1 Requirements ............................................................. 3

2.1.2 Intended use .............................................................. 4

2.1.3 Preliminary remarks for room sealed

appliances ................................................................... 4

2.1.4 Related documents ................................................... 4

2.2 Planning the air/flue duct layout .......................... 5

2.2.1 Alternative termination accessories available .. 5

2.2.2 Element descriptions ................................................ 7

2.2.3 Maximum flue lengths for use with

ecoTEC exclusive ...................................................... 9

2.2.4 Maximum flue lengths for use with ecoTEC ....... 9

2.3 Installing the air/flue duct sliding sleeve ............ 11

2.4 Installation of the horizontal air/flue duct ......... 11

2.4.1 Contants included with delivery ............................ 11

2.4.2 Preparation ................................................................. 12

2.4.3 Top outlet flue exiting to rear ............................... 12

2.4.4 Top outlet flue exiting to side ................................ 12

2.5 Installation of the telescopic horizontal

air/flue duct ................................................................ 14

2.5.1 Contents included with delivery ............................ 14

2.5.2 Preparation ................................................................. 14

2.5.3 Top outlet flue exiting to rear ............................... 15

2.5.4 Top outlet flue exiting to side ................................ 15

2.6 Installation of the black terminal kit .................... 17

2.6.1 Contents included with delivery ............................ 17

2.6.2 Assembly of the black terminal kit before

installing the flue duct ............................................. 17

2.6.3 Assembly of the black terminal kit after

installing the flue duct ............................................. 18

2.7 Installation of the variable termination

kit (VTK) ...................................................................... 18

2.7.1 Contents included with delivery ............................ 18

2.7.2 Assembly of the variable terminal kit before

installing the flue pipe ............................................. 19

2.7.3 Installing the variable terminal kit after

installing the flue duct ............................................. 20

2.7.4 Installing the pipes .................................................... 20

2.7.5 Routing around roof eaves ..................................... 22

2.8 Installing the deflector set...................................... 23

2.8.1 Contents included with delivery ............................ 23

2.8.2 Assembly of the deflector set before

installing the flue gas pipe ...................................... 23

2.8.3 Installation of the deflector set after

installing the flue gas pipe ...................................... 24

2.8.4 Installing the variable terminal set after

installing the flue gas pipe ...................................... 24

2.9 Installation of the vertical air/flue duct ............. 26

2.9.1 Contents included with delivery ............................ 26

2.9.2 Preparation ................................................................. 26

2.9.3 Pitched roof installation .......................................... 27

2.9.4 Flat-roof installation ................................................. 28

2.10 Installing the ridge tile terminal ............................ 29

2.10.1 Contents included with delivery ............................ 29

2.10.2 Preparation ................................................................. 29

2.10.3 Installing the ridge tile ............................................. 29

2.10.4 Installing the ridge tile terminal ............................ 30

2.11 Fitting air/flue duct extensions ............................. 30

2.11.1 How to add extensions ............................................ 30

2.11.2 How to install 2x 87° elbows ................................. 31

2.11.3 How to install 87° elbows ....................................... 33

2.11.4 How to install 45° elbows ....................................... 34

3 Optional Concentric System Ø 80/125 ......... 35

3.1 Requirements ............................................................. 35

3.2 Planning the air/flue duct layout .......................... 36

3.2.1 Alternative termination accessories available .. 36

3.2.2 Element descriptions ................................................ 37

3.2.3 Maximum flue lengths for use with

ecoTEC exclusive ...................................................... 38

3.2.4 Maximum flue lengths for use with ecoTEC ....... 38

3.3 Changing the appliance connection piece .......... 39

3.4 Installation of the sliding sleeve ........................... 40

3.5 Installation of the horizontal air/flue duct ......... 40

3.5.1 Contents included with delivery ............................ 40

3.5.2 Preparation ................................................................. 41

3.5.3 Side flue installations ............................................... 41

3.5.4 Indirect installation ................................................... 43

3.6 Installation of the vertical air/flue duct ............. 44

3.6.1 Contents included with delivery ............................ 44

3.6.2 Preparation ................................................................. 44

3.6.3 Pitched roof installation .......................................... 44

3.6.4 Flat-roof installation ................................................. 45

3.7 Fitting air/flue duct extensions ............................. 46

3.7.1 How to add extensions ............................................ 46

3.7.2 How to install 2x 87° elbows ................................. 47

3.7.3 How to install 87° elbows ....................................... 49

3.7.4 How to install 45° elbows ....................................... 50

Flue installation instructions ecoTEC 834449_132

Notes on the documentation 1

Standard Concentric Systems Ø 60/100 2

1 Notes on the documentation

The following instructions are intended to help you throughout the entire documentation. Further documents apply in combination with this installation manual. We accept no liability for any damage caused by non-observe these instructions.

Other applicable documents

For the heating engineer:

- Installation instructions for installed gas fired wall hung high efficiency boiler.

1.1 Storage of documents

Please pass on this installation manual, all other applicable documents any auxiliary equipment that may be required to the operator of the system whose responsibility it is to ensure the manuals and auxiliary equipment are available whenever required.

1.2 Symbols used

Please observe the safety instructions in this manual when using the device!

Danger!

Immediate risk of serious injury or death!

Caution!

Potentially dangerous situation for the product and environment!

2 Standard Concentric Systems

Ø 60/100

Galvanized steel air duct/plastic flue duct.

2.1 Requirements

Regulations and standards to be observed

Caution!

The air/flue duct must be installed by a suitably qualified service provider, which is responsible for observing the relevant specifications, regulations and standards.

Note

Vaillant ecoTEC gas fired wall hung boilers are certified as boiler systems with corresponding flue gas systems according to the EU gas appliance directive 90/396/EEC. The installation guide is part of the certification and is cited in the prototype test certificate. The usability proof of products identified by Vaillant item numbers for air/flue gas duct systems is supplied in observance of the specifications in this installation manual.

Note

These instructions should be read in conjunction with the instructions for installation and servicing supplied with the boiler.

Note

Useful information and instructions.

• Symbol for a necessary task

1.3 Applicability of the manual

This installation manual is only valid for the Vaillant boilers referred to in the other applicable documents.

Note

Ensure also that all legislation, rules, regulations and directives mentioned in the installation instructions are observed.

Note

The installation of the boiler and its flue must be carried out by a competent person who is registered with CORGI (The Council for Registered Gas Installers).

Note

The installation of the boiler and flue must be in accordance with the Gas Safety (Installation and Use) Regulations 1998 and the Building Regulations and BS 5440 Part 1.

Note

The requirements for flue termination detailed in the boiler installation instructions must be observed.

3Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

Note

Two types of flue gas installation are available for ecoTEC boilers:

- standard concentric flue gas installations (outer diameter 100 mm)

- a concentric system with a larger diameter (outer diameter 125mm) which can be used to achieve longer air/flue gas pipes.

Note

The air/flue duct operates at very low temperatures therefore no clearance is necessary between the air duct and adjacent services.

Note

Ensure while installation work is being carried out that no debris such as swarf, filings or fragments of mortar are allowed to remain in the air/flue duct.

2.1.1 Intended use

Valliant flue pipes for ecoTEC are state-of-the-art appliances which are designed in accordance with approved safety regulations. Nevertheless, there is still a risk of death or serious injury to the user or others or of damage to the device and other property in the event of improper use or use for which it is not intended. The Vaillant flue pipes for ecoTEC may only be used with the unit types named in this installation manual. Any other use or extended use is considered to be improper. The manufacturer or supplier is not liable for any resulting damage. The user alone bears the risk. Intended use includes the observance of the relevant manual.

2.1.2 Preliminary remarks for room sealed appliances

This appliance should only be installed in conjunction with either a Vaillant flue system or an alternative approved system (details of flue approval categories can be found in the technical section of the installation manual). Install the flue system as detailed in the separate flue installation instructions supplied with this boiler.

BS 6700: Services supplying water for domestic use

within buildings and their curtilages.

BS 6798: Specification for installation of gas fired boil-

ers not exceeding 60 kW input.

BS 6891: Specification for installation of low pressure

gas pipework up to 28 mm (R1) in domestic premises (2nd family gas).

BS 7593: Treatment of water in domestic hot water

central heating systems. Institute of Gas Engineers Publication IGE/UP/7/1998: ”Guide for gas installations in timber framed housing” BS. 5482 Pt. 1 Domestic butane and propane gas burn-

ing installations.

IGE/UP1 Soundness testing and purging of industrial

and commercial gas installation.

IGE/UP2 Gas installation pipework, boosters and com-

pressors on industrial and commercial premises.

IGE/UP10 Installation of gas appliances in industrial and

commercial premises. BS. 6644 Installation of gas fired hot water boilers of

rated inputs between 60 kW and 2 MW (2nd

and 3rd family gases). BS. 5449 Forced circulation hot water central heating

systems for domestic premises. Note: only up

to 45 kW. BS. 6880 Low temperature hot water heating systems

of output greater than 45 kW.

Part 1 Fundamental and design consid-

erations. Part 2 Selection of equipment. Part 3 Installation, commissioning and

maintenance. BS. 4814 Specification for: Expansion vessels using an

internal diaphragm, for sealed hot water heating systems.

BS. 5440 Installation and maintenance of flues and

ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd familygases).

Part 1 Specification for installation of

flues. Part 2 Specification for installation and

maintenance of ventilation for gas ap-

pliances.

2.1.3 Related documents

The installation of the boiler must be in accordance with the relevant requirements of Gas Safety (Installation and Use) Regulations 1998, Health and Safety Document No. 635 (The Electricity at Work Regulations 1989), BS7671 (IEE Wiring Regulations) and the Water Supply (Water Fitting) Regulations 1999, or The Water Bylaws 2000 (Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, The Building Regulations (Scotland), he Building Regulations (Northern Ireland) and the relevant recommendations of the following British Standards:

Flue installation instructions ecoTEC 834449_134

Standard Concentric Systems Ø 60/100 2

2.2 Planning the air/flue duct layout

2.2.1 Alternative termination accessories available

0020060570 = Vertical air/flue duct (black) 0020060571 = Vertical air/flue duct (red) 0020065937 = Vertical air/flue duct (black)

303 982 = Ridge tile terminal

303 933 = Horizontal air/flue duct 303 936 = Horizontal telescopic air/flue duct

Optional connection accessories Accy. No.

Air/flue duct extensions, concentric 470 mm - Ø 60/100

Air/flue duct extensions, concentric 970 mm - Ø 60/100

Air/flue duct extensions, concentric 1970 mm - Ø 60/100

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

Elbow, concentric 87° - Ø 60/100

Flue support clips (pack of 5), Ø 100

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

Sliding sleeve (PP) Ø 60/100

Adjustable roof tiles for pitched roof

Flexible pitched roof seal

303 902 X X X X

303 903 X X X X

303 905 X X X X

303 911 X X X X

303 910 X X X X

303 821 X X X X

303 935 X X X X

303 915 X X X X

009 076

(black)

303 980 X

0020060570

0020060571

0020065937

XXX

303 982 303 933 303 936

Flat roof penetration collar

Telescopic extension 440 mm - 690 mm Ø 60/100

Telescopic offset section

Black terminal kit for horizontal air/flue duct

Table 2.1 Product program

009 056 X

303 906 X X X X

303 919 X X X X

303 934 X X

5Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

Optional connection accessories Accy. No.

Variable termination kit - black *)

Extension pipe for variable termination kit VTK Ø 60 mm 1 m - black *)

87° elbow for variable termination kit - black *)

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

Variable termination kit - white *)

Extension pipe for variable termination kit VTK Ø 60 mm 1 m - white *)

87° elbow for variable termination kit - white *)

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

Deflector set DN 60 PP-black

303 942 X X

303 943 X X

303 944 X X

303 945 X X

303 946 X X

303 947 X X

303 949 X X

303 948 X X

00 2006 0584 X X

0020060570 0020060571 0020065937

303 982 303 922 303 923

Deflector set DN 60 PP-white

Table 2.1 Product program (continued)

*) delivered with support clips

00 2006 0585 X X

Flue installation instructions ecoTEC 834449_136

2.2.2 Element descriptions

Standard Concentric Systems Ø 60/100 2

Element Description

Air/flue duct extension, Ø 60/100

470 mm: Accy. No. 303 902 970 mm: Accy. No. 303 903 1970 mm: Accy. No. 303 905

Elbow, Ø 60/100

87°: Accy. No. 303 910 45°: Accy. No. 303 911

(pack of 2)

Elbow 87°, Ø 60/100

Only Part of: Accy. No.: 303 933 Accy. No.: 303 936

94 18

Element Description

Sliding sleeve (PP), Ø 60/100

Accy. No.: 303 915

155

132

498

132

Adjustable roof tile for pitched roof

Accy. No.: 009 076 (black)

255

Flexible pitched roof seal

Accy. No.: 303 980 (black)

140

100

250

Flue support clips, Ø 100,

(pack of 5) Accy. No.: 303 821

Adjustable flue support clips, Ø 100 (pack of 3)

Accy. No.: 303 935

495

440 – 690

495

Flat roof penetration collar

Accy. No.: 009 056

Telescopic extension (PP), Ø 60/100

440 mm - 690 mm Accy. No.: 303 906

Table 2.2 Elements 60/100

Table 2.2 Elements 60/100 (continued)

7Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

Element Description

Offset section, Ø 60/100

Accy. No.: 303 919

33 – 56

Black terminal kit for horizontal air/flue duct

Accy. No.: 303 934 For 303 933 and 303 936 only

Variable termination kit black

Accy. No.: 303 942 For 303 933 and 303 936 only

Variable termination kit white

Accy. No.: 303 946 For 303 933 and 303 936 only

290 – 374

Element Description

45° bend for variable termination kit - black

Accy. No.: 303 945

45° bend for variable termination kit - white

Accy. No.: 303 948

Deflector set DN 60 PPblack

with wall seal Accessory No.: 00 2006 0584

Deflector set DN 60 PPwhite

Accessory No.: 00 2006 0585

Flue support clip Ø 60 mm

delivered with kits

Extension pipe for variable termination kit Ø 60 mm 1 m

- black

including 1 support clip Accy. No.: 303 943

Extension pipe for variable termination kit Ø 60 mm 1 m

- white

including 1 support clip Accy. No.: 303 947

87° elbow for variable termination kit - black

including 1 support clip Accy. No.: 303 944

87° elbow for variable termination kit - white

including 1 support clip Accy. No.: 303 949

Table 2.2 Elements 60/100 (continued)

Flue installation instructions ecoTEC 834449_138

Standard Concentric Systems Ø 60/100 2

2.2.3 Maximum flue lengths for use with ecoTEC exclusive

Accessories Accy.-Nr.

Horizontal flue systems

Variable termination kit 303 942

Vertical flue systems 0020060570

Table 2.3 Maximum flue lengths for use with

ecoTEC exclusive

303 933 303 936

303 946

only in combination with 303 933 303 936

0020060571 0020065937 303 982

Max. permitted concentric flue length

2.2.4 Maximum flue lengths for use with ecoTEC

ecoTEC exclusive

832 838

4.0 m incl.

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

Maximum length of flue is reduced by 0.5 m for each additional 45° elbow

The maximum permitted concentric flue length given above is reduced as follows:

- 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

7.0 m

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

Maximum length of flue is reduced by 0.5 m for each additional 45° elbow

Accessories Accy.-Nr.

Horizontal flue systems

Variable termination kit

Vertical flue systems

Table 2.4 Maximum flue lengths for use with ecoTEC

303 933 Max. permitted

303 942 303 946

only in combination with 303 933 303 936

0020060570 0020060571 0020065937 303 982

concentric flue length

Max. permitted concentric flue length

ecoTEC

plus 612 plus 615 plus 618

8.0 m incl.

1 elbow 87°

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

Maximum length of flue is reduced by 0.5 m for each additional 45° elbow

The maximum permitted concentric flue length given above is reduced as follows:

- 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

The flue length ouside shall not exceed 10 m.

12.0 m 12.0 m 12.0 m 8.0 m 12.0 m 10.0 m

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

Maximum length of flue is reduced by 0.5 m for each additional 45° elbow

plus 624 plus 824

8.0 m incl.

1 elbow 87°

plus 630

plus 831

8.0 m incl.

1 elbow 87°

plus 637 plus 837 plus 937

5.5 m incl.

1 elbow 87°

pro 24 pro 28

8.0 m incl.

1 elbow 87°

plus 415

plus 418 plus 428 plus 438

10.0 m incl.

1 elbow 87°

9Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

Fig. 2.1 Horizontal flue systems

Key

A Maximum flue length

Fig. 2.3 Vertical flue systems

Key

A Maximum flue length

Fig. 2.2 Horizontal flue system installed with vertical termina-

tion kit

Key

A Concentric flue length B Flue length outside

Flue installation instructions ecoTEC 834449_1310

Standard Concentric Systems Ø 60/100 2

2.3 Installing the air/flue duct sliding sleeve

Note

For installations where there is insufficient movement to allow fitting of the flue into flue outlet, a sliding sleeve (Accy. No. 303 915) is available. When using the sliding sleeve both the air and flue ducts of the last extension must be shortened by a further 95 mm.

2.4 Installation of the horizontal air/flue duct

2.4.1 Contants included with delivery

Caution!

The air/flue duct is not concentric and the air duct has a slope of 1.5° (if the air flue duct is not cut). The hole through the wall can therefore be drilled horizontally with no slope.

Where extensions are used, these must be in-

stalled with a slope at 3° ± 1° (equivalent to 50 mm ± 20 mm rise per metre length) to ensure that condensate does not remain in the sleeve.

754

Fig. 2.4 Installing the sliding sleeve

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

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

• Pull back the sliding sleeve so that it engages into the socket (3) of the boiler (4). Ensure that the sliding sleeve penetrates the socket such that there is at least 20 mm engagement at both ends of the sliding sleeve.

• Fit the air duct clamp over the air ducts (5 and 6) of the extension/terminal and boiler outlet. Close the snap clamp.

• Drill two holes 3 mm diameter through the air duct clamp (the centre of the holes should be 6 mm from the edge of the clamp). Ensure that the drill does not penetrate the inner flue duct. Screw the air duct clamp to the air duct of the sleeve using the screws provided.

• Complete the installation of the flue as detailed in these instructions.

Fig. 2.5 Horizontal air/flue conduit

Horizontal air/flue duct

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.

11Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

2.4.2 Preparation

* 87

2.4.3 Top outlet flue exiting to rear

• For installations where the air/flue duct is to be installed directly to the rear of the boiler, the installation template details the position of the flue exit hole for horizontal top outlet installation.

2.4.4 Top outlet flue exiting to side

Fig. 2.6 Assembly of the boiler and of the roof duct to buildings

with pitched roofs

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937

• Determine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions.

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

Fig. 2.7 Distance to external wall

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937

• For installations where the air/flue duct is to be installed to the side, the position of the flue exit hole can be determined by carefully levelling across the wall from the centre line of the air/flue duct hole marked on the template.

• The position of the flue exit hole should allow the flue to be installed with a slight upward slope of about 3° ± 1° (equivalent to 50 mm ± 20 mm per metre of flue duct). Calculate the required rise according to the flue length and mark the position of the flue exit hole.

• Once the position of the flue exit hole has been determined, the hole should be cut through the wall using a core drill of 125 mm diameter.

Flue installation instructions ecoTEC 834449_1312

Note

If access can be gained to the proposed flue exit point from outside the dwelling, the hole can be cut with a 107 mm core drill and the flue external wall seal fitted from outside the dwelling.

Standard Concentric Systems Ø 60/100 2

• Cut the air duct and flue duct to the lengths shown in (fig. 2.9).

• All flue sockets should point towards the terminal.

• When cutting the air and flue ducts it is important to remove any burrs with a file, this ensures easy fitting of the ducts and prevents any rough edges from damaging the flue seals. Care should be taken not to scratch the white surface of the air duct.

• If the installation requires the use of air/flue duct extensions, additional bends or elbows refer to the section 2.11.

• Secure the air duct sections together by drilling a 3 mm diameter hole through the location hole in the end of the outer air duct. (Ensure that the drill does not pierce the inner flue duct). Secure the air ducts together using the screw provided.

3°

Fig. 2.8 Distance to external wall

Key

1. Rear exit

2. Side exit A Distance to external wall B Distance to internal wall

= 190 mm ecoTEC exclusive combination = 176 mm ecoTEC plus open vent = 125 mm ecoTEC plus system & combination = 323 mm ecoTEC plus 937

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 2.8). This is dimension A.

A + 22 mm

13 mm

Fig. 2.9 Length of air pipe

Fig. 2.10 Assembly of the horizontal wall duct

• Push the air/flue duct assembly (1) including the flexi-

ble external seal through the wall until the seal clears the outside face of the wall and pull air/flue duct back towards the boiler until the external seal touches the outside wall (fig. 2.6 and fig. 2.10).

• Ensure that the air/flue duct (1) is centred in the hole

and the terminal is correctly positioned with the inlet grille at the bottom (fig. 2.6 and fig. 2.10).

• Slide the internal trim ring (2) over the air duct until it is flush with the wall (2, fig. 2.6).

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

• Fit the elbow (4) to the boiler by inserting the spigot of the flue elbow into the flue socket on the boiler and secure using the 30 mm air duct clamp (3) provided (fig. 2.6).

• Pull the air/flue duct back through the wall such that the flue duct fully engages into the flue elbow socket.

• Fit the 48 mm air duct clamp (5) ensuring that it is positioned centrally (fig. 2.6).

13Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

the clamps to the air ducts of the flue assembly, the elbow and boiler using the screws supplied.

• Slide the internal trim ring back to the wall, securing in position with a small amount of sealant if required.

Caution!

If installed near a light, insects may fly into the opening. Tell the homeowner to clean the opening regularly.

2.5 Installation of the telescopic horizontal air/

flue duct

2.5.1 Contents included with delivery

Caution!

The air/flue duct is not concentric and the air duct has a slope of 1.5° (if the air flue duct is not cut). The hole through the wall can therefore be drilled horizontally with no slope.

Where extensions are used, these must be in-

stalled with a slope at 3° ± 1° (equivalent to 50 mm ± 20 mm rise per metre length) to ensure that condensate does not remain in the sleeve.

2.5.2 Preparation

* 87

405 - 610

4865

Fig. 2.11 Horizontal air/flue conduit

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.

Fig. 2.12 Assembly of the boiler

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937

• Determine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions.

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

Flue installation instructions ecoTEC 834449_1314

Standard Concentric Systems Ø 60/100 2

2.5.3 Top outlet flue exiting to rear

2.5.4 Top outlet flue exiting to side

Fig. 2.13 Installation template

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937

• Once the position of the flue exit hole has been determined, the hole should be cut through the wall using a core drill of 125 mm diameter.

Fig. 2.14 Distance to external wall

Key

1 Rear exit 2 Side exit A Distance to external wall B Distance to internal wall

= 190 mm ecoTEC exclusive combination = 176 mm ecoTEC plus open vent = 125 mm ecoTEC plus system & combination = 323 mm ecoTEC plus 937

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 2.14). This is dimension A.

Note

If access can be gained to the proposed flue exit point from outside the dwelling, the hole can be cut with a 107 mm core drill and the flue external wall seal fitted from outside the dwelling.

15Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

A + 22 mm

Fig. 2.15 Fixing the air pipe

• Adjust the air duct and flue duct to the lengths shown in (fig. 2.15).

• Secure the air duct sections together by drilling a 3 mm diameter hole through the location hole in the end of the outer air duct (1). (Ensure that the drill does not pierce the inner flue duct). Secure the air ducts together using the screw (1) provided. Place the adhesive tape (2) across the gap in the telescopic extensions. (fig. 2.15)

• All flue sockets should point towards the terminal.

• Care should be taken not to scratch the white surface of the air duct.

• If the installation requires the use of air/flue duct extensions, additional bends or elbows refer to the section 2.11.

secure using the 30 mm air duct clamp (3) provided (fig. 2.12).

• Pull the air/flue duct back through the wall such that the flue duct fully engages into the flue elbow socket.

• Fit the 48 mm air duct clamp (5) ensuring that it is positioned centrally (fig. 2.12).

• Drill two holes 3 mm Ø through the air duct of both the elbow/flue and elbow/boiler clamps at the most convienient holes on the air duct clamps. (Ensure that the drill does not penetrate the inner flue duct). Screw the clamps to the air ducts of the flue assembly, the elbow and boiler using the screws supplied.

• Slide the internal trim ring back to the wall, securing in position with a small amount of sealant if required.

Caution!

If installed near a light, insects may fly into the opening. Tell the homeowner to clean the opening regularly.

3°

Fig. 2.16 Assembly of the horizontal wall breakthrough

• Push the air/flue duct assembly (1) including the flexi-

• Ensure that the air/flue duct (1) is centred in the hole

and the terminal is correctly positioned with the inlet grille at the bottom (fig. 2.12 and fig. 2.16).

• Slide the internal trim ring (2) over the air duct until it

is flush with the wall (fig. 2.12).

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

• Fit the elbow (4) to the boiler by inserting the spigot of the flue elbow into the flue socket on the boiler and

Flue installation instructions ecoTEC 834449_1316

Standard Concentric Systems Ø 60/100 2

2.6 Installation of the black terminal kit

2.6.1 Contents included with delivery

Fig. 2.17 Black terminal kit, Accy.-No. 303 934

Black terminal kit

(Accy. No. 303 934)

Contents of the accessory:

- Black terminal

- External wall seal

2.6.2 Assembly of the black terminal kit before in-

stalling the flue duct

Fig. 2.20 Unlocking the catch

• Unlock the catch between the terminal and the flue duct by twisting them against each other.

• Pull the terminal off the flue duct.

• Push the new terminal into the flue duct and click to lock.

Fig. 2.18 Releasing the catches

• Use an 8 mm screwdriver to bend the catches inwards.

Fig. 2.19 Pulling out the terminal

• Pull the terminal together with the flue duct out of the air duct.

Fig. 2.21 Flue duct

Caution!

The catch on the top of the terminal must lock firmly into the notch in the flue duct.

Caution!

Make sure the seal fits tightly.

Fig. 2.22 Locking the catch

• Push the flue duct and the terminal back into the air duct and lock the two catches.

Caution!

The seam of the air duct must be at the top.

• Fit the horizontal air/flue duct as described in section

2.4 and 2.5.

17Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

2.6.3 Assembly of the black terminal kit after installing the flue duct

Danger!

Risk to life from escaping flue gas! Before starting work, shut down the appliance and prevent it from being switched on unintentionally.

• Remove the wall seal from the terminal.

• Use an 8 mm screwdriver to bend the catches inwards

(fig. 2.18).

• Pull the terminal together with the flue duct out of the

air duct (fig. 2.19).

Caution!

Do not twist the flue duct, because this might detach the following flue duct behind the terminal from the spacer.

• Unlock the catch between the terminal and the flue

duct by twisting them against each other (fig. 2.20).

• Pull the terminal off the flue duct.

• Push the new terminal into the flue duct and click to

lock.

Caution!

The catch on the top of the terminal must lock firmly into the notch in the flue duct (fig. 2.21).

Caution!

Make sure the seal fits tightly.

2.7 Installation of the variable termination kit (VTK)

Caution!

The flue outlet of the variable termination must face directly upwards.

Flue terminal clearances

Minimum flue terminal clearances are defined in BS5440, and these must apply unless the boiler manufacturer has received approval to quote smaller clearances that are not safety critical. Vaillant have reduced flue terminal clearances approved and these are given in the boiler installation instructions. These are the minimum clearances that must apply to all installations, except when a Variable Termination Kit (VTK) is fitted.

When a VTK is fitted to the horizontal flue, the terminal clearances for the air inlet are reduced. The terminal clearances for the ‘new’ flue outlet at the end of the VTK do not change.

The minimum terminal clearances A, B & C for the air inlet of the VTK are reduced to 150 mm from an opening such as a window. This means that the terminal on the horizontal flue becomes the air inlet when a VTK is fitted, and hence can be located less than 300 mm from an opening window or airbrick.

2.7.1 Contents included with delivery

• Push the flue duct with the terminal back in the air duct. Carefully push the flue duct back into the sleeve of the pipe or bend behind it. Lock the two catches (fig. 2.22).

• Fit the wall seal.

Danger!

Before starting up the appliance, check that the entire flue pipe is firmly seated and sealed.

Fig. 2.23 Variable termination kit

Variable termination kit

Contents of the kit (Accy. No. 303 942, black; 303 946, white):

- Variable terminal

- 2 x 1 m pipe

- 3 x pipe support clips

- 87° bend with bird protection grille

Flue installation instructions ecoTEC 834449_1318

Standard Concentric Systems Ø 60/100 2

2.7.2 Assembly of the variable terminal kit before

installing the flue pipe

Fig. 2.24 Wall clearance

Fig. 2.27 Unlocking the catch

• Unlock the catch between the terminal and the flue duct by twisting them against each other.

• Pull the terminal out off the flue duct.

• Push the variable terminal into the flue duct and click to lock.

Fig. 2.25 Releasing the catches

• Use an 8 mm screwdriver to bend the catches inwards.

Fig. 2.26 Pulling out the terminal

• Pull the terminal with the flue duct out of the air duct.

Fig. 2.28 Flue pipe

Caution!

The catch on the top of the terminal must lock firmly into the notch in the flue duct.

Caution!

Make sure the seal fits tightly.

Fig. 2.29 Locking the catch

• Push the flue duct and the variable terminal back into the air duct and lock the two catches.

Caution!

The seam of the air duct must be at the top.

• Fit the horizontal air/flue duct as described in section

2.4 and 2.5.

Caution!

It cannot be fitted from inside.

19Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

• Fit the rest of the variable termination kit as described in section 2.7.4.

2.7.3 Installing the variable terminal kit after in-

stalling the flue duct

Danger!

Risk to life from escaping flue gas! Before starting work, shut down the appliance and prevent it from being switched on unintentionally.

• Remove the wall seal from the terminal.

• Use an 8 mm screwdriver to bend the catches inwards (fig. 2.25).

• Pull the terminal with the flue duct out of the air duct (fig. 2.26).

Caution!

Do not twist the flue duct, because this might detach the following flue duct behind the terminal from the spacer.

• Unlock the catch between the terminal and the flue duct by twisting them against each other (fig. 2.27).

• Pull the terminal out of the flue duct.

• Push the new variable terminal onto the flue duct.

2.7.4 Installing the pipes

Caution!

The catch on the top of the variable terminal must lock firmly into the notch in the flue duct (fig. 2.28).

Caution!

Make sure the seal fits tightly.

• Push the flue duct with the variable terminal back in the air duct. Carefully push the flue duct back into the sleeve of the duct or bend behind it. Lock the two catches (fig. 2.29).

• Fit the wall seal on the variable terminal.

• Fit the rest of the VTK as described in section 2.7.4.

Fig. 2.30 Installation of basic kit showing position of support

clips

Flue installation instructions ecoTEC 834449_1320

Fig. 2.31 Bird protection grille

Standard Concentric Systems Ø 60/100 2

Fig. 2.32 Installation of basic kit with two additional 87° bends

showing position of support clips

Fig. 2.33 Installation of basic kit with two additional 45° bends

showing position of support clips

• Fit the pipes and bends, working from the variable terminal to the selected location for the flue exit using support clips supplied fig. 2.30, 2.31, 2.32 or 2.33.

Caution!

Pipe extensions must be fixed to the wall using support clips. Use one clamp for each extension directly beside the sleeve. Fit another clamp to the extension after each 87° bend (fig. 2.32).

Caution!

The extension pipe expands when heated. Leave 1 cm expansion space in eachsleeve.

Note

The maximum flue lengths where the variable termination kit is installed are shown in tables

2.3 and 2.4.

Note

The parts are simply pushed together (not bolted).

Caution!

Fasten the 87° bend with bird protection grille using a separate support clip (fig. 2.31).

21Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

Caution!

If installed near a light, insects may fly into the opening. Tell the home owner to clean the opening regularly.

Danger!

Before starting up the appliance, check that the entire flue pipe is firmly seated and sealed.

Caution!

During annual maintenance, check the 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.

2.7.5 Routing around roof eaves

min. 400 mm min. 100 mm

Fig. 2.34 Routing around roof eaves

When routing the variable termination kit around the roof eaves, additional lengths of M8 threaded bar will be required for the support clips. Threaded bar can be purchased from most local merchants.

• Change the bird protection grille from the 87° elbow to the extension installed at the end.

Flue installation instructions ecoTEC 834449_1322

Note

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

• The final pipe extension must be fixed to the wall using two support clips with a minimum distance of 400 mm.

• Additional 45° bends may be required.

Standard Concentric Systems Ø 60/100 2

2.8 Installing the deflector set

2.8.1 Contents included with delivery

Fig. 2.35 Deflector set

Deflector set DN 60 PP-black

(Accessory No.: 00 2006 0584) Contents of the accessory:

- Black terminal

- External wall seal

Deflector set DN 60 PP-white

(Accessory No.: 00 2006 0585) Contents of the accessory:

- White terminal

Fig. 2.37 Pulling out the terminal

• Pull the terminal with the flue duct out of the air duct.

Fig. 2.38 Unlocking the catch

• Unlock the catch between the terminal and the flue duct by twisting them against each other.

• Pull the terminal out of the flue duct.

• Push the variable terminal into the flue duct and click to lock.

2.8.2 Assembly of the deflector set before installing the flue gas pipe

Fig. 2.36 Releasing the catches

• Use an 8 mm screwdriver to bend the catches in-

wards.

Fig. 2.39 Flue duct

Caution!

The catch on the top of the terminal must lock firmly into the notch in the flue duct.

Caution!

Make sure the seal fits tightly.

23Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

Fig. 2.40 Locking the catch

• Push the flue gas pipe and the deflector back into the

air pipe and lock the two catches.

Fig. 2.41 Releasing the catches

Caution!

The seam of the air duct must be at the top.

• Fit the horizontal air/flue duct as described in section

2.4 and 2.5.

2.8.3 Installation of the deflector set after installing the flue gas pipe

Caution!

The deflector flue terminal must point directly upwards in the centre position.

Flue terminal clearances

The minimum flue terminal clearances are defined in BS 5440, and these must be adhered to unless the boiler manufacturer has received approval to use smaller clearances that are not considered to be safety critical. Vaillant have reduced the flue terminal clearances and these are given in the boiler installation instructions. These are the minimum clearances to be used on all installations. The minimum terminal clearances A, B and C for the deflector are reduced to 150 mm from an opening such as a window. This means that the terminal on the horizontal flue gas pipe becomes the air inlet when a deflector is connected, and hence can be situated less than 300 mm from an opening window or airbrick.

• Use an 8 mm screwdriver to bend the catches inwards.

Fig. 2.42 Pulling out the terminal

• Pull the terminal with the flue duct out of the air duct.

Caution!

Do not twist the flue gas pipe when doing this. Turning can cause the following flue gas pipe to come away from the spacer.

2.8.4 Installing the variable terminal set after installing the flue gas pipe

Danger!

Risk to life from escaping flue gas! Before starting work, shut down the boiler and prevent it from being switched on unintentionally.

• Remove the wall seal from the terminal.

Fig. 2.43 Unlocking the catch

• Unlock the catch between the terminal and the flue duct by twisting them against each other.

• Pull the terminal out of the flue gas pipe.

• Fit the deflector to the flue gas pipe.

Flue installation instructions ecoTEC 834449_1324

Fig. 2.44 Flue pipe

Standard Concentric Systems Ø 60/100 2

Setting the deflector in the centre position will direct the stream of flue gases upwards at an angle of approx. 45°.

45° 45°

Caution!

The catch on the top of the terminal must lock firmly into the notch in the flue duct.

Caution! Make sure the seal fits tightly.

Fig. 2.45 Locking the catch

• Push the flue gas pipe with the terminal back into the air duct.

• Carefully push the flue gas pipe back into the sleeve of the pipe or bend behind it.

• Lock the two catches (fig. 2.45).

Caution!

The seam of the flue gas pipe must be at the top.

Fig. 2.47 Lateral setting options

The terminal of the deflector can be turned to the left or the right by 45°, if required. These settings permit additional optimisation of the flue gas guiding.

Caution!

Turn the deflector until it latches palpably in one of the three positions shown in Fig. 2.47. The latching ensures that the deflector cannot twist of its own accord.

• Fit the wall seal to the deflector.

Fig. 2.46 Angle of flue gas stream in centre position

45°

25Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

2.9 Installation of the vertical air/flue duct

Note

Observe the maximum flue lengths as detailed in sections 2.2.3 and 2.2.4.

2.9.1 Contents included with delivery

542

1456

8 4

901

Fig. 2.48 Vertical roof duct

Vertical air/flue duct

Accy. No.: 0020060570 (black) Accy. No.: 0020060571 (red) Accy. No.: 0020065937 (black)

2.9.2 Preparation

• Determine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions.

• Determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof.

Note

The vertical air/flue duct and terminal accessory (Accy. No. 0020060570, 0020060571,

0020065937) may be shortened. The outer ‘white’ duct should be shortened first, then the inner flue duct cut so that it protrudes 13 mm out of the air duct. In case of installation directly to the boiler without elbows or bends, it is essential that the roof tile/collar is vertically aligned with the air/flue duct of the boiler.

Note

If a 87° elbow is connected directly to the boiler, use the the vertical air flue duct at this position.

48 mm air duct clamp supplied with

Contents of the accessory:

• Vertical air/flue duct and terminal assembly

• 48 mm air duct clamp

• Fixing bracket

Note

See section 2.2 for details of air/flue duct elements.

The air/flue duct assembly may be connected directly to the flue outlet on top of the boiler. In addition to the vertical air/flue duct and terminal accessory, air/flue duct extensions can be added to increase the length of the flue.

Flue installation instructions ecoTEC 834449_1326

Standard Concentric Systems Ø 60/100 2

2.9.3 Pitched roof installation

542

20 - 50

0-5

Fig. 2.49 Fitting the appliance and the vertical roof duct to a

building with a pitched roof

Ø 100

100-110

901

Key * = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937 ** = 750 mm ecoTEC exclusive combination ** = 530 mm ecoTEC plus open vent (top holes of

bracket) ** = 622 mm ecoTEC plus system & combination ** = 622 mm ecoTEC plus 937

Note

See section 2.11 for further details on the installation of extensions and elbows.

• Push the sliding sleeve (4) firmly into place on the ex-

tension.

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

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

Note

Using the sliding sleeve allows the appliance to be easily removed and replaced without dismantling the flue.

• Drill two holes 3 mm Ø through the air duct of the flue/boiler clamp at the most convienient holes on the air duct clamp. (Ensure that the drill does not penetrate the inner flue duct). Screw the clamp to the air ducts of the flue assembly and the boiler using the screws supplied.

• Ensure that any air duct clamps used are positioned centrally and fixed to the air duct using the self tapping screws supplied.

Note

The air/duct clamp must not be screwed to the bottom of the vertical air/flue duct and terminal accessory to allow for any slight movement in the roof structure.

• Ensure that at least one pipe clamp supports the air/ flue duct at each extension fitted.

• Determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof.

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

• Working from above, insert the vertical roof duct (5) through the roof tile and push it firmly into place.

• Vertically align the roof duct and attach it to the roof structure with the fixing bracket (6) supplied.

• Fit the boiler hanging bracket (2).

• Install the appliance (3) with reference to the installation and servicing instructions supplied with the boiler.

27Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

2.9.4 Flat-roof installation

542

901

Ø 100

Fig. 2.50 Fitting the appliance and vertical flue duct to a build-

ing with a flat roof

120

100 - 110

• Join the sliding sleeve (4) to the appliance’s connec-

tion piece. This permits easy separation between the air/flue duct and the appliance.

• Ensure that any air duct clamps used are positioned centrally and fixed to the air duct using the self tapping screws supplied.

Note

The air/duct clamp must not be screwed to the bottom of the vertical air/flue duct and terminal accessory to allow for any slight movement in the roof structure.

• Ensure that at least one pipe clamp supports the air/ flue duct at each extension fitted.

Key

A cold roof B warm roof

* = 750 mm ecoTEC exclusive combination * = 530 mm ecoTEC plus open vent (top holes of bracket) * = 622 mm ecoTEC plus system & combination * = 622 mm ecoTEC plus 937

• Determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof.

• Fit the flat roof penetration collar (1).

• Stick the flat roof penetration collar firmly into place with adhesive in accordance with the codes of practice for flat roofs (CP 144) to ensure a watertight seal.

• Working from above, insert the vertical roof duct (5) through the flat roof collar and push it firmly into place.

• Vertically align the roof duct and attach it to the roof structure with the fixing bracket (6) supplied.

• Fit the boiler hanging bracket (2).

• Install the appliance (2) with reference to the installation and servicing instructions supplied with the boiler.

Note

See section 2.11 for further details on the installation of extensions and elbows.

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

• Join the vertical roof duct (5) to the extension (3).

Flue installation instructions ecoTEC 834449_1328

Standard Concentric Systems Ø 60/100 2

2.10 Installing the ridge tile terminal

Note

Observe the maximum flue gas pipe lengths as detailed in sections 2.2.3 and 2.2.4.

2.10.1 Contents included with delivery

760

Fig. 2.51 Ridge tile terminal

Ridge tile terminal

Accessory No.: 303 982 (black)

Contents of the accessory:

- Ridge tile terminal

- 40 mm air duct clamp

2.10.3 Installing the ridge tile

130 130

min.25

133

Fig. 2.52 Ridge tile dimensions

The ridge tile must be purchased from a roof tile manufacturer: Recommended manufacturer: Aspect East Anglia Limited The Old Mill, East Harling NORWICH, Norfolk NR16 2QW Website: www.aspectroofing.co.uk Contact: Chris Haythorpe General Manager - Tile Division Tel: 01953 717777 Fax: 01953 717164

130 130

min.20

max.125°

Note

See section 2.2 for details of air/flue gas pipe elements.

When connecting the ridge tile terminal to the boiler, elbows and extensions can be added to the air/flue gas pipe to produce longer flue gas pipes.

2.10.2 Preparation

Determine the installation site for the boiler with reference to the installation and maintenance instructions supplied with the boiler.

• Ensure that all the clearances required for installation and maintenance are available and that the boiler flue gas pipe can be installed as detailed in these instructions.

• Determine the point where the ridge tile terminal is to pass through the ridge.

Note

If an 87° elbow is connected directly to the boiler, use the 40 mm air duct clamp supplied with the vertical air flue duct at this position.

Fig. 2.53 Assembly of the ridge tile

• Fit the ridge tile (1) in accordance with the tile manufacturer's guidelines.

29Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

2.10.4 Installing the ridge tile terminal

Fig. 2.54 Installing the ridge tile terminal

• Insert the ridge tile terminal into the ridge tile.

• Align the ridge tile terminal in such a way that the two fixing straps (1) are sitting across the run of the ridge tile. This ensures that the combustion air can be drawn in between the ridge tile and the cowling above it.

Note

See section 2.11 for further details on the installation of extensions and elbows.

• Connect the ridge tile terminal and the boiler using extensions and elbows.

• Drill two holes (3 mm Ø) in the air duct of the flue gas/boiler clamp through the most convenient holes on the air duct clamp. (Ensure that the drill does not penetrate the inner flue gas pipe).

• Screw the clamp to the air ducts of the flue assembly, the elbow and the boiler using the bolts supplied.

• Ensure that any air duct clamps used are positioned centrally and fixed to the air duct using the self tapping screws supplied.

• Ensure that at least one pipe clamp supports the air/ flue gas pipe at each extension fitted.

2.11 Fitting air/flue duct extensions

2.11.1 How to add extensions

Fig. 2.55 Fastening the ridge tile terminal

• Bend the two fixing straps (1) over a beam (2) and se-

cure with nails or bolts.

• Install the boiler with reference to the installation and maintenance instructions supplied with the boiler.

Fig. 2.56 Loosening the flue conduit

Note

No tools are required when separating extensions for cutting to size air and flue tubes separately. When doing so, the flue conduit should be twisted into a position where the shoulders on the plastic tube can be pushed through the spacer-piece. After cutting to size, refit the flue conduit and secure it to the air conduit.

Flue installation instructions ecoTEC 834449_1330

Standard Concentric Systems Ø 60/100 2

+ 40 mm

Fig. 2.57 Cutting tubes to size

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

• Start by measuring the required length of air conduit*

), and then calculate the corresponding length of

air

flue conduit (L

= L

exhaust

= length of air conduit (A)

air

* Minimum length of air-conduit extension: 80 mm.

+ 40 mm

air

= length of flue conduit (B)

) as follows:

exhaust

Caution!

You must fasten extensions to the ceiling or wall using pipe clamps. Use one clamp for each extension.

Caution!

Where extensions are used, these must be installed with a slope of 3° ± 1° to ensure that condensate does not remain in the sleeve (equivalent to 50 mm ± 20 mm rise per metre length).

2.11.2 How to install 2x 87° elbows

Fig. 2.58 Arrangement of 2 x 87° elbows – View from above

* = 3°

Fig. 2.59 Arrangement of 2 x 87° elbows – View from front

Caution!

The seals are sensitive to mineral oil-based grease products. For this reason, the seals must not be greased. If the seals need wetting to aid in installation, use water only.

Caution!

De-burr and file down any rough edges on the tubes before fitting in order to prevent damage to the seals. Remove all metal filings and other debris.

Caution!

Do not use damaged or dented tubes, as they will not form an adequate seal.

Caution!

Ensure that the seals remain correctly aligned when installing the tubes. Do not fit damaged seals.

Caution!

Secure the exhaust conduit with the fixing device in order to ensure that it is correctly centred relative to the air conduit.

Fig. 2.60 Arrangement of 2 x 87° elbows – View from side

* = 3°

When using 2 x 87° elbows follow fig. 2.58 to fig. 2.60 to avoid obstructions on outer wall.

Caution!

The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage.

• The elbow fitted to the top of the boiler (1) should be twisted by 3° to ensure that the second 87° elbow (2) exits the wall perpendicular.

31Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

90°

max. 5 m

Fig. 2.61 Connecting extensions with 87° elbows

max. 5 m

* = 3°

90°

Fig. 2.62 Connecting extensions with 45° elbows

When using elbows for long flue runs in a corner follow fig. 2.61 and fig. 2.62 to avoid obstructions.

Caution!

The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage.

Note

The elbow fitted to the top of the boiler (1) should be twisted by 3° to ensure that the second 87° elbow (2) exits the wall perpendicular.

Note

When using 87° elbow install with a slope of 3° between wall and air-flue pipe (fig. 2.61) or use 2 x 45° elbows (fig. 2.62).

max. 5 m

Flue installation instructions ecoTEC 834449_1332

2.11.3 How to install 87° elbows

Standard Concentric Systems Ø 60/100 2

Key

A = Offset B = Length of air conduit

Note

190

The elbow delilvered with the flue kits 303 933 and 303 936 is not the same dimension as shown here.

Caution!

Fig. 2.63 Installation of 87° elbows, Accy. No.: 303 910

This gives a corresponding exhaust-conduit length of 190 + 40 = 230 mm.

Example: An offset of 400 mm is measured. This value is then used, along with the table below, to determine the length of the air conduit ( = 190 mm in this case).

Offset [in mm]

> 190 to < 210 mm

> 215 to < 265 mm

> 270 to < 290 mm

295 85 485 275 675 465 300 90 490 280 680 470 305 95 495 285 685 475 310 100 500 290 690 480 315 105 505 295 695 485 320 110 510 300 700 490 325 115 515 305 705 495 330 120 520 310 710 500 335 125 525 315 715 505 340 130 530 320 720 510 345 135 535 325 725 515 350 140 540 330 730 520 355 145 545 335 735 525 360 150 550 340 740 530 365 155 555 345 745 535 370 160 560 350 750 540 375 165 565 355 755 545 380 170 570 360 760 550 385 175 575 365 765 555 390 180 580 370 770 560 395 185 585 375 775 565 400 190 590 380 780 570 405 195 595 385 785 575 410 200 600 390 790 580 415 205 605 395 795 585 420 210 610 400 800 590 425 215 615 405 430 220 620 410 435 225 625 415

Table 2.5 Length of surplus with 87° elbows

Length of air conduit [in mm]

0 440 230 630 420

not possible 455 245 645 435

80 470 260 660 450

Offset [in mm]

445 235 635 425 450 240 640 430

460 250 650 440 465 255 655 445

475 265 665 455 480 270 670 460

Length of air conduit [in mm]

Offset [in mm]

Length of air conduit [in mm]

33Flue installation instructions ecoTEC 834449_13

2 Standard Concentric Systems Ø 60/100

2.11.4 How to install 45° elbows

Key

A = Offset B = Length of air conduit C = Height

Caution!

This gives a corresponding exhaust-conduit length of 284 + 40 = 324 mm.

Example: An offset of 400 mm is measured. This value is then used, along with the table below, to determine the length of the air conduit (= 284 mm) and the height

Fig. 2.64 Installation of 45° bends, Accy. No.: 303 911

Offset [in mm]

90 0 210 325 320 445 525 602 645 95 0 215 330 327 450 530 610 650 100 0 220 335 334 455 535 617 655 > 105 to < 155 mm

160 86 280 360 369 480 560 652 680 165 93 285 365 376 485 565 659 685 170 100 290 370 383 490 570 666 690 175 107 295 375 390 495 575 673 695 180 115 300 380 397 500 580 680 700 185 122 305 385 404 505 585 687 705 190 129 310 390 412 510 590 694 710 195 136 315 395 419 515 595 701 715 200 143 320 400 426 520 600 709 720 205 150 325 405 433 525 605 716 725 210 157 330 410 440 530 610 723 730 215 164 335 415 447 535 615 730 735 220 171 340 420 454 540 620 737 740 225 178 345 425 461 545 625 744 745 230 185 350 430 468 550 630 751 750 235 192 355 435 475 555 635 758 755 240 199 360 440 482 560 640 765 760 245 206 365 445 489 565 645 772 765 250 214 370 450 496 570 650 779 770 255 221 375 455 503 575 655 786 775 260 228 380 460 511 580 660 793 780 265 235 385 465 519 585 665 800 785 270 242 390 470 525 590 670 808 790 275 249 395 475 532 595 675 815 795 280 256 400 480 539 600 680 822 800 285 263 405 485 546 605 290 270 410 490 553 610 295 277 415 495 560 615 300 284 420 500 567 620 305 291 425 505 574 625 310 298 430 510 581 630 315 306 435 515 588 635 320 313 440 520 595 640

Table 2.6 Length of surplus with 45° bends

Length of air conduit [in mm]

not possible 340 341 460 540 624 660

Height [in mm] Offset

[in mm]

345 348 465 545 631 665 350 355 470 550 638 670 355 362 475 555 645 675

Length of air conduit [in mm]

(= 420 mm).

Height [in mm] Offset

[in mm]

Length of air conduit [in mm]

Height [in mm]

Flue installation instructions ecoTEC 834449_1334

Optional Concentric System Ø 80/125 3

3 Optional Concentric System

Ø 80/125

Galvanized steel air duct/plastic flue duct.

3.1 Requirements

Regulations and standards to be observed

Caution!

The air/flue duct must be installed by a suitably qualified service provider, which is responsible for observing the relevant specifications, regulations and standards.

Note

These instructions should be read in conjunction with the instructions for installation and servicing supplied with the boiler.

Note

Two types of flue gas installation are available for ecoTEC boilers:

- standard concentric flue gas installations (outer diameter 100 mm)

- a concentric system with a larger diameter (outer diameter 125mm) which can be used to achieve longer air/flue gas pipes.

Note

The air/flue duct operates at very low temperatures therefore no clearance is necessary between the air duct and adjacent services.

Note

Ensure while installation work is being carried out that no debris such as swarf, filings or fragments of mortar are allowed to remain in the air/flue duct.

Note

Ensure also that all legislation, rules, regulations and directives mentioned in the installation instructions are observed.

Note

The installation of the boiler and its flue must be carried out by a competent person who is registered with CORGI (The Council for Registered Gas Installers).

Note

The installation of the boiler and flue must be in accordance with the Gas Safety (Installation and Use) Regulations 1998 and the Building Regulations and BS 5440 Part 1.

Note

The requirements for flue termination detailed in the boiler installation instructions must be observed.

35Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

3.2 Planning the air/flue duct layout

3.2.1 Alternative termination accessories available

303 200 = Vertical air/flue duct (black)

303 209 = Horizontal air/flue duct

Optional connection accessories Accy. No.

Appliance connection piece

Air/flue duct extensions, concentric 470 mm - Ø 80/125

Air/flue duct extensions, concentric 970 mm - Ø 80/125

Air/flue duct extensions, concentric 1970 mm - Ø 80/125

Bends (PP), concentric (pack of 2) 45° - Ø 80/125

303 926 =Appliance connection piece

303 926 X X

303 202 X X

303 203 X X

303 205 X X

303 211 X X

303 200 303 209

Elbow (PPs), concentric 87° - Ø 80/125

Flue support clips (pack of 5), Ø 125

Sliding sleeve (PPs) Ø 80/125

Adjustable roof tiles for pitched roof

Flat roof penetration collar

Flexible pitched roof seal

Table 3.1 Product program

303 210 X X

303 616 X X

303 215 X X

009 076 (black) X

009 056 X

303 980 X

Flue installation instructions ecoTEC 834449_1336

3.2.2 Element descriptions

Optional Concentric System Ø 80/125 3

Element Description

Appliance connection piece Ø 80/125

Accy. No.: 303 926 (with 2 measuring apertures)

Air/flue duct extension (PPs) Ø 80/125

470 mm: Accy. No.: 303 202 970 mm: Accy. No.: 303 203 1970 mm: Accy. No.: 303 205

Elbow (PPs), 87°, Ø 80/125

Accy. No.: 303 210

Bends (PPs), 45° , Ø 80/125

(pack of 2) Accy. No.: 303 211

Element Description

Adjustable roof tiles for pitched roof

Accy. No.: 009 076 (black)

Flat roof penetration collar

Accy. No.: 009 056

Flexible pitched roof seal

132

(black)

Accy. No.: 303 980

495

125

140

Table 3.2 Elements 80/125

Flue support clips, Ø 125

(pack of 5) Accy. No.: 303 616

Sliding sleeve (PPs), Ø 80/125

Accy. No.: 303 215

164

120

495

Table 3.2 Elements 80/125 (continued)

37Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

3.2.3 Maximum flue lengths for use with ecoTEC exclusive

Accessories Accy.-Nr.

Horizontal flue systems

Vertical flue systems 303 200 Max. permitted

Table 3.3 Maximum flue lengths for use with ecoTEC exclusive

303 209 Max. permitted

concentric flue length

Maximum length of flue is reduced by 2.5 m for each additional 87° elbow

Maximum length of flue is reduced by 1.0 m for each additional 45° elbow

Maximum length of flue is reduced by 2.5 m for each additional 87° elbow

Maximum length of flue is reduced by 1.0 m for each additional 45° elbow

3.2.4 Maximum flue lengths for use with ecoTEC

Accessories Accy.-Nr.

Horizontal flue systems

Vertical flue systems

303 209 Max. permitted

303 200 Max. permitted

concentric flue length

plus 612 plus 615

13.0 m

1 elbow 87°

Maximum length of flue is reduced by 2.5 m for each additional 87° elbow

Maximum length of flue is reduced by 1.0 m for each additional 45° elbow

14.0 m 27.0 m 23.0 m 27.0 m 20.0 m

Maximum length of flue is reduced by 2.5 m for each additional 87° elbow

Maximum length of flue is reduced by 1.0 m for each additional 45° elbow

incl.

plus 618 plus 624 plus 630 plus 824

plus 831

25.0 m incl.

1 elbow 87°

ecoTEC exclusive

832 838

21.0 m incl.

1 elbow 87°

22.0 m

ecoTEC

plus 637 plus 837 plus 937

21.0 m incl.

1 elbow 87°

pro 24 pro 28

25.0 m incl.

1 elbow 87°

plus 415 plus 418 plus 428 plus 438

20.0 m incl.

1 elbow 87°

Table 3.4 Maximum flue lengths for use with ecoTEC

Flue installation instructions ecoTEC 834449_1338

Fig. 3.1 Horizontal flue systems

Key

A Maximum flue length

Optional Concentric System Ø 80/125 3

3.3 Changing the appliance connection piece

Installation

Accy No.: 303 926

Fig. 3.2 Vertical flue systems

Key

A Maximum flue length

Fig. 3.3 Fitting the appliance connection piece

The appliance is supplied ready-fitted with the connection piece for the 60/100 air/flue duct system.

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

• Push the appliance connection piece with the selected connection diameter down from above, inserting the push-in end onto the sleeve of the flue collecting chamber. Now push the appliance connection piece downwards until the flange comes into contact with the low-pressure chamber.

• Refit the fixing screws (2).

Caution!

The seals are sensitive to mineral oil-based grease products. For this reason, the seals must not be greased. If the seals need wetting to aid in installation, use water only.

39Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

3.4 Installation of the sliding sleeve

Installing the air/flue duct sliding sleeve

Note

For installations where there is insufficient movement to allow fitting of the flue into flue outlet, a sliding sleeve (Accy. No. 303 215) is available. When using the sliding sleeve both the air and flue ducts of the last extension must be shortened by a further 85 mm.

3.5 Installation of the horizontal air/flue duct

Caution!

The air/flue duct is not concentric and the air duct has a slope of 1.5° (if the air flue duct is not cut). The hole through the wall can therefore be drilled horizontally with no slope.

Where extensions are used, these must be in-

stalled with a slope at 3° ± 1° (equivalent to 50 mm ± 20 mm rise per metre length) to ensure that condensate does not remain in the sleeve.

Note

Observe the maximum flue lengths as detailed in sections 3.2.3 and 3.2.4.

Note

See section 3.2 for details of air/flue duct elements.

3.5.1 Contents included with delivery

1103

Fig. 3.4 Installing the sliding sleeve

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

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

• Fit the air duct clamp over the air ducts (5 and 6) of the extension/terminal and boiler outlet. Close the snap clamp.

• Complete the installation of the flue as detailed in these instructions.

Fig. 3.5 Horizontal air/flue conduit

Horizontal air/flue duct

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

Flue installation instructions ecoTEC 834449_1340

Optional Concentric System Ø 80/125 3

Fig. 3.6 Example of installation with horizontal air/flue duct

3.5.2 Preparation

• Determine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions.

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

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937

• Identify the correct measurement as shown in fig. 3.7, carefully measure the distance from the bottom centre of the boiler hanging bracket (centreline of the two lower hanging bracket fixing holes). This gives the position of the centreline of the 127 mm flue elbow and adaptor when installed.

• The position of the flue exit hole can be determined by carefully levelling across the wall from this mark.

3.5.3 Side flue installations

• For installations where the air/flue duct is to be installed to the side, the position of the flue exit hole can be determined as follows:

Fig. 3.8 Distance between hanging bracket and wall break-

through

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937

• The position of the flue exit hole should allow the flue to be installed with an upwards slope towards the terminal of approximately 3° ± 1°, equivalent to 50 mm ± 20 mm rise per metre of flue length. Calculate the required rise according to the flue length and mark the position of the flue exithole (fig 3.8).

Fig. 3.7 Installation template

41Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

Note

Due to the long lengths of flue possible and the slope required, it may be necessary to adjust the location of the boiler installation template. Please check that both the boiler installation site and flue termination are in accordance with these instructions prior to drilling any holes for the boiler hanging bracket.

• Once the position of the flue exit hole has been determined, the hole should be cut through the wall using a core drill of 127 mm diameter. The flue exit hole should be cut with a rise towards outside of 3°.

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 3.9). This is dimension A.

Fig. 3.9 Distance to external wall

• For installations where the measured distance dimension A (fig. 3.9) is greater than 960 mm, an air/flue extension accessory will be required. The number of air/flue duct extensions which can be used depends on the boiler.

• Taking each extension to be used, fit the flue duct into the air duct and secure using the 3 screws provided.

Note

The joints between the flue duct sections are of a push-fit type, with the flue duct spigot inserted into a socket containing a sealing ring. For ease of installation lubricate the seal using soap solution prior to assembling.

• Assemble the flue such that there is a gap of about 5 mm between each air duct, which will ensure the correct flue duct penetration into the flue sockets of 30 mm. All flue sockets should point towards the flue terminal.

• Measure from the flue terminal and mark the air duct to a length of: Dimension A + 60 mm.

• Take the extension(s) to be shortened and remove the 3 screws. Separate the ducts.

Note

For assembly reasons do not shorten any air duct to a length of less than 100 mm. If necessary shorten two adjacent extensions to achieve 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.

15 mm

25 mm

5 mm

Fig. 3.10 Air duct

Key

A = Mark air duct here B = Dimension A + 10 mm

• For ease of measuring and marking the air/flue duct extensions, assemble them loosely together with the air/flue duct and terminal assembly as shown (fig.

3.10).

Fig. 3.11 Flue duct

Key

A = Mark flue duct here

• Cut the flue duct as detailed in fig. 3.11.

• When cutting the air and flue ducts it is important to remove any burrs with a file, this ensures easy fitting of the ducts and prevents any rough edges from damaging the flue seals.

• Care should be taken not to scratch the white surface of the air duct.

• If the installation requires the use of air/flue duct extensions, additional bends or elbows refer to the section 3.7.

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

• Fit the appliance flue outlet adaptor to the boiler.

Flue installation instructions ecoTEC 834449_1342

220

82 - 90

Optional Concentric System Ø 80/125 3

• Change the appliance connection piece (3) as described in section 3.3.

• Join the 87° elbow to the appliance connection piece.

• Push the sliding sleeve (7) firmly into place on the ap-

3°

propriate extensions (6).

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

Fig. 3.12 Installing the horizontal wall duct

• Push the assembled air/flue duct and terminal assembly through the flue exit hole until it protrudes 220 mm out from the outside wall.

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

• Slide one of the two trim rings over the air duct until it is flush with the internal wall face.

3.5.4 Indirect installation

This section functions subsequently as a sepa-

ration point.

• Join all separation points with the air-conduit fixing

collars (1).

See section 3.7 for further details on the in-

stallation of extensions and elbows.

For horizontal flue installations through sloping

roofs, please order the Horizontal Flue Flashing from Ubbink (Nothants, Tel: 01280 700211)

Fig. 3.13 Distance to external wall

Key

* = 750 mm ecoTEC exclusive combination * = 530 mm ecoTEC plus open vent (from top holes on bracket) * = 622 mm ecoTEC plus system & combination * = 622 mm ecoTEC plus 937 ** = 253 mm ecoTEC exclusive combination ** = 210 mm ecoTEC plus open vent (from top holes on bracket) ** = 238 mm ecoTEC plus system & combination ** = 238 mm ecoTEC plus 937

• Fit the wall mounting (4).

• Install the appliance (5) with reference to the installation and servicing instructions supplied with the boiler.

43Flue installation instructions ecoTEC 834449_13

0-5

82 - 90

3 Optional Concentric System Ø 80/125

3.6 Installation of the vertical air/flue duct

Note

Observe the maximum flue lengths as detailed in sections 3.2.3 and 3.2.4.

3.6.1 Contents included with delivery

1430

Fig. 3.14 Vertical roof duct

Vertical air/flue duct

Accy. No.: 303 200 (black)

Contents of the accessory:

• Vertical roof duct

• Adapter (air) for Ø 110/125

• 70 mm air duct clamp

• Fixing bracket

Please note: The vertical air/flue duct and ter-

minal accessory (Accy. No. 303 200) may be shortened. The outer ‘white’ duct should be shortened first, then the inner flue duct cut so that it protrudes 15 mm out of the air duct. In case of installation directly to the boiler without elbows or bends, it is essential that the roof tile/collar is vertically aligned with the air/ flue duct of the boiler.

3.6.3 Pitched roof installation

20 - 50°

Ø 125

545885

5 6

Note

See section 3.2 for details of air/flue duct elements.

3.6.2 Preparation

• Determine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions.

• Determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof.

Fig. 3.15 Fitting the appliance and the vertical roof duct to a

building with a pitched roof

Key

* = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC plus open vent * = 125 mm ecoTEC plus system & combination * = 323 mm ecoTEC plus 937 ** = 750 mm ecoTEC exclusive combination ** = 530 mm ecoTEC plus open vent (top holes of bracket) ** = 622 mm ecoTEC plus system & combination ** = 622 mm ecoTEC plus 937

• Determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof.

• Fit the flexible pitched roof seal (2).

• Working from above, insert the vertical roof duct (1) through the roof tile and push it firmly into place.

• Vertically align the roof duct and attach it to the roof structure with the fixing bracket (3) supplied.

• Fit the boiler hanging bracket (6).

Flue installation instructions ecoTEC 834449_1344

82 - 90

Optional Concentric System Ø 80/125 3

• Install the appliance (7) with reference to the installa-

tion and servicing instructions supplied with the boiler.

Note

See section 3.7 for further details on the installation of extensions and elbows.

• Push the sliding sleeve (8) firmly into place on the ex-

tension.

• Join the vertical roof duct (1) to the extension (4).

• Join the sliding sleeve (8) to the appliance’s connection piece (5).

Note

Using the sliding sleeve allows the appliance to be easily removed and replaced without dismantling the flue.

• Ensure that any air duct clamps used are positioned centrally and fixed to the air duct using the self tapping screws supplied.

Note

The air/duct clamp must not be screwed to the bottom of the vertical air/flue duct and terminal accessory to allow for any slight movement in the roof structure.

• Ensure that at least one pipe clamp supports the air/ flue duct at each extension fitted.

3.6.4 Flat-roof installation

545

885

4 5

Fig. 3.16 Fitting the appliance and vertical flue duct to a build-

ing with a flat roof

Key

A cold roof B warm roof * = 750 mm ecoTEC exclusive combination * = 530 mm ecoTEC plus open vent (top holes of bracket) * = 622 mm ecoTEC plus system & combination * = 622 mm ecoTEC plus 937

• Determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof.

• Fit the flat roof penetration collar (2).

• Stick the flat roof penetration collar firmly into place with adhesive in accordance with the codes of practice for flat roofs (CP 144) to ensure a watertight seal.

• Working from above, insert the vertical roof duct (1) through the flat roof collar and push it firmly into place.

• Vertically align the roof duct and attach it to the roof structure with the fixing bracket (3) supplied.

• Fit the boiler hanging bracket (5).

• Install the appliance (6) with reference to the installation and servicing instructions supplied with the boiler.

Ø 125

Ø 120

Note

See section 3.7 for further details on the installation of extensions and elbows.

45Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

• Push the sliding sleeve (7) firmly on to the vertical roof duct (1) or, where appropriate, on to an extension.

• Where appropriate, join the vertical roof duct (1) to an extension.

• Join the sliding sleeve (7) to the appliance’s connection piece. This permits easy separation between the air/flue duct and the appliance.

• Ensure that any air duct clamps used are positioned centrally and fixed to the air duct using the self tapping screws supplied.

Note

The air/duct clamp must not be screwed to the bottom of the vertical air/flue duct and terminal accessory to allow for any slight movement in the roof structure.

• Ensure that at least one pipe clamp supports the air/ flue duct at each extension fitted.

3.7 Fitting air/flue duct extensions

3.7.1 How to add extensions

Fig. 3.17 Loosening the flue conduit

Note

+ 40 mm

Fig. 3.18 Cutting tubes to size

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

• Start by measuring the required length of air conduit* ), and then calculate the corresponding length of

air

flue conduit (L

= L

exhaust

= length of air conduit (A)

air

* Minimum length of air-conduit extension: 80 mm.

+ 40 mm

air

= length of flue conduit (B)

) as follows:

exhaust

Flue installation instructions ecoTEC 834449_1346

Optional Concentric System Ø 80/125 3

Caution!

You must fasten extensions to the ceiling or wall using pipe clamps. Use one clamp for each extension.

Caution!

Where extensions are used, these must be installed with a slope of 3° ± 1° to ensure that condensate does not remain in the sleeve (equivalent to 50 mm ± 20 mm rise per metre length).

Caution!

The seals are sensitive to mineral oil-based grease products. For this reason, the seals must not be greased. If the seals need wetting to aid in installation, use water only.

Caution!

De-burr and file down any rough edges on the tubes before fitting in order to prevent damage to the seals. Remove all metal filings and other debris.

Caution!

Do not use damaged or dented tubes, as they will not form an adequate seal.

* = 3°

Fig. 3.20 Arrangement of 2 x 87° elbows – View from front

* = 3°

Caution!

Ensure that the seals remain correctly aligned when installing the tubes. Do not fit damaged seals.

Caution!

Secure the exhaust conduit with the fixing device in order to ensure that it is correctly centred relative to the air conduit.

3.7.2 How to install 2 x 87° elbows

Fig. 3.19 Arrangement of 2 x 87° elbows – View from above

Fig. 3.21 Arrangement of 2 x 87° elbows – View from side

When using 2 x 87° elbows follow fig. 3.19 to fig. 3.21 to avoid obstructions on outer wall.

Caution!

The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage.

• The elbow fitted to the top of the boiler (1) should be

twisted by 3° to ensure that the second 87° elbow (2) exits the wall perpendicular.

47Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

90°

max. 5 m

Fig. 3.22 Connecting extensions with 87° elbows

max. 5 m

* = 3°

Note

When using 87° elbow install with a slope of 3° between wall and air-flue pipe (fig. 3.22) or use 2 x 45° elbows (fig. 3.23).

90°

Fig. 3.23 Connecting extensions with 45° elbows

When using elbows for long flue runs in a corner follow fig. 3.22 and fig. 3.23 to avoid obstructions.

Caution!

The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage.

Note

The elbow fitted to the top of the boiler (1) should be twisted by 3° to ensure that the second 87° elbow (2) exits the wall perpendicular.

max. 5 m

Flue installation instructions ecoTEC 834449_1348

3.7.3 How to install 87° elbows

Optional Concentric System Ø 80/125 3

Key

A = Offset B = Length of air conduit

Caution!

190

This gives a corresponding exhaust-conduit length of 190 + 40 = 230 mm.

Example: An offset of 400 mm is measured. This value is then

Fig. 3.24 Installation of 87° elbows, Accy. No.: 303 210

Offset [in mm] Length of air

200, 205, 210 0 505 295 730 520

> 210 to < 310

310 100 535 325 760 550 315 105 540 330 765 555 320 110 545 335 770 560 325 115 550 340 775 565 330 120 555 345 780 570 335 125 560 350 785 575 340 130 565 355 790 580 345 135 570 360 795 585 350 140 575 365 800 590 355 145 580 370 805 595 360 150 585 375 810 600 365 155 590 380 815 605 370 160 595 385 820 610 375 165 600 390 825 615 380 170 605 395 830 620 385 175 610 400 835 625 390 180 615 405 840 630 395 185 620 410 845 635 400 190 625 415 850 640 405 195 630 420 855 645 410 200 635 425 860 650 415 205 640 430 865 655 420 210 645 435 870 660 425 215 650 440 875 665 440 220 655 445 880 670 445 225 660 450 885 675 440 230 665 455 890 680 445 235 670 460 895 685 450 240 675 465 900 690 455 245 680 470 905 695 460 250 685 475 910 700 465 255 690 480 915 705 470 260 695 485 920 710 475 265 700 490 925 715 480 270 705 495 930 720 485 275 710 500 935 725 490 280 715 505 940 730 495 285 720 510 500 290 725 515

Table 3.5 Length of surplus with 87° elbows

conduit [in mm]

not possible 520 310 745 535

Offset [in mm] Length of air

510 300 735 525 515 305 740 530

525 315 750 540 530 320 755 545

used, along with the table below, to determine the length of the air conduit ( = 190 mm in this case).

conduit [in mm]

Offset [in mm] Length of air

conduit [in mm]

49Flue installation instructions ecoTEC 834449_13

3 Optional Concentric System Ø 80/125

3.7.4 How to install 45° elbows

Key

A = Offset B = Length of air conduit C = Height

Caution!

This gives a corresponding exhaust-conduit length of 284 + 40 = 324 mm.

Example: An offset of 400 mm is measured. This value is then used, along with the table below, to determine the length of the air conduit (= 284 mm) and the height

Fig. 3.25 Installation of 45° bends, Accy. No.: 303 211

Offset [in mm]

90 0 210 335 334 455 535 617 655 95 0 215 340 341 460 540 624 660 100 0 220 345 348 465 545 631 665 > 100 to < 170 mm

170 100 290 370 383 490 570 666 690 175 108 295 375 390 495 575 673 695 180 115 300 380 397 500 580 680 700 185 122 305 385 405 505 585 687 705 190 129 310 390 412 510 590 695 710 195 136 315 395 419 515 595 702 715 200 143 320 400 426 520 600 709 720 205 150 325 405 433 525 605 716 725 210 157 330 410 440 530 610 723 730 215 164 335 415 447 535 615 730 735 220 171 340 420 454 540 620 737 740 225 178 345 425 461 545 625 744 745 230 185 350 430 468 550 630 751 750 235 192 355 435 475 555 635 758 755 240 199 360 440 482 560 640 765 760 245 207 365 445 489 565 645 772 765 250 214 370 450 496 570 650 779 770 255 221 375 455 504 575 655 786 775 260 228 380 460 511 580 660 794 780 265 235 385 465 518 585 665 801 785 270 242 390 470 525 590 670 808 790 275 249 395 475 532 595 675 815 795 280 256 400 480 539 600 680 822 800 285 263 405 485 546 605 685 829 805 290 270 410 490 553 610 690 836 810 295 277 415 495 560 615 695 843 815 300 284 420 500 567 620 700 850 820 305 291 425 505 574 625 705 857 825 310 298 430 510 581 630 710 864 830 315 306 435 515 588 635 715 871 835 320 313 440 520 596 640 720 878 840 325 320 445 525 603 645 330 327 450 530 610 650

Table 3.6 Length of surplus with 45° bends

Length of air conduit [in mm]

not possible 350 355 470 550 638 670

Height [in mm]

Offset [in mm]

355 362 475 555 645 675 360 369 480 560 652 680 365 376 485 565 659 685

(= 420 mm).

Length of air conduit [in mm]

Height [in mm]

Offset [in mm]

Length of air conduit [in mm]

Height [in mm]

Flue installation instructions ecoTEC 834449_1350

834449_13 GB 052008

Vaillant Air flue duct Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual