Vaillant ecoMAX 613/2 E, ecoMAX 618/2 E, ecoMAX 622/2 E, ecoMAX 824/2 E, ecoMAX 828/2 E Installation Instructions Manual
...
For the installer
Flue installation instructions
Air flue duct for use with ecoMAX
ecoMAX 613/2 E
ecoMAX 618/2 E
ecoMAX 622/2 E
ecoMAX 824/2 E
ecoMAX 828/2 E
ecoMAX 835/2 E
ecoMAX pro 18 E
ecoMAX pro 28 E
GB
2000225123A-10.02
2
OVERVIEW
3
PART 2 CONCENTRIC 80/125
PART 1 Pages 4 - 20
Standard Concentric Systems Ø 60/100
(Aluminium air duct/plastic flue duct)
PART 2 Pages 21 - 40
Optional Concentric System Ø 80/125
(Aluminium air duct/plastic flue duct)
PART 2 CONCENTRIC 80/125
PART 1 CONCENTRIC 60/100
4
CONTENTS: PART 1 CONCENTRIC 60/100
Page
The air/flue duct must be installed by a suitably
qualified service provider, which is responsible
for 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 6
Maximum flue lengths 9
§
Installation of the vertical roof duct
15
Installation of the horizontal air/flue duct
11
Fitting air/flue duct extensions
Installation of the sliding sleeve
How to add extensions 18
How to install elbows 19
10
5
PART 1 CONCENTRIC 60/100
REQUIREMENTS
Regulations and
standards to be
observed
§
☞ Vaillant ecoMAX boilers are
certified as heating boilers with
corresponding flue systems
according to EC Directive
90/396/EEC on gas-fired
devices. This installation manual is
covered by this certification and is
referred to in the design approval
test certificate.
☞ These instructions should be read
in conjunction with the instructions
for installation and servicing
supplied with the boiler.
☞ Ensure also that all legislation,
rules, regulations and directives
mentioned in the installation
instructions are observed.
☞ 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).
☞ 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.
☞ The requirements for flue
termination detailed in the boiler
installation instructions must be
observed.
☞ Two types of flue system are
available for ecoMAX boilers. The
standard concentric flue system
(100 mm outside diameter) and a
larger diameter concentric system
(125 mm outside diameter) which
allows longer air/flue duct lengths
to be achieved.
☞ The air/flue duct operates at very
low temperatures therefore no
clearance is necessary between
the air duct and adjacent
services.
☞ 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.
Optional connection accessories
Offset section
Telescopic extension
440 mm - 690 mm Ø 60/100
6
PLANNING THE AIR/FLUE DUCT LAYOUT
Alternative termination accessories available
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
Sliding sleeve (PP) Ø 60/100
Adjustable roof tiles for pitched roof
303 900 = Vertical air/flue duct (black)
303 930 = Horizontal air/flue duct
Accy. No.
303 930 303 900
303 919
303 906
303 902 x
303 903 x
303 905 x
303 911 x
x
303 910 x
303 921 x
303 915 x
009076 black
x
x
x
x
x
x
x
x
x
x
x
7
PART 1 CONCENTRIC 60/100
PLANNING THE AIR/FLUE DUCT LAYOUT
Fig. 1.1: Extensions, Ø 60/100
Fig. 1.3: Flue support clips, Ø 100/Ø 80
Flue support clips, Ø 100 (pack of 5)
Vaillant Accy. No.: 303 921
☞ Use one clip per extension to
support the air/flue duct.
18
27
18
27
18
27
Fig. 1.2: Elbow joints, Ø 60/100
Elbow, 87°, Ø 60/100
Vaillant Accy. No.: 303 910
Bends, 45° (pack of 2),
Ø 60/100
Vaillant Accy. No.: 303 911
Air/flue duct extension 470 mm
Ø 60/100
Vaillant Accy. No.: 303 902
Air/flue duct extension 970 mm,
Ø 60/100
Vaillant Accy. No.: 303 903
Air/flue duct extension 1970 mm,
Ø 60/100
Vaillant Accy. No.: 303 905
GU_LAZ 70/0
GU_LAZ 72/0
440 – 690
Fig. 1.4: Telescopic extension, Ø 60/100
Telescopic extension (PP), Ø 60/100
440 mm - 690 mm
Vaillant Accy. No.: 303 906
8
PLANNING THE AIR/FLUE DUCT LAYOUT
155
Fig. 1.6: Sliding sleeve, Ø 60/100
Sliding sleeve (PP), Ø 60/100
Vaillant Accy. No.: 303 915
290 – 374
33 – 56
Fig. 1.5: Offset section, Ø 60/100
Offset section, Ø 60/100
Vaillant Accy. No.: 303 919
303919_IAx
Fig. 1.8: Flat roof penetration collar
GU_LAZ 42/0
Flat roof penetration collar
Vaillant Accy. No.: 009 056
Fig. 1.7: Adjustable roof tile for pitched roof
Adjustable roof tile for pitched roof
Vaillant Accy. No.: 009 076 (black)
GU_LAZ 41/0
9
PART 1 CONCENTRIC 60/100
PLANNING THE AIR/FLUE DUCT LAYOUT
Maximum flue lengths for use with ecoMAX
Maximum flue length
Maximum flue length
LAS Euro B/S 074/0
LAS Euro B/S 074/0
Fig. 1.5
Fig. 1.6
Accessories Accy. No.
Vertical
flue systems
303 900
Max. permitted
concentric
flue length
Horizontal
flue systems
303 930 Max. permitted
concentric
flue length
12.0 m
8.0 m
incl.
1 elbow 87°
828/2 E 835/2 E pro 18 E
pro 28 E
10.0 m 7.0 m 10.0 m
8.0 m
incl.
1 elbow 87°
4.0 m
incl.
1 elbow 87°
10.0 m
incl.
1 elbow 87°
824/2 E
9.0 m
7.0 m
incl.
1 elbow 87°
613/2 E
618/2 E
622/2 E
ecoMAX
of which no more than 5 m lie in exposed position.
Maximum length of flue is reduced by 1.0 m for each additional 90° elbow
Maximum length of flue is reduced by 0.5 m for each additional 45° elbow
of which no more than 5 m lie in exposed position.
Maximum length of flue is reduced by 1.0 m for each additional 90° elbow
Maximum length of flue is reduced by 0.5 m for each additional 45° elbow
10
INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE
Fig. 2.0: Installing the sliding sleeve
1
2
3 1 24
567
Schiebemuffe_neu
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.
• 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.
11
800
☞ Observe the maximum flue
lengths as detailed in table on
page 9
Horizontal air/flue duct
Vaillant Accy No.: 303 930
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
☞See page 6 et seq. for details of
air/flue duct elements.
Fig. 3.0: Horizontal air/flue conduit
Important:
The flue hole should be cut with a
slight rise to outside of 3°± 1°
(equivalent to 50 mm ± 20 mm rise
per metre length).
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT
PART 1 CONCENTRIC 60/100
12
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT
Horizontal air/flue duct
Accy No.: 303 930
(Length 0.8 m)
Contents of the accessory:
• Horizontal air/flue duct
• 87° elbow
• 2 x 70 mm air duct clamps
• 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 a
slight rise to outside if 3° ± 1°
(equivalent to 50 mm ± 20 mm rise
per metre length).
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.
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.
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 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.
800
40
13
70
LAS Euro B/S 037/0
5
190 150
6
6
2
3
Fig. 3.1a
LAS Euro B/S 072/0GB
*
* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
13
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• 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.
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.
• Measure the distance from the
outside face of the wall to the
centre of the fan outlet on the
boiler.
This is dimension A.
• Cut the air duct and flue duct to
the lengths shown in figure 3.4.
• 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 sections on pages 20 – 21.
• 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.
1
2
*
* = 190 mm
Fig. 3.2
LAS Euro B/S 077/1
150
A
B
A
150
Fig. 3.3
LAS Euro B/S 078/0
A + 45 mm
13 mm
Fig. 3.4
LAS Euro B/S 076/0
Rear exit
Side exit
PART 1 CONCENTRIC 60/100
*
* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 190 mm ecoMAX combination and system boilers
* = 176 mm ecoMAX 400
14
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• Push the air/flue duct assembly
(1) including the flexible external
seal (2) 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.
• 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.
• Slide the internal trim ring (3) over
the air duct until it is flush with the
wall.
• 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 to the boiler by
inserting the spigot of the flue
elbow into the flue socket on the
boiler and secure using the air
duct clamp provided.
• Pull the air/flue duct back through
the wall such that the flue duct
fully engages into the flue elbow
socket.
• Fit the air duct clamp ensuring
that it is positioned centrally.
• 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.
150
13
3°
1
Fig. 3.5
LAS Euro B/S 001/0GB
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