Vaillant ecoMAX 613/2 E, ecoMAX 618/2 E, ecoMAX 622/2 E, ecoMAX 824/2 E, ecoMAX 828/2 E Installation Instructions Manual

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Page 1

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

2000225123A-10.02

Page 2

Page 3

OVERVIEW

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

Page 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

Installation of the horizontal air/flue duct

Fitting air/flue duct extensions

Installation of the sliding sleeve

How to add extensions 18 How to install elbows 19

Page 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.

Page 6

Optional connection accessories

Offset section

Telescopic extension 440 mm - 690 mm Ø 60/100

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

303 910 x

303 921 x

303 915 x

009076 black

Page 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.

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

Page 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

Page 9

PART 1 CONCENTRIC 60/100

PLANNING THE AIR/FLUE DUCT LAYOUT

Maximum flue lengths for use with ecoMAX

Maximum flue length

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

Page 10

INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE

Fig. 2.0: Installing the sliding sleeve

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.

Page 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

Page 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

LAS Euro B/S 037/0

190 150

Fig. 3.1a

LAS Euro B/S 072/0GB

* = 190 mm ecoMAX

combination and system boilers

* = 176 mm ecoMAX pro

Page 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.

* = 190 mm

Fig. 3.2

LAS Euro B/S 077/1

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

Page 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

3°

Fig. 3.5

LAS Euro B/S 001/0GB

Page 15

PART 1 CONCENTRIC 60/100

1530

880

Vertical air/flue duct

Accy. Vaillant Part No.: 303 900 (black)

Contents of the accessory:

• Vertical air/flue duct and terminal assembly

• 70 mm air duct clamp

• Fixing bracket

☞See page 6 et seq. for details of

air/flue duct elements.

☞ Observe the maximum flue

lengths as detailed in table on page 9

Fig. 4.1: Vertical roof duct

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.

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.

☞ Please note: The vertical air/flue

duct and terminal accessory (Accy. No. 303 900) 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.

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Page 16

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Pitched roof installation

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

• Fit the adjustable pitched roof tile (1).

• Working from above, insert the vertical roof duct (5) through the roofing 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.

☞ See pages 18 et seq. 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 (7).

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

• 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.

750

790

740

Ø100

20 – 50°

0 – 20

190

Fig. 4.2: Fitting the appliance and the vertical roof duct to a building with a pitched roof

* = 190 mm ecoMAX

combination and system boilers

* = 176 mm ecoMAX pro

750 mm ecoMAX

combination and system boilers

530 mm ecoMAX pro

(top holes of bracket)

Page 17

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

PART 1 CONCENTRIC 60/100

880

warm roof

cold roof

650

Ø100

≥120

750

Fig. 4.4: Fitting the appliance and vertical flue duct to a building with a flat roof

Flat-roof installation

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

☞ See pages 19 et seq. for further

details on the installation of extensions and elbows.

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

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

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

750 mm ecoMAX

combination and system boilers

530 mm ecoMAX pro

(top holes of bracket)

Page 18

FITTING AIR/FLUE DUCT EXTENSIONS

How to add extensions

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

☞ 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.

Tip:

Start by measuring the required length of air conduit* (L

air

), and then calculate the corresponding length of flue conduit (L

exhaust

) as follows:

exhaust

= L

air

+ 40 mm

exhaust

= length of flue conduit

air

= length of air conduit

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

air

exhaust

+ 40 mm

Fig. 9.1: Cutting tubes to size

☞ 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.

☞ 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.

☞ Do not use damaged or dented

tubes, as they will not form an adequate seal.

☞ Ensure that the seals remain

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

☞ Secure the exhaust conduit with

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

Fig. 9.2: Loosening the flue conduit

GU_LAZ 290/1

Page 19

PART 1 CONCENTRIC 60/100

FITTING AIR/FLUE DUCT EXTENSIONS

Offset Length of

[in mm] air conduit

[in mm

]

Offset Length of

[in mm] air conduit

[in mm

]

Offset Length of

[in mm] air conduit

[in mm

]

690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515 730 520 735 525 740 530 745 535 750 540 755 545 760 550 765 555 770 560 775 565 780 570 785 575 790 580 795 585 800 590

470 260 475 265 480 270 485 275 490 280 495 285 500 290 505 295 510 300 515 305 520 310 525 315 530 320 535 325 540 330 545 335 550 340 555 345 560 350 565 355 570 360 575 365 580 370 585 375 590 380 595 385 600 390 605 395 610 400 615 405 620 410 625 415 630 420 635 425 640 430 645 435 650 440 655 445 660 450 665 455 670 460 675 465 680 470 685 475

Table 10.1: Length of surplus with 87° elbows

> 190 to

< 210 mm 0

> 215 to not

< 265 mm possible

> 270 to

< 290 mm 80

295 85 300 90 305 95 310 100 315 105 320 110 325 115 330 120 335 125 340 130 345 135 350 140 355 145 360 150 365 155 370 160 375 165 380 170 385 175 390 180 395 185 400 190 405 195 410 200 415 205 420 210 425 215 430 220 435 225 440 230 445 235 450 240 455 245 460 250 465 255

How to install elbows

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).

Important:

This gives a corresponding exhaust-conduit length of 190 + 40 = 230 mm. (cf. page 19)

Fig. 10.1: Installation of 87° elbows

190

Offset

Lenght of air conduit

GU_LAZ 102/2GB

Page 20

FITTING AIR/FLUE DUCT EXTENSIONS

90 0 210 95 0 215

100 0 220

> 105 to not

< 155 mm possible

160 86 280 165 93 285 170 100 290 175 107 295 180 115 300 185 122 305 190 129 310 195 136 315 200 143 320 205 150 325 210 157 330 215 164 335 220 171 340 225 178 345 230 185 350 235 192 355 240 199 360 245 206 365 250 214 370 255 221 375 260 228 380 265 235 385 270 242 390 275 249 395 280 256 400 285 263 405 290 270 410 295 277 415 300 284 420 305 291 425 310 298 430 315 306 435 320 313 440

Offset Length of Height

[in mm] air conduit [in mm]

[in mm]

Offset Length of Height

[in mm] air conduit [in mm]

[in mm]

Table 10.2: Length of surplus with 45° bends

Offset Length of Height

[in mm] air conduit [in mm]

[in mm]

How to install elbows

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 (= 420 mm).

Important:

This gives a corresponding exhaust-conduit length of 284 + 40 = 324 mm. (cf. page 19)

GU_LAZ 103/2GB

Fig. 10.2: Installation of 45° bends

325 320 445 330 327 450 335 334 455 340 341 460 345 348 465 350 355 470 355 362 475 360 369 480 365 376 485 370 383 490 375 390 495 380 397 500 385 404 505 390 412 510 395 419 515 400 426 520 405 433 525 410 440 530 415 447 535 420 454 540 425 461 545 430 468 550 435 475 555 440 482 560 445 489 565 450 496 570 455 503 575 460 511 580 465 518 585 470 525 590 475 532 595 480 539 600 485 546 605 490 553 610 495 560 615 500 567 620 505 574 625 510 581 630 515 588 635 520 595 640

525 602 645 530 610 650 535 617 655 540 624 660 545 631 665 550 638 670 555 645 675 560 652 680 565 659 685 570 666 690 575 673 695 580 680 700 585 687 705 590 694 710 595 701 715 600 709 720 605 716 725 610 723 730 615 730 735 620 737 740 625 744 745 630 751 750 635 758 755 640 765 760 645 772 765 650 779 770 655 786 775 660 793 780 665 800 785 670 808 790 675 815 795 680 822 800

Height

Offset

Lenght of air conduit

Page 21

CONTENTS: PART 2 CONCENTRIC 80/125

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 22

Alternative termination accessories available 23 Maximum flue lengths 26

Changing the appliance connection piece

Installation of the vertical air/flue duct

Installation of the horizontal air/flue duct

Fitting air/flue duct extensions

Installation of the sliding sleeve

How to add extensions 38 How to install elbows 39

Page 22

REQUIREMENTS

Regulations and standards to be observed

☞ Vaillant ecoMAX boilers are

☞ 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.

☞ 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.

Page 23

PART 2 CONCENTRIC 80/125

PLANNING THE AIR/FLUE DUCT LAYOUT

Alternative termination accessories available

303 200 = Vertical air/flue duct (black) 303 209 = Horizontal air/flue duct

303 907 = Appliance connection piece

Optional connection accessories Accy. No.

303 200

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

303 202 x

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

303 203 x

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

303 205 x

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

303 211 x

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

303 210 x

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

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

Adjustable roof tiles for pitched roof

009076 black

Flat roof penetration collar 009 056 x

303 209

Page 24

PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.2: Extensions, Ø 80/125

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

Flue support clips, Ø 125 (pack of 5)

Vaillant Accy. No.: 303 616

☞ Use one clip per extension to

support the air/flue duct.

Fig. 1.3: Elbow joints, Ø 80/125

Elbow (PPs), 87°, Ø 80/125

Vaillant Accy. No.: 303 210

Bends (PPs), 45° (pack of 2), Ø 80/125

Vaillant Accy. No.: 303 211

Air/flue duct extension (PPs) 470 mm, Ø 80/125

Vaillant Accy. No.: 303 202

Air/flue duct extension (PPs) 970 mm, Ø 80/125

Vaillant Accy. No.: 303 203

Air/flue duct extension (PPs) 1970 mm, Ø 80/125

Vaillant Accy. No.: 303 205

GU_LAZ 70/0

GU_LAZ 72/0

GU_LAZ 71/0

15,5

Fig. 1.1: Appliance connection piece

Appliance connection piece Ø 80/125

Vaillant Accy. No.: 303 907 (with 2 measuring apetures)

Page 25

PART 2 CONCENTRIC 80/125

PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.6: Adjustable roof tile for pitched roof

Adjustable roof tiles for pitched roof

Vaillant Accy. No.: 009 076 (black)

GU_LAZ 41/0

164

120

Fig. 1.5: Sliding sleeve, Ø 80/125

Sliding sleeve (PPs), Ø 80/125

Vaillant Accy. No.: 303 215

GU_LAZ 76/0

Fig. 1.7: Flat roof penetration collar

GU_LAZ 42/0

Flat roof penetration collar

Vaillant Accy. No.: 009 056

Page 26

PLANNING THE AIR/FLUE DUCT LAYOUT

Maximum flue lengths for use with ecoMAX

Accessories Accy. No.

Vertical flue systems

303 200

Max. permitted concentric flue length

Horizontal flue systems

303 209 Max. permitted

concentric flue length

14.0 m

13.0 m incl.

1 elbow 87°

31.0 m

20.0 m

30.0 m incl.

1 elbow 87°

20.0 m incl.

1 elbow 87°

27.0 m

25.0 m incl.

1 elbow 87°

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

pro 28 E

ecoMAX

of which no more than 5 m lie in exposed position. Maximum length of flue is reduced by 2.5 m for each additional 90° elbow.

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

of which no more than 5 m lie in exposed position. Maximum length of flue is reduced by 2.0 m for each additional 90° elbow

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

Accessories Accy. No.

Vertical flue systems

303 200

Max. permitted concentric flue length

Horizontal flue systems

303 209 Max. permitted

concentric flue length

26.0 m

25.0 m incl.

1 elbow 87°

22.0 m

21.0 m incl.

1 elbow 87°

29.0 m

30.0 m incl.

1 elbow 87°

824/2 E 828/2 E 835/2 E

ecoMAX

of which no more than 5 m lie in exposed position. 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.

of which no more than 5 m lie in exposed position. Maximum length of flue is reduced by 2.5 m for each additional 90° elbow

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

Page 27

PART 2 CONCENTRIC 80/125

PLANNING THE AIR/FLUE DUCT LAYOUT

Maximum flue length

LAS Euro B/S 074/0

Fig. 1.9

Fig. 1.8

Page 28

CHANGING THE APPLIANCE CONNECTION-PIECE

Fig. 2.0: Fitting the appliance connection-piece

Installation

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 connectionpiece (1) upwards to remove it.

• Push the appliance connectionpiece 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).

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.

Page 29

PART 2 CONCENTRIC 80/125

INSTALLATION OF THE SLIDING SLEEVE

Fig. 3.0: Installing the sliding sleeve

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. 303 215) 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.

• 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.

Page 30

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT

☞ Observe the maximum flue

lengths as detailed in table on page 27

1103

Horizontal air/flue duct

Vaillant Accy No.: 303 209

Contents of the accessory:

• Horizontal air/flue duct

• 87° elbow

• 2 x 70 mm air duct clamps

• 2 x internal trim rings Ø 125 ☞See page 24 et seq. for details of

air/flue duct elements.

Fig. 4.1: Horizontal air/flue conduit

GU_LAZ 82/0

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).

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

inspection-access T-piece

Page 31

PART 2 CONCENTRIC 80/125

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).

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:

• Identify the correct measurement as shown in fig. 3.2, 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.

• 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.

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. 4.5).

This is dimension A.

• For installations where the measured distance dimension A (fig. 6) 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.

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.

* = 190 mm

Fig. 4.3

LAS Euro B/S 077/1

253

Fig. 4.4

LAS Euro B/S 083/1

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

EXTENSIONS

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

* = 253 mm ecoMAX

combination and system boilers

* = 210 mm ecoMAX pro

(from top holes on bracket)

Page 32

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITH EXTENSIONS

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

• 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.

4.6).

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 10 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.

• Cut the flue duct as detailed in fig. 4.7.

• 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 40 - 42.

• 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.

Fig. 4.5

LAS Euro B/S 082/0

10 mm

Mark air duct here

Dimension A + 20 mm

Fig. 4.6

LAS Euro B/S 084/0

25 mm

Mark flue duct here

15 mm

Fig. 4.7

LAS Euro B/S 080/0

Dimension A + 60 mm

Page 33

PART 2 CONCENTRIC 80/125

220

3°

Fig. 4.8: Installing the horizontal wall duct

LGU_LAZ 384/0_IT

• 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.

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

EXTENSIONS

Page 34

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

82 - 84

253

750

Fig. 4.9: Indirect installation

Indirect installation

• Fit the wall mounting (2).

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

• Change the appliance connectionpiece (7) as described on page

29.

• Join the 87° elbow (5) to the appliance connection piece.

• Push the sliding sleeve (7) firmly into place on the appropriate extensionns (6).

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

☞ This section functions

subsequently as a separation point.

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

☞ See pages 41 et seq. for further

details on the installation of extensions and elbows.

* = 750 mm ecoMAX

combination and system boilers

* = 530 mm ecoMAX pro

(from top holes on bracket)

** = 253 mm ecoMAX

combination and system boilers

** = 210 mm ecoMAX pro

(from top holes on bracket)

Page 35

PART 2 CONCENTRIC 80/125

1530

880

Vertical air/flue duct

Accy. Vaillant Part No.: 303 200 (black)

Contents of the accessory:

• Vertical air/flue duct and terminal assembly

• Adapter (air) for Ø 110/125

• 70 mm air duct clamp

• Fixing bracket

☞See page 24 et seq. for details of

air/flue duct elements.

☞ Observe the maximum flue

lengths as detailed in table on page 27

Fig. 5.1: Vertical roof duct

GU_LAZ 81/0

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.

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.

☞Please note: The vertical air/flue

duct and terminal 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.

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Page 36

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

750

790

740

Ø125

20 – 50°

190

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

Pitched roof installation

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

• Fit the adjustable pitched roof tile (1).

• Working from above, insert the vertical roof duct (5) through the roofing 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.

☞ See pages 41 et seq. for further

details on the installation of extensions and elbows.

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

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

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

* = 190 mm ecoMAX

combination and system boilers

* = 176 mm ecoMAX pro

750 mm ecoMAX combination and system boilers

530 mm ecoMAX pro

(top holes of bracket)

Page 37

PART 2 CONCENTRIC 80/125

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

880

warm roof

cold roof

650

Ø125

≥120

750

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

Flat-roof installation

• Determine the point where the 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 (3) with reference to the installation and servicing instructions supplied with the boiler.

☞ See pages 41 et seq. for further

details on the installation of extensions and elbows.

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

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

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

750 mm ecoMAX combinatin

and system boilers

530 mm ecoMAX pro

(top holes of bracket)

Page 38

FITTING AIR/FLUE DUCT EXTENSIONS

How to add extensions

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

☞ No tools are required when

removing previously-fitted 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 spacerpiece. After cutting to size, refit the flue conduit and secure it to the air conduit.

Tip:

Start by measuring the required length of air conduit* (L

air

), and then calculate the corresponding length of flue conduit (L

exhaust

) as follows:

exhaust

= L

air

+ 40 mm

exhaust

= length of flue conduit

air

= length of air conduit

* Minimum length of air-conduit extension: 100 mm.

air

exhaust

+ 40 mm

Fig. 10.1: Cutting tubes to size

☞ 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.

☞ 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.

☞ Do not use damaged or dented

tubes, as they will not form an adequate seal.

☞ Ensure that the seals remain

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

☞ Secure the exhaust conduit with

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

Fig. 10.2: Loosening the flue conduit

GU_LAZ 290/1

Page 39

PART 2 CONCENTRIC 80/125

FITTING AIR/FLUE DUCT EXTENSIONS

Offset Length of

[in mm] air conduit

[in mm

]

Offset Length of

[in mm] air conduit

[in mm

]

Offset Length of

[in mm] air conduit

[in mm

]

730 520 735 525 740 530 745 535 750 540 755 545 760 550 765 555 770 560 775 565 780 570 785 575 790 580 795 585 800 590 805 595 810 600 815 605 820 610 825 615 830 620 835 625 840 630 845 635 850 640 855 645 860 650 865 655 870 660 875 665 880 670 885 675 890 680 895 685 900 690 905 695 910 700 915 705 920 710 925 715 930 720 935 725 940 730

505 295 510 300 515 305 520 310 525 315 530 320 535 325 540 330 545 335 550 340 555 345 560 350 565 355 570 360 575 365 580 370 585 375 590 380 595 385 600 390 605 395 610 400 615 405 620 410 625 415 630 420 635 425 640 430 645 435 650 440 655 445 660 450 665 455 670 460 675 465 680 470 685 475 690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515

Table 11.1: Length of surplus with 90° elbows

200, 205 0

210, 0

> 210 to not

< 310 mm possible

310 100 315 105 320 110 325 115 330 120 335 125 340 130 345 135 350 140 355 145 360 150 365 155 370 160 375 165 380 170 385 175 390 180 395 185 400 190 405 195 410 200 415 205 420 210 425 215 430 220 435 225 440 230 445 235 450 240 455 245 460 250 465 255 470 260 475 265 480 270 485 275 490 280 495 285 500 290

How to install elbows

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).

Important:

This gives a corresponding exhaust-conduit length of 190 + 40 = 230 mm. (cf. page 41)

190

Offset

Lenght of air conduit

Fig. 11.1: Installation of 90° elbows

GU_LAZ 102/2GB

Page 40

90 0 210 95 0 215

100 0 220

> 100 to not

< 170 mm possible

170 100 290 175 108 295 180 115 300 185 122 305 190 129 310 195 136 315 200 143 320 205 150 325 210 157 330 215 164 335 220 171 340 225 178 345 230 185 350 235 192 355 240 199 360 245 207 365 250 214 370 255 221 375 260 228 380 265 235 385 270 242 390 275 249 395 280 256 400 285 263 405 290 270 410 295 277 415 300 284 420 305 291 425 310 298 430 315 306 435 320 313 440 325 320 445 330 327 450

FITTING AIR/FLUE DUCT EXTENSIONS

Offset Length of Height

[in mm] air conduit [in mm]

[in mm]

Offset Length of Height

[in mm] air conduit [in mm]

[in mm]

Table 11.2: Length of surplus with 45° bends

Offset Length of Height

[in mm] air conduit [in mm]

[in mm]

Height

Offset

Lenght of air conduit

How to install elbows

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 (= 420 mm).

Important:

This gives a corresponding exhaust-conduit length of 284 + 40 = 324 mm. (cf. page 41)

GU_LAZ 103/2GB

Fig. 11.2: Installation of 45° bends

335 334 455 340 341 460 345 348 465 350 355 470 355 362 475 360 369 480 365 376 485 370 383 490 375 390 495 380 397 500 385 405 505 390 412 510 395 419 515 400 426 520 405 433 525 410 440 530 415 447 535 420 454 540 425 461 545 430 468 550 435 475 555 440 482 560 445 489 565 450 496 570 455 504 575 460 511 580 465 518 585 470 525 590 475 532 595 480 539 600 485 546 605 490 553 610 495 560 615 500 567 620 505 574 625 510 581 630 515 588 635 520 596 640 525 603 645 530 610 650

535 617 655 540 624 660 545 631 665 550 638 670 555 645 675 560 652 680 565 659 685 570 666 690 575 673 695 580 680 700 585 687 705 590 695 710 595 702 715 600 709 720 605 716 725 610 723 730 615 730 735 620 737 740 625 744 745 630 751 750 635 758 755 640 765 760 645 772 765 650 779 770 655 786 775 660 794 780 665 801 785 670 808 790 675 815 795 680 822 800 685 829 805 690 836 810 695 843 815 700 850 820 705 857 825 710 864 830 715 871 835 720 878 840

Page 41

Page 42

Page 43

Page 44

83 44 49 GB03 08/2002 Mü Subject to alteration

Head Office Service Solutions 0870 6060 777 Vaillant Ltd., Vaillant House Technical Advice 01634 292392

Medway City Estate, Trident Close, Rochester, Kent ME2 4EZ