For the installer Flue installation instructions ecoMAX 613/2 E ecoMAX 618/2 E ecoMAX 622/2 E ecoMAX 635/ E ecoMAX 824/2 E ecoMAX 828/2 E ecoMAX 835/ E ecoMAX pro 18 E ecoMAX pro 28 E ecoTEC plus 612/3 ecoTEC plus 615/3 ecoTEC plus 618/3 ecoTEC plus 624/3 ecoTEC plus 630/3 ecoTEC plus 824/3 ecoTEC plus 831/3 ecoTEC pro 28/3 GB Air flue duct for use with ecoMAX and ecoTEC boilers
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Transcript
For the installer
Flue installation instructions
ecoMAX 613/2 E
ecoMAX 618/2 E
ecoMAX 622/2 E
ecoMAX 635/ E
ecoMAX 824/2 E
ecoMAX 828/2 E
ecoMAX 835/ E
ecoMAX pro 18 E
ecoMAX pro 28 E
ecoTEC plus 612/3
ecoTEC plus 615/3
ecoTEC plus 618/3
ecoTEC plus 624/3
ecoTEC plus 630/3
ecoTEC plus 824/3
ecoTEC plus 831/3
ecoTEC pro 28/3
GB
Air flue duct for use with ecoMAXand ecoTEC boilers
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OVERVIEW
PART
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IC 8
0/12
5
PART 1 Pages 4 - 35
Standard Concentric Systems Ø 60/100(Galvanized steel air duct/plastic flue duct)
PART 2 Pages 37 - 57
Optional Concentric System Ø 80/125(Galvanized steel air duct/plastic flue duct)
PART
2 C
ONC
ENTR
IC 8
0/12
5PA
RT 1
CO
NCEN
TRIC
60/
100
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4
CONTENTS: PART 1 CONCENTRIC 60/100
Page
The air/flue duct must be installed by a suitablyqualified service provider, which is responsiblefor observing the relevant specifications,regulations and standards.
Requirements
Planning the air/flue duct layout
Regulations and standards to be observed 5
Alternative termination accessories available 6Maximum flue lengths for ecoMAX 11Maximum flue lengths for ecoTEC 12
§
Installation of the vertical air/flue duct 31
Installation of the horizontal air/flue duct 15
Installation of the black terminal kit 24
Fitting air/flue duct extensions
Installing the air/flue duct sliding sleeve
How to add extensions 34How to install elbows 35
14
Installation of the variable termination kit 26
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REQUIREMENTS
Regulations andstandards to beobserved
§
☞ Vaillant ecoMAX/ecoTEC boilersare certified as heating boilerswith corresponding flue systems according to EC Directive90/396/EEC on gas-fired devi-ces. This installation manual iscovered by this certification and isreferred to in the design approvaltest certificate.
☞ These instructions should be readin conjunction with the instructionsfor installation and servicing supplied with the boiler.
☞ Ensure also that all legislation,rules, regulations and directivesmentioned in the installationinstructions are observed.
☞ The installation of the boiler andits flue must be carried out by acompetent person who is registered with CORGI (TheCouncil for Registered GasInstallers).
☞ The installation of the boiler andflue must be in accordance withthe Gas Safety (Installation andUse) Regulations 1998 and theBuilding Regulations and BS 5440 Part 1.
☞ The requirements for flue termination detailed in the boilerinstallation instructions must beobserved.
☞ Two types of flue system are available for ecoMAX/ecoTECboilers. The standard concentricflue system (100 mm outsidediameter) and a larger diameterconcentric system (125 mmoutside diameter) which allowslonger air/flue duct lengths to beachieved.
☞ The air/flue duct operates at verylow temperatures therefore noclearance is necessary betweenthe air duct and adjacent services.
☞ Ensure while installation work isbeing carried out that no debrissuch as swarf, filings or fragmentsof mortar are allowed to remainin the air/flue duct.
834449_05GB_022005.qxd 02.02.2005 17:12 Uhr Seite 5
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
303 936Optional connection accessories
Telescopic offset section
Telescopic extension440 mm - 690 mm Ø 60/100
6
PLANNING THE AIR/FLUE DUCT LAYOUT
Alternative termination accessories available
Air/flue duct extensions, concentric470 mm - Ø 60/100
Air/flue duct extensions, concentric970 mm - Ø 60/100
Air/flue duct extensions, concentric1970 mm - Ø 60/100
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 asfollows:
- Reduced by 0.5 m for the variable terminal- Reduced by 0.5 m for every 1 m VTK pipe- Reduced by 0.5 m for every 87° bend- Reduced by 0.5 m for 2 x 45° bend
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
834449_05GB_022005.qxd 02.02.2005 17:12 Uhr Seite 11
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
Vertical flue systems
303 900
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
Maximum flue lengths for use with ecoTEC
The maximum permitted concentric flue length given above is reduced asfollows:
- Reduced by 0.5 m for the variable terminal- Reduced by 0.5 m for every 1 m VTK pipe- Reduced by 0.5 m for every 87° bend- Reduced by 0.5 m for 2 x 45° bend
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Maximum flue length
Max
imum
flue
leng
th
LAS
Euro
B/S
074
/0
LAS
Euro
B/S
074
/0
Fig. 1.17: Horizontal flue systems Fig. 1.18: Vertical flue systems
PLANNING THE AIR/FLUE DUCT LAYOUT
Concentric flue length
Flue
leng
th o
utsi
de
Fig. 1.19: Horizontal flue system installed with vertical termination kit
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INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE
Fig. 2.0: Installing the sliding sleeve
1
34
675
2
Schi
ebem
uffe
_neu
INSTALLING THEAIR/FLUE DUCT SLIDINGSLEEVE☞ NOTE:
For installations where there is in-sufficient movement to allow fittingof the flue into flue outlet, a slid-ing sleeve (Accy. No. 303 915) isavailable. When using the slidingsleeve both the air and flue ductsof the last extension must beshortened by a further 95 mm.
• Push the sliding sleeve (1) over thecut end of the flue duct (2).
• Place the air duct clamp (7) overthe air duct.
• Pull back the sliding sleeve so thatit engages into the socket (3) ofthe boiler (4). Ensure that thesliding sleeve penetrates thesocket such that there is at least20 mm engagement at both endsof the sliding sleeve.
• Fit the air duct clamp over the airducts (5 and 6) of theextension/terminal and boileroutlet. Close the snap clamp.
• Drill two holes 3 mm diameterthrough the air duct clamp (thecentre of the holes should be 6mm from the edge of the clamp).Ensure that the drill does notpenetrate the inner flue duct.Screw the air duct clamp to theair duct of the sleeve using thescrews provided.
• Complete the installation of theflue as detailed in theseinstructions.
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT
Horizontal air/flue duct
Accy No.: 303 930for ecoMAX only(Length 0.8 m)
Contents of the accessory:• Horizontal air/flue duct• 87° elbow• 1 x 70 mm air duct clamp• 1 x 40 mm air duct clamp• Internal trim ring Ø 100• External wall seal
Fig. 3.1: Horizontal air/flue conduit
IMPORTANT:The flue hole should be cut with aslight rise to outside if 3° ± 1°(equivalent to 50 mm ± 20 mm riseper metre length).
Preparation• Determine the installation site for
the boiler with reference to theinstallation and servicing instructions supplied with the boiler.
• Ensure that all installation and service clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.
• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of the template is vertical using a plumbline or spirit level.
Top outlet flue exiting to rear• For installations where the air/flue
duct is to be installed directly tothe rear of the boiler, the installation template details theposition of the flue exit hole forhorizontal top outlet installation.
Top outlet flue exiting to side• For installations where the air/flue
duct is to be installed to the side,the position of the flue exit holecan be determined by carefullylevelling across the wall from thecentre line of the air/flue ducthole marked on the template.
• The position of the flue exit holeshould allow the flue to be installed with a slight upwardslope of about 3° ± 1° (equivalentto 50 mm ± 20 mm per metre offlue duct). Calculate the requiredrise according to the flue lengthand mark the position of the flueexit hole.
4013
70
800
95
LAS
Euro
B/S
037
/03
* 150
2
4
1
5
Fig. 3.2
LAS
Euro
B/S
072
/0G
B
*
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro
☞ Observe the maximum fluelengths as detailed in table onpage 11.
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 125 mmdiameter.Note: If access can be gained tothe proposed flue exit point fromoutside the dwelling, the hole canbe cut with a 107 mm core drilland the flue external wall seal fitted from outside the dwelling.
• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler.
This is dimension A.
• Cut the air duct and flue duct tothe lengths shown in (fig. 3.5).
• All flue sockets should pointtowards the terminal.
• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.Care should be taken not toscratch the white surface of the airduct.
• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 34 - 35.
• Secure the air duct sectionstogether by drilling a 3 mmdiameter hole through the locationhole in the end of the outer airduct. (Ensure that the drill doesnot pierce the inner flue duct).Secure the air ducts together usingthe screw provided.
1
2
*
* = 190 mm
Fig. 3.3 LAS
Euro
B/S
077
/1
150
A
B
A
150
Fig. 3.4 LAS
Euro
B/S
078
/0
A + 45 mm
13 mm
Fig. 3.5 LAS
Euro
B/S
076
/0
Rear exit
Side exit
*
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro
* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• Push the air/flue duct assembly(1) including the flexible externalseal through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall.
• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom.
• Slide the internal trim ring (2) overthe air duct until it is flush with thewall.
• At this stage it is necessary to prepare and fit the boiler onto thehanging bracket – refer to the boiler installation instructions.
• Fit the elbow (3) to the boiler by inserting the spigot of the flueelbow into the flue socket on theboiler and secure using the 40mm air duct clamp (4) provided.
• Pull the air/flue duct back throughthe wall such that the flue ductfully engages into the flue elbowsocket.
• Fit the 70 mm air duct clamp (5)ensuring that it is positionedcentrally.
• Drill two holes 3 mm Ø throughthe air duct of both the elbow/flueand elbow/boiler clamps at themost convienient holes on the airduct clamps. (Ensure that the drilldoes not penetrate the inner flueduct). Screw the clamps to the airducts of the flue assembly, theelbow and boiler using the screws supplied.
• Slide the internal trim ring back tothe wall, securing in position witha small amount of sealant if required.
Caution!If installed near a light, insects mayfly into the opening. Tell thehomeowner to clean the openingregularly.
150
13
3°
1
Fig. 3.6 LAS
Euro
B/S
001
/0G
B
PART
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT
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.
Fig. 3.7: Horizontal air/flue conduit
Preparation• Determine the installation site for
the boiler with reference to theinstallation and servicing instructions supplied with the boiler.
• Ensure that all installation and service clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.
• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of the template is vertical using a plumbline or spirit level.
Top outlet flue exiting to rear• For installations where the air/flue
duct is to be installed directly tothe rear of the boiler, the installation template details theposition of the flue exit hole forhorizontal top outlet installation.
Top outlet flue exiting to side• For installations where the air/flue
duct is to be installed to the side,the position of the flue exit holecan be determined by carefullylevelling across the wall from thecentre line of the air/flue ducthole marked on the template.
• The position of the flue exit holeshould allow the flue to be installed with a slight upwardslope of about 3° ± 1° (equivalentto 50 mm ± 20 mm per metre offlue duct). Calculate the requiredrise according to the flue lengthand mark the position of the flueexit hole.
3013
754
4865
3
* 87
5
4
2
1
Fig. 3.8
LAS
Euro
B/S
072
/0G
B
*
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro* = 125 mm ecoTEC
IMPORTANT:The air/flue duct is not concentricand the air duct has a slope of 1.5°(if the air flue duct is not cut). Thehole through the wall can thereforebe drilled horizontally with no slope.
Where extensions are used, thesemust be installed with a slope at 3° ±1° (equivalent to 50 mm ± 20 mmrise per metre length) to ensure thatcondensate dows not remain in thesleeve.
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 125 mmdiameter.Note: If access can be gained tothe proposed flue exit point fromoutside the dwelling, the hole canbe cut with a 107 mm core drilland the flue external wall seal fitted from outside the dwelling.
• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler.
This is dimension A.
• Cut the air duct and flue duct tothe lengths shown in (fig. 3.11).
• All flue sockets should pointtowards the terminal.
• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.Care should be taken not toscratch the white surface of the airduct.
• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 34 - 35.
• Secure the air duct sectionstogether by drilling a 3 mmdiameter hole through the locationhole in the end of the outer airduct. (Ensure that the drill doesnot pierce the inner flue duct).Secure the air ducts together usingthe screw provided.
1
2
*
* = 190 mm
Fig. 3.9 LAS
Euro
B/S
077
/187
A
B
A
87
Fig. 3.10 LAS
Euro
B/S
078
/0
13 mm
A + 22 mm
Fig. 3.11 LAS
Euro
B/S
076
/0
Rear exit
Side exit
*
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro* = 125 mm ecoTEC
* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro* = 125 mm ecoTEC PA
RT 1
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• Push the air/flue duct assembly(1) including the flexible externalseal through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall.
• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom.
• Slide the internal trim ring (2) overthe air duct until it is flush with thewall.
• At this stage it is necessary to prepare and fit the boiler onto thehanging bracket – refer to the boiler installation instructions.
• Fit the elbow (3) to the boiler by inserting the spigot of the flueelbow into the flue socket on theboiler and secure using the 30mm air duct clamp (4) provided.
• Pull the air/flue duct back throughthe wall such that the flue ductfully engages into the flue elbowsocket.
• Fit the 48 mm air duct clamp (5)ensuring that it is positionedcentrally.
• Drill two holes 3 mm Ø throughthe air duct of both the elbow/flueand elbow/boiler clamps at themost convienient holes on the airduct clamps. (Ensure that the drilldoes not penetrate the inner flueduct). Screw the clamps to the airducts of the flue assembly, theelbow and boiler using the screws supplied.
• Slide the internal trim ring back tothe wall, securing in position witha small amount of sealant if required.
Caution!If installed near a light, insects mayfly into the opening. Tell thehomeowner to clean the openingregularly.
13
87
1
Fig. 3.12 LAS
Euro
B/S
001
/0G
B
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INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT
Horizontal telescopic air/flue duct
Accy No.: 303 936(Length 0.4 - 0.61 m)
Contents of the accessory:• Horizontal telescopic air/flue duct• 87° elbow• 1 x 48 mm air duct clamp• 1 x 30 mm air duct clamp• Internal trim ring Ø 100• External wall seal.
Fig. 3.13: Horizontal air/flue conduit
Preparation• Determine the installation site for
the boiler with reference to theinstallation and servicing instructions supplied with the boiler.
• Ensure that all installation and service clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.
• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of the template is vertical using a plumbline or spirit level.
Top outlet flue exiting to rear• For installations where the air/flue
duct is to be installed directly tothe rear of the boiler, the installation template details theposition of the flue exit hole forhorizontal top outlet installation.
Top outlet flue exiting to side• For installations where the air/flue
duct is to be installed to the side,the position of the flue exit holecan be determined by carefullylevelling across the wall from thecentre line of the air/flue ducthole marked on the template.
• The position of the flue exit holeshould allow the flue to be installed with a slight upwardslope of about 3° ± 1° (equivalentto 50 mm ± 20 mm per metre offlue duct). Calculate the requiredrise according to the flue lengthand mark the position of the flueexit hole.
3013
405 - 610
4865
LAS
Euro
B/S
037
/0
3
* 87
5
4
2
1
Fig. 3.14
LAS
Euro
B/S
072
/0G
B
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro* = 125 mm ecoTEC
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IMPORTANT:The air/flue duct is not concentricand the air duct has a slope of 1.5°(if the air flue duct is not cut). Thehole through the wall can thereforebe drilled horizontally with no slope.
Where extensions are used, thesemust be installed with a slope at 3° ±1° (equivalent to 50 mm ± 20 mmrise per metre length) to ensure thatcondensate dows not remain in thesleeve.
*
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INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 125 mmdiameter.Note: If access can be gained tothe proposed flue exit point fromoutside the dwelling, the hole canbe cut with a 107 mm core drilland the flue external wall seal fitted from outside the dwelling.
• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler.
This is dimension A.
• Adjust the air duct and flue ductto the lengths shown in (fig.3.17).
• Secure the air duct sectionstogether by drilling a 3 mmdiameter hole through the locationhole in the end of the outer airduct (1). (Ensure that the drill doesnot pierce the inner flue duct).Secure the air ducts together usingthe screw (1) provided. Place theadhesive tape (2) across the gapin the telescopic extensions.(fig. 3.17)
• All flue sockets should pointtowards the terminal.
• Care should be taken not toscratch the white surface of the airduct.
• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 34 - 35.
1
2
*
* = 190 mm
Fig. 3.15 LAS
Euro
B/S
077
/1
87
A
B
A
87
Fig. 3.16 LAS
Euro
B/S
078
/0
1 2
A + 22 mm
Fig. 3.17
Rear exit
Side exit
*
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro* = 125 mm ecoTEC
* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro* = 125 mm ecoTEC
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INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT(TOP OUTLET)
• Push the air/flue duct assembly(1) including the flexible externalseal through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall.
• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom.
• Slide the internal trim ring (2) overthe air duct until it is flush with thewall.
• At this stage it is necessary to prepare and fit the boiler onto thehanging bracket – refer to the boiler installation instructions.
• Fit the elbow (3) to the boiler by inserting the spigot of the flueelbow into the flue socket on theboiler and secure using the 30mm air duct clamp (4) provided.
• Pull the air/flue duct back throughthe wall such that the flue ductfully engages into the flue elbowsocket.
• Fit the 48 mm air duct clamp (5)ensuring that it is positionedcentrally.
• Drill two holes 3 mm Ø throughthe air duct of both the elbow/flueand elbow/boiler clamps at themost convienient holes on the airduct clamps. (Ensure that the drilldoes not penetrate the inner flueduct). Screw the clamps to the airducts of the flue assembly, theelbow and boiler using the screws supplied.
• Slide the internal trim ring back tothe wall, securing in position witha small amount of sealant if required.
Caution!If installed near a light, insects mayfly into the opening. Tell thehomeowner to clean the openingregularly.
13
87
1
Fig. 3.18 LAS
Euro
B/S
001
/0G
B
PART
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ONC
ENTR
IC 6
0/10
0
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INSTALLATION OF THE BLACK TERMINAL KIT
Black terminal kit Accy. No.: 303 934
Contents of the accessory:• Black terminal• External wall seal
Fig. 3.19: Black kit
AssemblyBefore installing the flueduct• Use an 8 mm screwdriver to bend
the catches inwards (fig. 3.20).• Pull the terminal together with the
flue duct out of the air duct (fig.3.21).
• Unlock the catch between theterminal and the flue duct bytwisting them against each other(fig. 3.22).
• Pull the terminal off the flue duct.• Put the new terminal into the flue
duct and click the lock.
☞ Please note: The catch on the topof the terminal must lock firmlyinto the notch in the flue duct(fig. 3.23).
☞ Please note: Make sure the sealfits tightly.
• Push the flue duct and the terminalback into the air duct and lock thetwo catches (fig. 3.24).
Caution!The seam of the air duct must be atthe top.
• Fit the horizontal air/flue duct asdescribed on pages 18 and 21.
Fig. 3.22: Unlocking the catch
Fig. 3.21: Pulling out the terminal
Fig. 3.20: Releasing the catches
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INSTALLATION OF THE BLACK TERMINAL KIT
Fig. 3.24: Locking the catch
Fig. 3.23: Flue duct
AssemblyAfter installing the flueduct
Danger!Before starting work, shut down theappliance and prevent it from beingswitched on unintentionally.
• Remove the wall seal from theterminal.
• Use an 8 mm screwdriver to bendthe catches inwards (fig. 3.20).
• Pull the terminal together with theflue duct out of the air duct (fig.3.21).
Caution!Do not twist the flue duct, becausethis might detach the following flueduct behind the terminal from thespacer.
• Unlock the catch between theterminal and the flue duct bytwisting them against each other(fig. 3.22).
• Pull the terminal off the flue duct.• Push the new terminal into the flue
duct and click the lock.
☞ Please note: The catch on the topof the terminal must lock firmlyinto the notch in the flue duct (fig.3.23).
☞ Please note: Make sure the sealfits tightly.
• Push the flue duct with theterminal back in the air duct.Carefully push the flue duct backinto the sleeve of the pipe or bendbehind it. Lock the two catches(fig. 3.24).
• Fit the wall seal.
Danger!Before starting up the appliance,check that the entire flue pipe isfirmly seated and sealed.
834449_05GB_022005.qxd 02.02.2005 17:12 Uhr Seite 25
Contents of the kit:• Variable terminal• 2 x 1m pipe• 3 x pipe support clips• 87° bend with bird protection
grille
Important: The sleeve of the wall connectormust face directly upwards.
Fig. 4.1: Variable termination kit
Assembly
Before installing the fluepipe• Use an 8 mm screwdriver to bend
the catches inwards (fig. 4.3).• Pull the terminal with the flue duct
out of the air duct (fig. 4.4).
Fig. 4.4: Pulling out the variable terminal
Fig. 4.3: Releasing the catch
55
Fig. 4.2
Flue Terminal ClearancesPlease refer to the boiler installationinstructions for guidance about flueterminal clearances.
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• Unlock the catch between theterminal and the flue duct bytwisting them against each other(fig. 4.5).
• Pull the terminal out of the flueduct.
• Push the variable terminal onto theflue duct.
☞ Please note: The catch on the topof the variable terminal must lockfirmly into the notch in the flueduct (fig. 4.6).
Caution!Make sure the seal fits tightly.
• Push the flue duct and the variableterminal back into the air ductand lock the two catches(fig. 4.7).
☞ Please note: The seam of the airduct must be at the top.
• Fit the horizontal ait/flue duct asdescribed on pages 18 and 21.
Caution!It cannot be fitted from inside.
• Fit the rest of the variabletermination kit as described onpage 28.
INSTALLATION OF THE VARIABLE TERMINATION KIT
Fig. 4.7: Locking the catch
Fig. 4.6: Flue pipe
Fig. 4.5: Unlocking the catch
AssemblyAfter installing the flueductDanger!Before starting work, shut down theappliance and prevent it from beingswitched on unintentionally.
• Remove the wall seal from theterminal.
• Use an 8 mm screwdriver to bendthe catches inwards (fig. 4.3).
• Pull the terminal with the flue ductout of the air duct (fig. 4.4).
Caution!Do not twist the flue duct, becausethis might detach the following flueduct behind the terminal from thespacer.• Unlock the catch between the
terminal and the flue duct bytwisting them against each other(fig. 4.5).
• Pull the terminal out of the flueduct.
• Push the new variable terminalonto the flue duct.
☞ Please note: The catch on the topof the variable terminal must lockfirmly into the notch in the flueduct (fig. 4.6).
☞ Please note: Make sure the sealfits tightly.
• Push the flue duct with thevariable terminal back in the airduct. Carefully push the flue ductback into the sleeve of the duct orbend behind it. Lock the twocatches (fig. 4.7).
• Fit the wall seal on the variableterminal.
• Fit the rest of the VTK asdescribed on page 28.
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INSTALLATION OF THE VARIABLE TERMINATION KIT
• Fit the pipes and bends, workingfrom the variable terminal to theselected location for the flue exitusing support clips supplied fig4.8, 4.9, 4.10 or 4.11.
Caution!Pipe extensions must be fixed to thewall using pipe clamps. Use oneclamp for each extension directlybeside the sleeve. Fit another clampto the extension after each 87° bend (fig. 4.9).
Caution!The extension pipe expands whenheated. Leave 1 cm expansion space in eachsleeve.
☞ Please note: The maximum fluelengths where the variabletermination kit is installed areshown in the tables on pages 11and 12.
☞ Please note: The parts are simplypushed together (not bolted).
Caution!Fasten the 87° bend with birdprotection grille using a separatepipe clamp (fig. 4.9).
Caution!If installed near a light, insects mayfly into the opening. Tell thehomeowner to clean the openingregularly.
Danger!Before starting up the appliance,check that the entire flue pipe isfirmly seated and sealed.
Caution!During annual maintenance, checkthe flue system for- visible defects, such as
embrittlement or damage- tight connection of the pipes- dirt in the air intake and flue exits
due to leaves, insects etc.
Fig. 4.9: Bird protection grille
Fig. 4.8: Basic installation
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Fig. 4.11: Support clips with 45° bends
INSTALLATION OF THE VARIABLE TERMINATION KIT
Fig. 4.10: Support clips with 87° bend
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Routing around roofeavesWhen routing the variabletermination kit around the roof eaves,additional lengths of M8 threadedbar will be required for the supportbrackets. Threaded bar can bepurchased from most local merchants.
• Change the bird protection grillefrom the 87° elbow to theextension installed at the end.
☞ When using the 87° elbow, put inthe seal from the extension.
• The extension installed at the endmust be fixed to the wall using 2support clips with a minimaldistance of 400 mm.
min
400
mm
Fig. 4.12: Routing around roof eaves
30
INSTALLATION OF THE VARIABLE TERMINATION KIT
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31
40
1435
550
880
Vertical air/flue duct Accy. No.: 303 900 (black)
Contents of the accessory:• Vertical air/flue duct and terminal
assembly• 40 mm air duct clamp• Fixing bracket
☞ See page 6 et seq. for details ofair/flue duct elements.
☞ Observe the maximum fluelengths as detailed in table onpage 11.
Fig. 5.1: Vertical roof duct
The air/flue duct assembly may beconnected directly to the flue outleton top of the boiler.
In addition to the vertical air/flueduct and terminal accessory, air/flueduct extensions can be added toincrease the length of the flue.
Preparation
• Determine the installation site forthe boiler with reference to theinstallation and servicinginstructions supplied with theboiler.
• Ensure that all installation andservice clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.
• Determine the point where thevertical air/flue duct and terminalassembly will penetrate the roof.
☞ Please note: The vertical air/flueduct and terminal accessory(Accy. No. 303 900) may beshortened. The outer ‘white’ ductshould be shortened first, then theinner flue duct cut so that itprotrudes 13 mm out of the airduct. In case of installationdirectly to the boiler withoutelbows or bends, it is essentialthat the roof tile/collar is verticallyaligned with the air/flue duct ofthe boiler.
☞ Please note: If a 87° elbow isconnected directly to the boiler,use the 40 mm air duct clampsupplied with the vertical air flueduct at this position (fig. 5.2).
INSTALLATION OF THE VERTICAL AIR/FLUE DUCT
5
40
Fig. 5.2: 40 mm air duct clamp
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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT
Pitched roof installation• Determine the point where the
vertical air/flue duct and terminalassembly will penetrate the roof.
• Fit the flexible pitched roof (Accy.No. 303 980) tile (1).
• Working from above, insert thevertical roof duct (5) through theroofing tile and push it firmly intoplace.
• Vertically align the roof duct andattach it to the roof structure withthe fixing bracket (6) supplied.
• Fit the boiler hanging bracket (2).• Install the appliance (3) with
reference to the installation andservicing instructions supplied withthe boiler.
☞ See pages 34 et seq. for furtherdetails on the installation ofextensions and elbows.
• Push the sliding sleeve (4) firmlyinto place on the extension.
• Join the vertical roof duct (5) tothe extension (7).
• Join the sliding sleeve (4) to theappliance’s connection piece (8).This permits easy separationbetween the air/flue duct and theappliance.
• Drill two holes 3 mm Ø throughthe air duct of the flue/boilerclamp at the most convienientholes on the air duct clamp.(Ensure that the drill does notpenetrate the inner flue duct).Screw the clamp to the air ductsof the flue assembly and the boilerusing the screws supplied.
• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.
• Note: The air/duct clamp must notbe screwed to the bottom of thevertical air/flue duct and terminalaccessory to allow for any slightmovement in the roof structure.
• Ensure that at least one pipeclamp supports the air/flue ductat each extension fitted.
750
2
3
550
885
Ø100
20 –
50
6
7
8
1
0 - 5
8
4
100-
110
5
Fig. 5.3: Fitting the appliance and the vertical roof duct to a building with a pitched roof
*
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro* = 125 mm ecoTEC
750
mm
eco
MA
Xco
mbi
natio
n an
d sy
stem
boi
lers
530
mm
eco
MA
X pr
o (to
p ho
les
of b
rack
et)
622
mm
eco
TEC
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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT
885
warm roofcold roof
550
Ø100
≥120
2
1
6
7
750
5
7
410
0- 1
10
Fig. 5.4: 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 terminalassembly will penetrate the roof.
• Fit the flat roof penetration collar(1).
• Stick the flat roof penetrationcollar firmly into place withadhesive in accordance with thecodes of practice for flat roofs (CP 144) to ensure a watertightseal.
• Working from above, insert thevertical roof duct (5) through theflat roof collar and push it firmlyinto place.
• Vertically align the roof duct andattach it to the roof structure withthe fixing bracket (6) supplied.
• Fit the boiler hanging bracket (2).• Install the appliance (3) with
reference to the installation andservicing instructions supplied withthe boiler.
☞ See pages 34 et seq. for furtherdetails on the installation ofextensions and elbows.
• Push the sliding sleeve (4) firmlyinto place on the extension.
• Join the vertical roof duct (5) tothe extension (7).
• Join the sliding sleeve (4) to theappliance’s connection piece (8).This permits easy separationbetween the air/flue duct and theappliance.
• Drill two holes 3 mm Ø throughthe air duct of the flue/boilerclamp at the most convienientholes on the air duct clamp.(Ensure that the drill does notpenetrate the inner flue duct).Screw the clamp to the air ductsof the flue assembly and the boilerusing the screws supplied.
• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.
• Note: The air/duct clamp must notbe screwed to the bottom of thevertical air/flue duct and terminalaccessory to allow for any slightmovement in the roof structure.
• Ensure that at least one pipeclamp supports the air/flue ductat each extension fitted.
750
mm
eco
MA
Xco
mbi
natio
n an
d sy
stem
boi
lers
530
mm
eco
MA
X pr
o (to
p ho
les
of b
rack
et)
622
mm
eco
TEC
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FITTING AIR/FLUE DUCT EXTENSIONS
How to add extensions
Use a saw, tin-snips, etc. to cut tubesto size.
☞ No tools are required whenseparating extensions for cutting tosize air and flue tubes separately.When doing so, the flue conduitshould be twisted into a positionwhere the shoulders on the plastictube can be pushed through thespacer-piece. After cutting to size,refit the flue conduit and secure itto the air conduit.
Tip:Start by measuring the requiredlength of air conduit* (Lair), and thencalculate the corresponding length offlue conduit (Lexhaust) as follows:
Lexhaust = Lair + 40 mm
Lexhaust = length of flue conduitLair = length of air conduit
* Minimum length of air-conduitextension: 80 mm.
1
2
13
2
70L air
Lexhaust
1.
2.
+ 40 mm
27
1
Fig. 6.1: Cutting tubes to size
☞ The seals are sensitive to mineraloil-based grease products. For thisreason, the seals must not begreased. If the seals need wettingto aid in installation, use wateronly.
☞ De-burr and file down any roughedges on the tubes before fitting inorder to prevent damage to theseals. Remove all metal filings andother debris.
☞ Do not use damaged or dentedtubes, as they will not form anadequate seal.
☞ Ensure that the seals remaincorrectly aligned when installingthe tubes. Do not fit damagedseals.
☞ Secure the exhaust conduit withthe fixing device in order to ensurethat it is correctly centred relativeto the air conduit.
Fig. 6.2: Loosening the flue conduit GU
_LA
Z 29
0/1
Important:You must fasten extensions to theceiling or wall using pipe clamps.Use one clamp for each extension.
Important:Where extensions are used, thesemust be installed with a slope of 3°±1° to ensure that condensate doesnot remain in the sleeve (equivalentto 50 mm ± 20 mm rise per metrelength).
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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 6.2: Length of surplus with 45° bends
Offset Length of Height[in mm] air conduit [in mm]
[in mm]
How to install elbowsAccy. No.: 303 911Example:
An offset of 400 mm is measured.This value is then used, along with thetable below, to determine the lengthof the air conduit (= 284 mm) and theheight (= 420 mm).
Important:This gives a correspondingexhaust-conduit length of 284 + 40 = 324 mm.
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CONTENTS: PART 2 CONCENTRIC 80/125
Page
The air/flue duct must be installed by a suitablyqualified service provider, which is responsiblefor observing the relevant specifications,regulations and standards.
Requirements
Planning the air/flue duct layout
Regulations and standards to be observed 38
Alternative termination accessories available 39Maximum flue lengths for ecoMAX 42Maximum flue lengths for ecoTEC 43
Changing the applianceconnection piece
§
45
Installation of the vertical air/flue duct 52
Installation of the horizontal air/flue duct 47
Fitting air/flue duct extensions
Installation of the sliding sleeve
How to add extensions 55How to install elbows 56
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REQUIREMENTS
Regulations andstandards to beobserved
§
☞ Vaillant ecoMAX/ecoTEC boilersare certified as heating boilerswith corresponding flue systems according to EC Directive90/396/EEC on gas-fireddevices. This installation manual iscovered by this certification and isreferred to in the design approvaltest certificate.
☞ These instructions should be readin conjunction with the instructionsfor installation and servicing supplied with the boiler.
☞ Ensure also that all legislation,rules, regulations and directivesmentioned in the installationinstructions are observed.
☞ The installation of the boiler andits flue must be carried out by acompetent person who is registered with CORGI (TheCouncil for Registered GasInstallers).
☞ The installation of the boiler andflue must be in accordance withthe Gas Safety (Installation andUse) Regulations 1998 and theBuilding Regulations and BS 5440 Part 1.
☞ The requirements for flue termination detailed in the boilerinstallation instructions must beobserved.
☞ The air/flue duct operates at verylow temperatures therefore noclearance is necessary betweenthe air duct and adjacent services.
☞ Ensure while installation work isbeing carried out that no debrissuch as swarf, filings or fragmentsof mortar are allowed to remainin the air/flue duct.
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Alternative terminationaccessories available
303 200 = Vertical air/flue duct (black)
303 209 = Horizontal air/flue duct
303 907 = Appliance connection piece for ecoMAX only303 926 = Appliance connection piece for ecoTEC and ecoMAX
Optional connection accessories Accy. No.303 200
Air/flue duct extensions (PPs), concentric470 mm - Ø 80/125 303 202 x
Air/flue duct extensions (PPs), concentric970 mm - Ø 80/125 303 203 x
Air/flue duct extensions (PPs), concentric1970 mm - Ø 80/125 303 205 x
Bends (PPs), concentric (pack of 2)45° - Ø 80/125 303 211 x
Elbow (PPs), concentric87° - Ø 80/125
303 210 x
Flue support clips (pack of 5), Ø 125 303 616 x
Sliding sleeve (PPs) Ø 80/125 303 215 x
Adjustable roof tiles for pitched roof 009076 black x
Flat roof penetration collar 009 056 x
303 209
x
x
x
x
x
x
x
x
x
Flexible pitched roof seal 303 980 x
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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.
Flexible pitched roof seal (black)Vaillant Accy. No.: 303 980
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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. permittedconcentricflue length
14.0 m
13.0 mincl.
1 elbow 87°
31.0 m 20.0 m
30.0 mincl.
1 elbow 87°
20.0 mincl.
1 elbow 87°
27.0 m
25.0 mincl.
1 elbow 87°
613/2 E 618/2 E 622/2 E pro 18 Epro 28 E
ecoMAX
Maximum length of flue is reduced by 2.5 m for each additional 90° elbow.
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 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. permittedconcentricflue length
26.0 m
25.0 mincl.
1 elbow 87°
22.0 m
21.0 mincl.
1 elbow 87°
29.0 m
30.0 mincl.
1 elbow 87°
824/2 E 828/2 E 635/ E835/ E
ecoMAX
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 90° elbow
Maximum length of flue is reduced by 1.0 m for each additional 45° elbow
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PLANNING THE AIR/FLUE DUCT LAYOUT
Maximum flue lengths for use with ecoTEC
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Accessories Accy. No.
Vertical flue systems
303 200 Max. permitted concentric flue length
Horizontal flue systems
303 209 Max. permittedconcentricflue length
14.0 m
13.0 mincl.
1 elbow 87°
27.0 m 27.0 m
25.0 mincl.
1 elbow 87°
25.0 mincl.
1 elbow 87°
14.0 m
13.0 mincl.
1 elbow 87°
plus 612 plus 615 plus 618 plus 624
ecoTEC
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.
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
Accessories Accy. No.
Vertical flue systems
303 200 Max. permitted concentric flue length
Horizontal flue systems
303 209 Max. permittedconcentricflue length
27.0 m
25.0 mincl.
1 elbow 87°
27.0 m 27.0 m
25.0 mincl.
1 elbow 87°
25.0 mincl.
1 elbow 87°
27.0 m
25.0 mincl.
1 elbow 87°
plus 630 plus 824 plus 831 pro 28
ecoTEC
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 90° elbow
Maximum length of flue is reduced by 1.0 m for each additional 45° elbow
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PLANNING THE AIR/FLUE DUCT LAYOUT
Maximum flue length
Max
imum
flue
leng
th
LAS
Euro
B/S
074
/0LA
S Eu
ro B
/S 0
74/0
Fig. 1.10
Fig. 1.9
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CHANGING THE APPLIANCE CONNECTION-PIECE
1
2
Fig. 2.0: Fitting the appliance connection-piece
InstallationAccy No.: 303 907 for ecoMAXonlyAccy No.: 303 926 for ecoTEC andecoMAX
The appliance is supplied ready-fittedwith the connection-piece for the60/100 air/flue duct system.
• Loosen the four screws (2) andpull the appliance connection-piece (1) upwards to remove it.
• Push the appliance connection-piece with the selected connectiondiameter down from above,inserting the push-in end onto thesleeve of the flue collectingchamber. Now push theappliance connection-piecedownwards until the flange comesinto contact with the low-pressurechamber.
• Refit the fixing screws (2).
The seals are sensitive tomineral oil-based greaseproducts. For this reason, the seals mustnot be greased. If the sealsneed wetting to aid ininstallation, use water only.
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INSTALLATION OF THE SLIDING SLEEVE
Fig. 3.0: Installing the sliding sleeve
1
34
675
2
Schi
ebem
uffe
_neu
INSTALLING THEAIR/FLUE DUCT SLIDINGSLEEVE☞ NOTE:
For installations where there is in-sufficient movement to allow fittingof the flue into flue outlet, a slid-ing sleeve (Accy. No. 303 215) isavailable. When using the slidingsleeve both the air and flue ductsof the last extension must beshortened by a further 85 mm.
• Push the sliding sleeve (1) over thecut end of the flue duct (2).
• Place the air duct clamp (7) overthe air duct.
• Pull back the sliding sleeve so thatit engages into the socket (3) ofthe boiler (4). Ensure that thesliding sleeve penetrates thesocket such that there is at least20 mm engagement at both endsof the sliding sleeve.
• Fit the air duct clamp over the airducts (5 and 6) of theextension/terminal and boileroutlet. Close the snap clamp.
• Drill two holes 3 mm diameterthrough the air duct clamp (thecentre of the holes should be 6mm from the edge of the clamp).Ensure that the drill does notpenetrate the inner flue duct.Screw the air duct clamp to theair duct of the sleeve using thescrews provided.
• Complete the installation of theflue as detailed in theseinstructions.
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT
☞ Observe the maximum fluelengths as detailed in table onpage 42.
70
1103
70
15
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 • 1 x internal plastic ring Ø 125• 1 x external metal plate
☞ See page 39 et seq. for details ofair/flue duct elements.
Fig. 4.1: Horizontal air/flue conduit
GU
_LA
Z 82
/0
Fig. 4.2: Example of installation with horizontal air/flue duct
IMPORTANT:The air/flue duct is not concentricand the air duct has a slope of 1.5°(if the air flue duct is not cut). Thehole through the wall can thereforebe drilled horizontally with no slope.
Where extensions are used, thesemust be installed with a slope at 3° ±1° (equivalent to 50 mm ± 20 mmrise per metre length) to ensure thatcondensate dows not remain in thesleeve.
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Side flue installations• For installations where the air/flue
duct is to be installed to the side,the position of the flue exit holecan be determined as follows:
• Identify the correct measurementas shown in fig. 4.3, carefullymeasure the distance from the bottom centre of the boiler hanging bracket (centreline of thetwo lower hanging bracket fixingholes). This gives the position ofthe centreline of the 127 mm flueelbow and adaptor when installed.
• The position of the flue exit holecan be determined by carefullylevelling across the wall from thismark.
• The position of the flue exit holeshould allow the flue to be installed with an upwards slopetowards the terminal of approximately 3° ± 1°, equivalentto 50 mm ± 20 mm rise per metreof flue length. Calculate therequired rise according to the fluelength and mark the position ofthe flue exithole.
Note: Due to the long lengths of fluepossible and the slope required, itmay be necessary to adjust the location of the boiler installation template. Please check that both theboiler installation site and flue termination are in accordance withthese instructions prior to drilling anyholes for the boiler hanging bracket.• Once the position of the flue exit
hole has been determined, thehole should be cut through thewall using a core drill of 127 mmdiameter. The flue exit hole shouldbe cut with a rise towards outsideof 3°.
• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 4.5).This is dimension A.
• For installations where the measured distance dimension A(fig. 4.5) is greater than 960 mm,an air/flue extension accessorywill be required. The number ofair/flue duct extensions which canbe used depends on the boiler.
Preparation• Determine the installation site for
the boiler with reference to theinstallation and servicing instructions supplied with the boiler.
• Ensure that all installation and service clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.
• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of thetemplate is vertical using a plumbline or spirit level.
1
2
*
* = 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 WITHEXTENSIONS
* = 190 mm ecoMAX combination and system boilers* = 176 mm ecoMAX pro* = 125 mm ecoTEC
*
* = 253 mm ecoMAXcombination and system boilers
* = 210 mm ecoMAX pro(from top holes on bracket)
* = 238 mm ecoTEC
IMPORTANT:The air/flue duct is not concentricand the air duct has a slope of 1.5°(if the air flue duct is not cut). Thehole through the wall can thereforebe drilled horizontally with no slope.
Where extensions are used, thesemust be installed with a slope at 3° ±1° (equivalent to 50 mm ± 20 mmrise per metre length) to ensure thatcondensate dows not remain in thesleeve.
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITHEXTENSIONS
• Taking each extension to be used,fit the flue duct into the air ductand secure using the 3 screwsprovided.
• For ease of measuring and marking the air/flue duct extensions, assemble them looselytogether with the air/flue duct andterminal assembly as shown(fig. 4.6).
Note: The joints between the flue ductsections are of a push-fit type, withthe flue duct spigot inserted into asocket containing a sealing ring. Forease of installation lubricate the sealusing soap solution prior to assembling.• Assemble the flue such that there
is a gap of about 10 mm betweeneach air duct, which will ensurethe correct flue duct penetrationinto the flue sockets of 30 mm. All flue sockets should pointtowards the flue terminal.
• Measure from the flue terminaland mark the air duct to a lengthof:Dimension A + 60 mm
• Take the extension(s) to be shortened and remove the3 screws. Separate the ducts.
Note: For assembly reasons do notshorten any air duct to a length ofless than 100 mm. If necessary shorten two adjacent extensions toachieve the overall required length.• Cut the air duct square and
remove any burrs.• Refit the flue duct into the air duct
and secure using the 3 screws.• Cut the flue duct as detailed in
fig. 4.7.• When cutting the air and flue
ducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.
• Care should be taken not toscratch the white surface of the airduct.
• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 55 - 56.
• At this stage it is necessary toprepare and fit the boiler onto thehanging bracket – refer to theboiler installation instructions.
• Fit the appliance flue outletadaptor to the boiler.
A
Fig. 4.5 LAS
Euro
B/S
082
/0
10 mm
Mark air duct here
Dimension A + 20 mm
Fig. 4.6 LAS
Euro
B/S
084
/0
25 mm
Mark flue duct here
15 mm
Fig. 4.7 LAS
Euro
B/S
080
/0
Dimension A + 60 mm
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220
15
3°
1
Fig. 4.8: Installing the horizontal wall duct LGU
_LA
Z 38
4/0_
IT
• Push the assembled air/flue ductand terminal assembly through theflue exit hole until it protrudes 220 mm out from the outsidewall.
• Ensure that the terminal is correctly positioned with the airinlet grille at the bottom.
• Slide one of the two trim ringsover the air duct until it is flushwith the internal wall face.
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITHEXTENSIONS
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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (80/125 Ø)
8
82 - 90
253
7
4
2
3
6
750
Fig. 4.9: Indirect installation
Indirect installation• Fit the wall mounting (2).• Install the appliance (3) with
reference to the installation andservicing instructions supplied withthe boiler.
• Change the appliance connection-piece (4) as described onpage 28.
• Join the 87° elbow to theappliance connection piece.
• Push the sliding sleeve (7) firmlyinto place on the appropriateextensions (6).
• Install the extensions and join theclutch sleeve to the 87° elbow.
☞ This section functionssubsequently as a separationpoint.
• Join all separation points with theair-conduit fixing collars (8).
☞ See pages 55 et seq. for furtherdetails on the installation ofextensions and elbows.
**
*
* = 750 mm ecoMAXcombination and system boilers
* = 530 mm ecoMAX pro(from top holes on bracket)
* = 622 mm ecoTEC
** = 253 mm ecoMAXcombination and system boilers
** = 210 mm ecoMAX pro(from top holes on bracket)
** = 238 mm ecoTEC
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1530
880
70
650
Vertical air/flue duct Accy. No.: 303 200 (black)
Contents of the accessory:• Vertical air/flue duct and terminal
assembly• Adapter (air) for Ø 110/125• 70 mm air duct clamp• Fixing bracket
☞ See page 39 et seq. for details ofair/flue duct elements.
☞ Observe the maximum fluelengths as detailed in table onpage 42.
Fig. 5.1: Vertical roof duct GU
_LA
Z 81
/0
The air/flue duct assembly may beconnected directly to the flue outleton top of the boiler.
In addition to the vertical air/flueduct and terminal accessory, air/flueduct extensions can be added toincrease the length of the flue.
Preparation
• Determine the installation site forthe boiler with reference to theinstallation and servicinginstructions supplied with theboiler.
• Ensure that all installation andservice clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.
• Determine the point where thevertical air/flue duct and terminalassembly will penetrate the roof.
☞ Please note: The vertical air/flueduct and terminal accessory (Accy.No. 303 200) may be shortened.The outer ‘white’ duct should beshortened first, then the inner flueduct cut so that it protrudes 15 mmout of the air duct. In case ofinstallation directly to the boilerwithout elbows or bends, it isessential that the roof tile/collar isvertically aligned with the air/flueduct of the boiler.
INSTALLATION OF THE VERTICAL AIR/FLUE DUCT
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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT
750
2
3
790
740
Ø125
20 –
50°
5
6
8
*
7
1
0 - 5
8
4
82 -
90
Fig. 5.2: Fitting the appliance and the vertical roof duct to a building with a pitched roof
Pitched roof installation• Determine the point where the
vertical air/flue duct and terminalassembly will penetrate the roof.
• Fit the adjustable pitched roof tile(1).
• Working from above, insert thevertical roof duct (5) through theroofing tile and push it firmly intoplace.
• Vertically align the roof duct andattach it to the roof structure withthe fixing bracket (6) supplied.
• Fit the boiler hanging bracket (2).• Install the appliance (3) with
reference to the installation andservicing instructions supplied withthe boiler.
☞ See pages 55 et seq. for furtherdetails on the installation ofextensions and elbows.
• Push the sliding sleeve (4) firmlyinto place on the extension.
• Join the vertical roof duct (5) tothe extension (7).
• Join the sliding sleeve (4) to theappliance’s connection piece (8).This permits easy separationbetween the air/flue duct and theappliance.
• Drill two holes 3 mm Ø throughthe air duct of the flue/boilerclamp at the most convienientholes on the air duct clamp.(Ensure that the drill does notpenetrate the inner flue duct).Screw the clamp to the air ductsof the flue assembly and the boilerusing the screws supplied.
• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.
• Note: The air/duct clamp must notbe screwed to the bottom of thevertical air/flue duct and terminalaccessory to allow for any slightmovement in the roof structure.
• Ensure that at least one pipeclamp supports the air/flue ductat each extension fitted.
* = 190 mm ecoMAXcombination and system boilers
* = 176 mm ecoMAX pro* = 125 mm ecoTEC
750
mm
eco
MA
X co
mbi
natio
n an
d sy
stem
boi
lers
530
mm
eco
MA
X pr
o(to
p ho
les
of b
rack
et)
622
mm
eco
TEC
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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT
880
warm roofcold roof
650
Ø125
≥120
2
1
5
6
7
750
7
4
82 -
90
Fig. 5.3: Fitting the appliance and vertical flue duct to a building with a flat roof
Flat-roof installation• Determine the point where the
vertical air/flue duct and terminalassembly will penetrate the roof.
• Fit the flat roof penetration collar(1).
• Stick the flat roof penetrationcollar firmly into place withadhesive in accordance with thecodes of practice for flat roofs (CP 144) to ensure a watertightseal.
• Working from above, insert thevertical roof duct (5) through theflat roof collar and push it firmlyinto place.
• Vertically align the roof duct andattach it to the roof structure withthe fixing bracket (6) supplied.
• Fit the boiler hanging bracket (2).• Install the appliance (3) with
reference to the installation andservicing instructions supplied withthe boiler.
☞ See pages 55 et seq. for furtherdetails on the installation ofextensions and elbows.
• Push the sliding sleeve (4) firmlyinto place on the extension.
• Join the vertical roof duct (5) tothe extension (7).
• Join the sliding sleeve (4) to theappliance’s connection piece (8).This permits easy separationbetween the air/flue duct and theappliance.
• Drill two holes 3 mm Ø throughthe air duct of the flue/boilerclamp at the most convienientholes on the air duct clamp.(Ensure that the drill does notpenetrate the inner flue duct).Screw the clamp to the air ductsof the flue assembly and the boilerusing the screws supplied.
• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.
• Note: The air/duct clamp must notbe screwed to the bottom of thevertical air/flue duct and terminalaccessory to allow for any slightmovement in the roof structure.
• Ensure that at least one pipeclamp supports the air/flue ductat each extension fitted.
750
mm
eco
MA
X co
mbi
natin
and
syste
m b
oile
rs53
0 m
m e
coM
AX
pro
(top
hole
s of
bra
cket
)62
2 m
m e
coTE
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FITTING AIR/FLUE DUCT EXTENSIONS
How to add extensions
Use a saw, tin-snips, etc. to cut tubesto size.
☞ No tools are required whenremoving previously-fittedextensions for cutting to size airand flue tubes separately. Whendoing so, the flue conduit shouldbe twisted into a position wherethe shoulders on the plastic tubecan be pushed through the spacer-piece. After cutting to size, refitthe flue conduit and secure it tothe air conduit.
Tip:Start by measuring the requiredlength of air conduit* (Lair), and thencalculate the corresponding length offlue conduit (Lexhaust) as follows:
Lexhaust = Lair + 40 mm
Lexhaust = length of flue conduitLair = length of air conduit
* Minimum length of air-conduitextension: 100 mm.
1
2
15
1 2
70
L air
Lexhaust
1.
2.
+ 40 mm
25
Fig. 6.1: Cutting tubes to size
☞ The seals are sensitive to mineraloil-based grease products. For thisreason, the seals must not begreased. If the seals need wettingto aid in installation, use wateronly.
☞ De-burr and file down any roughedges on the tubes before fitting inorder to prevent damage to theseals. Remove all metal filings andother debris.
☞ Do not use damaged or dentedtubes, as they will not form anadequate seal.
☞ Ensure that the seals remaincorrectly aligned when installingthe tubes. Do not fit damagedseals.
☞ Secure the exhaust conduit withthe fixing device in order to ensurethat it is correctly centred relativeto the air conduit.
Fig. 6.2: Loosening the flue conduit GU
_LA
Z 29
0/1
Important:You must fasten extensions to theceiling or wall using pipe clamps.Use one clamp for each extension.
Important:Where extensions are used, thesemust be installed with a slope of 3°±1° to ensure that condensate doesnot remain in the sleeve (equivalentto 50 mm ± 20 mm rise per metrelength).
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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 6.2: Length of surplus with 45° bends
Offset Length of Height[in mm] air conduit [in mm]
[in mm]
Hei
ght
Offset
Length
of ai
r con
duit 10
10
How to install elbowsAccy. No.: 303 211Example:
An offset of 400 mm is measured.This value is then used, along with thetable below, to determine the lengthof the air conduit (= 284 mm) and theheight (= 420 mm).
Important:This gives a correspondingexhaust-conduit length of 284 + 40 = 324 mm.