Vaillant ecoMAX 618/2 E User manual

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 ith ecoMAX
and ecoTEC boilers
834449_05GB_022005.qxd 02.02.2005 17:12 Uhr Seite 1

834449_05GB_022005.qxd 02.02.2005 17:12 Uhr Seite 2

OVERVIEW
PART 2 CONCENTRIC 80/125
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 CONCENTRIC 80/125 PART 1 CONCENTRIC 60/100
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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 for ecoMAX 11
Maximum 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 34
How to install elbows 35
14
Installation of the variable termination kit 26
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5
PART 1 CONCENTRIC 60/100
REQUIREMENTS
Regulations and
standards to be
observed
§
☞Vaillant ecoMAX/ecoTEC boilers
are certified as heating boilers
with corresponding flue systems
according to EC Directive
90/396/EEC on gas-fired devi-
ces. 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/ecoTEC
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.
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
303 936
Optional connection accessories
Telescopic offset section
Telescopic extension
440 mm - 690 mm Ø 60/100
6
PLANNING THE AIR/FLUE DUCT LAYOUT
Alternative termination accessories available
Air/flue duct extensions, concentric
470 mm - Ø 60/100
Air/flue duct extensions, concentric
970 mm - Ø 60/100
Air/flue duct extensions, concentric
1970 mm - Ø 60/100
Bends (PP), concentric (pack of 2)
45° - Ø 60/100
Elbow, concentric
87° - Ø 60/100
Flue support clips (pack of 5), Ø 100
Sliding sleeve (PP) Ø 60/100
Adjustable roof tiles for pitched roof
303 900 = Vertical air/flue duct (black)
303 930 = Horizontal air/flue duct (only ecoMAX)
303 933 = Horizontal air/flue duct
303 936 = Horizontal telescopic air/flue duct
Accy. No. 303 900
303 919
303 906
303 902
303 903
303 905
303 911
x
303 910
303 821
303 915
009076 black
x
x
x
x
x
x
x
x
x
303 930 303 933
Black terminal kit for horizontal air/flue duct 303 934
Adjustable flue support clips (pack of 3); Ø100 303 935 x
Variable termination kit - black *) 303 942
Extension pipe for variable termination kit VTK
Ø60 mm 1 m - black *) 303 943
87°elbow for variable termination kit - black *) 303 944
45°bend for variable termination kit - black (2 pieces) 303 945

Variable termination kit - white *) 303 946
Extension pipe for variable termination kit VTK
Ø60 mm 1 m - white *) 303 947
87°elbow for variable termination kit - white *) 303 949
45°bend for variable termination kit - white (2 pieces) 303 948

Flexible pitched roof seal 303 980 x
Flat roof penetration collar 009 056 x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
*) delivered with support clips
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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.: 303 821
☞Use one clip per extension to
support the air/flue duct.
18
27
18
27
18
27
Fig. 1.2: Elbow joints, Ø 60/100
Elbow, 87°, Ø 60/100
Vaillant Accy. No.: 303 910
Bends, 45° (pack of 2),
Ø 60/100
Vaillant Accy. No.: 303 911
Air/flue duct extension 470 mm
Ø 60/100
Vaillant Accy. No.: 303 902
Air/flue duct extension 970 mm,
Ø 60/100
Vaillant Accy. No.: 303 903
Air/flue duct extension 1970 mm,
Ø 60/100
Vaillant Accy. No.: 303 905
GU_LAZ 70/0
GU_LAZ 72/0
250
Fig. 1.4: Flue support clips, Ø 100
Adjustable flue support clips, Ø 100
(pack of 3)
Vaillant Accy. No.: 303 935
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8
PLANNING THE AIR/FLUE DUCT LAYOUT
155
Fig. 1.7: Sliding sleeve, Ø 60/100
Sliding sleeve (PP), Ø 60/100
Vaillant Accy. No.: 303 915
290 –374
33 –56
Fig. 1.6: Offset section, Ø 60/100
Offset section, Ø 60/100
Vaillant Accy. No.: 303 919
303919_IAx
498
132
255
Fig. 1.8: Adjustable roof tile for pitched roof
Adjustable roof tile for pitched roof
Vaillant Accy. No.: 009 076 (black)
GU_LAZ 41/0
440 –690
Fig. 1.5: Telescopic extension, Ø 60/100
Telescopic extension (PP), Ø 60/100
440 mm - 690 mm
Vaillant Accy. No.: 303 906
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9
153
130
390
Fig. 1.10: Flat roof penetration collar
Flat roof penetration collar
Vaillant Accy. No.: 009 056
PLANNING THE AIR/FLUE DUCT LAYOUT
Fig. 1.11: Black terminal kit
Fig. 1.12: Variable termination kit
Variable termination kit - black
Vaillant Accy. No.: 303 942
For 303 933 and 303 936 only
Variable termination kit - white
Vaillant Accy. No.: 303 946
For 303 933 and 303 936 only
Black terminal kit for horizontal
air/flue duct
Vaillant Accy. No.: 303 934
For 303 933 and 303 936 only
PART 1 CONCENTRIC 60/100
495
132
495
Fig. 1.9: Flexible pitched roof seal
Flexible pitched roof seal (black)
Vaillant Accy. No.: 303 980
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10
PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.15: 45° bend
45° bend for variable termination kit
- black
Vaillant Accy. No.: 303 945
45° bend for variable termination kit
- white
Vaillant Accy. No.: 303 948
Fig. 1.14: 87° elbow
87° elbow for variable termination kit
- black
including 1 support clip
Vaillant Accy. No.: 303 944
87° elbow for variable termination kit
- white
including 1 support clip
Vaillant Accy. No.: 303 949
Fig. 1.13: Extension Ø 60 1 m pipe
Extension pipe for variable
termination kit Ø 60 mm 1 m - black
including 1 support clip
Vaillant Accy. No.: 303 943
Extension pipe for variable
termination kit Ø 60 mm 1 m - white
including 1 support clip
Vaillant Accy. No.: 303 947
80
Flue support clip, Ø 60 mm
delivered with kits
Fig. 1.16: Flue support clip, Ø 60 mm
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Vertical
flue systems 303 900 Max. permitted
concentric
flue length
Fig. 1.18
12.0 m 10.0 m 7.0 m 10.0 m
9.0 m
Variable
termination
kit
303 942
303 946
only in
combina-
tion with
303 933
Max. permitted
concentric
flue length
Fig. 1.19
Horizontal
flue systems 303 930
303 933 Max. permitted
concentric
flue length
Fig. 1.17
8.0 m
incl.
1 elbow 87°
8.0 m
incl.
1 elbow 87°
4.0 m
incl.
1 elbow 87°
10.0 m
incl.
1 elbow 87°
7.0 m
incl.
1 elbow 87°
11
PART 1 CONCENTRIC 60/100
PLANNING THE AIR/FLUE DUCT LAYOUT
Maximum flue lengths for use with ecoMAX
Accessories Accy. No. 828/2 E 635/ E
835/ E pro 18 E pro 28 E
824/2 E
613/2 E
618/2 E
622/2 E
ecoMAX
Maximum length of flue is reduced by 1.0 m for each additional 87°elbow
Maximum length of flue is reduced by 0.5 m for each additional 45°elbow
The maximum permitted concentric flue length given above is reduced as
follows:
- Reduced by 0.5 m for the variable terminal
- Reduced by 0.5 m for every 1 m VTK pipe
- Reduced by 0.5 m for every 87°bend
- Reduced by 0.5 m for 2 x 45°bend
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

Max. permitted
concentric
flue length
Fig. 1.18
12.0 m 12.0 m 12.0 m
12.0 m
12
PLANNING THE AIR/FLUE DUCT LAYOUT
Variable
termination
kit
303 942
303 946
only in
combina-
tion with
303 933
Max. permitted
concentric
flue length
Fig. 1.19
Accessories Accy. No.
Horizontal
flue systems 303 933 Max. permitted
concentric
flue length
Fig. 1.17
8.0 m
incl.
1 elbow 87°
plus 630
plus 831 pro 28
8.0 m
incl.
1 elbow 87°
8.0 m
incl.
1 elbow 87°
plus 624
plus 824
8.0 m
incl.
1 elbow 87°
plus 612
plus 615
plus 618
ecoTEC
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 as
follows:
- Reduced by 0.5 m for the variable terminal
- Reduced by 0.5 m for every 1 m VTK pipe
- Reduced by 0.5 m for every 87°bend
- Reduced by 0.5 m for 2 x 45°bend
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13
PART 1 CONCENTRIC 60/100
Maximum flue length
Maximum flue length
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 length outside
Fig. 1.19: Horizontal flue system installed with vertical termination kit
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14
INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE
Fig. 2.0: Installing the sliding sleeve
1
34
6
7
5
2
Schiebemuffe_neu
INSTALLING THE
AIR/FLUE DUCT SLIDING
SLEEVE
☞NOTE:
For installations where there is in-
sufficient movement to allow fitting
of the flue into flue outlet, a slid-
ing 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 (5and 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.
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15
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT
Horizontal air/flue duct
Accy No.: 303 930
for 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 Ø100
•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.
40 13
70
800
95
LAS Euro B/S 037/0
3
* 150
2
4
1
5
Fig. 3.2
LAS Euro B/S 072/0GB
*
*= 190 mm ecoMAX
combination and system boilers
*= 176 mm ecoMAX pro
☞Observe the maximum flue
lengths as detailed in table on
page 11.
PART 1 CONCENTRIC 60/100
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16
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 (fig. 3.5).
•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 34 - 35.
•Secure the air duct sections
together by drilling a 3 mm
diameter hole through the location
hole in the end of the outer air
duct. (Ensure that the drill does
not pierce the inner flue duct).
Secure the air ducts together using
the screw provided.
1
2
*
* = 190 mm
Fig. 3.3
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 ecoMAX
combination and system boilers
*= 176 mm ecoMAX pro
*= 190 mm ecoMAX combination and system boilers
*= 176 mm ecoMAX pro
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17
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
•Push the air/flue duct assembly
(1) including the flexible external
seal through the wall until the
seal clears the outside face of the
wall and pull air/flue duct back
towards the boiler until the
external seal touches the outside
wall.
•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 (2) 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 (3) to the boiler by
inserting the spigot of the flue
elbow into the flue socket on the
boiler and secure using the 40
mm air duct clamp (4) provided.
•Pull the air/flue duct back through
the wall such that the flue duct
fully engages into the flue elbow
socket.
•Fit the 70 mm air duct clamp (5)
ensuring that it is positioned
centrally.
•Drill two holes 3 mm Øthrough
the air duct of both the elbow/flue
and elbow/boiler clamps at the
most convienient holes on the air
duct clamps. (Ensure that the drill
does not penetrate the inner flue
duct). Screw the clamps to the air
ducts of the flue assembly, the
elbow and boiler using the
screws supplied.
•Slide the internal trim ring back to
the wall, securing in position with
a small amount of sealant if
required.
Caution!
If installed near a light, insects may
fly into the opening. Tell the
homeowner to clean the opening
regularly.
150
13
3°
1
Fig. 3.6
LAS Euro B/S 001/0GB
PART 1 CONCENTRIC 60/100
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18
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 Ø100
•External wall seal.
Fig. 3.7: Horizontal air/flue conduit
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.
30 13
754
48
65
3
*87
5
4
2
1
Fig. 3.8
LAS Euro B/S 072/0GB
*
*= 190 mm ecoMAX
combination and system boilers
*= 176 mm ecoMAX pro
*= 125 mm ecoTEC
IMPORTANT:
The air/flue duct is not concentric
and the air duct has a slope of 1.5°
(if the air flue duct is not cut). The
hole through the wall can therefore
be drilled horizontally with no slope.
Where extensions are used, these
must be installed with a slope at 3°±
1°(equivalent to 50 mm ± 20 mm
rise per metre length) to ensure that
condensate dows not remain in the
sleeve.
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19
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 (fig. 3.11).
•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 34 - 35.
•Secure the air duct sections
together by drilling a 3 mm
diameter hole through the location
hole in the end of the outer air
duct. (Ensure that the drill does
not pierce the inner flue duct).
Secure the air ducts together using
the screw provided.
1
2
*
* = 190 mm
Fig. 3.9
LAS Euro B/S 077/1
87
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 ecoMAX
combination and system boilers
*= 176 mm ecoMAX pro
*= 125 mm ecoTEC
*= 190 mm ecoMAX combination and system boilers
*= 176 mm ecoMAX pro
*= 125 mm ecoTEC
PART 1 CONCENTRIC 60/100
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20
INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)
•Push the air/flue duct assembly
(1) including the flexible external
seal through the wall until the
seal clears the outside face of the
wall and pull air/flue duct back
towards the boiler until the
external seal touches the outside
wall.
•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 (2) 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 (3) to the boiler by
inserting the spigot of the flue
elbow into the flue socket on the
boiler and secure using the 30
mm air duct clamp (4) provided.
•Pull the air/flue duct back through
the wall such that the flue duct
fully engages into the flue elbow
socket.
•Fit the 48 mm air duct clamp (5)
ensuring that it is positioned
centrally.
•Drill two holes 3 mm Øthrough
the air duct of both the elbow/flue
and elbow/boiler clamps at the
most convienient holes on the air
duct clamps. (Ensure that the drill
does not penetrate the inner flue
duct). Screw the clamps to the air
ducts of the flue assembly, the
elbow and boiler using the
screws supplied.
•Slide the internal trim ring back to
the wall, securing in position with
a small amount of sealant if
required.
Caution!
If installed near a light, insects may
fly into the opening. Tell the
homeowner to clean the opening
regularly.
13
87
1
Fig. 3.12
LAS Euro B/S 001/0GB
834449_05GB_022005.qxd 02.02.2005 17:12 Uhr Seite 20