Vaillant turboMAX plus 2 E Series User manual

For the installer
Flue installation instructions
Air flue duct for use with
turboMAX plus .../2 E
turboMAX pro .../2 E
thermoCOMPACT .../2 E
aquaPLUS
PART 1:
Standard Concentric Systems
Ø 60/100
PART 2:
Optional Concentric Systems
Ø 80/125
GB

2
CONTENTS: PART 1 CONCENTRIC 60/100
Requirements
Planning the air/flue duct layout
4
Alternative termination accessories available 5
Maximum flue lengths Ø 60/100 9
Flue restrictor rings 10
Preparation 11
Top outlet flue exiting to rear 11
Top outlet flue exiting to side 11
Preparation 14
Preparation of boiler for rear outlet air/flue duct 16
Installation of the horizontal
air/flue duct (top outlet)
Fitting air/flue duct extensions
Page
§
25
Fitting air/flue duct extensions
between two 90° elbows
26
Fitting air/flue duct extensions
between two 45° elbows
27
Installing the air/flue duct sliding
sleeve
28
Installation of the vertical
roof duct
Installation of the horizontal
air/flue duct (rear outlet)
Preparation 19
Top outlet flue exiting to rear 19
Top outlet flue exiting to side 19
Preparation 22
Pitched roof 23
Flat roof 23
Pitched and flat roof installation 23
Installation of the Se-Duct flue

3
CONTENTS: PART 2 CONCENTRIC 80/125
Planning the air/flue duct layout Termination accessories available 29
Maximum flue lengths Ø 80/125 32
Flue restrictor rings 33
35
Preparation 37
Side flue installations 37
Fitting the appliance flue outlet
adapter to the boiler
Fitting air/flue duct extensions
Page
45
Fitting air/flue duct extensions
between two 90° elbows
46
Fitting air/flue duct extensions
between two 45° elbows
47
Installing the air/flue duct sliding
sleeve
48
Installation of the vertical
roof duct
Installation of the horizontal
air/flue with extensions
Preparation 39
Fitting extensions 40
Connect the flue assembly to the adaptor 40
Installation of the horizontal
air/flue duct and terminal
accessory (80/125)
Preparation 41
Pitched roof 42
Flat roof 42
Pitched and flat roof installation 42
Connect the flue assembly to the adaptor 44

§
REQUIREMENTS
4
☞Vaillant turboMAX,
thermoCOMPACT and aquaPLUS
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 turboMAX,
thermoCOMPACT and aquaPLUS
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.

Air/flue duct (adjustable) offset (33 -56 mm)
Ø 60/100
5
PART 1 CONCENTRIC 60/100
PLANNING THE AIR/FLUE DUCT LAYOUT
Alternative termination
accessories available
Optional connection accessories Accy. No.
303 807 303 806
Air/flue duct extension
500 mm - Ø 60/100 303 801 x x
Air/flue duct extension
1000 mm - Ø 60/100 303 802 x x
Telescopic air/flue duct extension
500 - 800 mm - Ø 60/100 303 804 x x
2 x 45° Bends
Ø 60/100 303 809 x x
90° Elbow
Ø 60/100 303 808 x x
Flue support clips (Pack of 5), Ø 100 303 821 x x
Air/flue duct extension
1960 mm - Ø 60/100 303 803 x x
Air/flue duct 15° offset
Ø 60/100 303 820
Sliding sleeve Ø 60/100 303 816 x x
Adjustable roof tile 9076
Flat roof collar-piece 9056
x x
303 810
x
x
x
x
x
x
x
x
x
303 800
x
x
x
x
x
x
x
x
x
x
x
303 807 = Horizontal air/flue duct with 90° elbow and
terminal (750 mm)
303 806 = Telescopic horizontal air/flue duct with 90° elbow and
terminal (450 - 650 mm; turboMAX and thermoCOMPACT only)
303 817 = Rear outlet flue and terminal (for wall thicknesses
200 mm to 305 mm; turboMAX and thermoCOMPACT only)
303 810 = Se-duct flue accessory
303 800 = Vertical air/flue duct and terminal accessory
x303 819 x x x

4
36
4
36
4
36
6
PLANNING THE AIR/FLUE DUCT LAYOUT
Fig. 1.1: Extensions, Ø 60/100
Fig. 1.3: Elbow joints, Ø 60/100
90° Elbow, Ø 60/100
Accy. No.: 303 808
2 x 45° Bends, Ø 60/100
Accy. No.: 303 809
Fig. 1.2: Telescopic extension
Telescopic air/flue duct extension
500 – 800 mm Ø 60/100
Accy. No.: 303 804
Air/flue duct extension 500 mm,
Ø 60/100
Accy. No.: 303 801
Air/flue duct extension 1000 mm,
Ø 60/100
Accy. No.: 303 802
Air/flue duct extension 1960 mm,
Ø 60/100
Accy. No.: 303 803
GU_LAZ 70/0
LAS Euro B/S 015/0 Teleskop_Verlängerung
Air/flue duct 15° offset Ø 60/100
Accy. No.: 303 820
Air/flue duct (adjustable) offset pipe
Ø 60/100
Accy. No.: 303 819
33 - 56
Abb. 1.4: Adjustable offset pipe
LAS Euro B/S 070/0GB

135
145
PART 1 CONCENTRIC 60/100
PLANNING THE AIR/FLUE DUCT LAYOUT
7
Fig. 1.7: Tiles for pitched roofs
Adjustable roof tile
Accy. No.: 9076
GU_LAZ 41/0
Fig. 1.6: Sliding sleeve, Ø 60/100
Sliding sleeve, Ø 60/100
Accy. No.: 303 816
LAS Euro B/S 016/0
Fig. 1.5: Flue support clip, Ø 100
Flue support clips, Ø 100 (Pack of 5)
Accy. No.: 303 821
GU_LAZ 72/0
☞Use one clip per extension to
support the air/flue duct.
Fig. 1.8: Flat roof penetration collar
GU_LAZ 42/0
Flat roof penetration collar
Accy. No.: 9056

5.3 5.3 4.5 3.3 3.0
PLANNING THE AIR/FLUE DUCT LAYOUT
8
Horizontal flue
systems
303 807
303 806
303 810
Maximum flue lengths Ø 60/100
Maximum flue length
Maximum flue length
Fig. 1.9 Fig. 1.10
LAS Euro B/S 074/0
LAS Euro B/S 075/0
Vertical flue
systems
303 800
thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT
615/2 E 620/2 E 624/2 E 628/2 E 637 E
turboMAX pro 24/2 E turboMAX pro turboMAX plus
turboMAX plus 28/2 E 837 E
824/2 E turboMAX plus aquaPLUS
828/2 E
6.3 6.3 5.5 4.3 4.0
Max.
permitted
flue length
(L)
Max.
permitted
flue length
(L)
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.
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.

3
2
1
= B
= D
= A
= C
PART 1 CONCENTRIC 60/100
PLANNING THE AIR/FLUE DUCT LAYOUT
9
Fig. 1.11: Flue restrictor rings
Flue restrictor rings
The flue restrictor ring marked A, C
or D is packed with the boiler
connection accessories. The restrictor
ring should be fitted as shown in the
diagram according to the equivalent
flue length in the table.
The total equivalent flue length is the
total length of the flue (including the
terminal assembly for vertical flues),
plus the resistance of any bends or
elbows used.
-equivalent length of 90° elbow is
1 m
-equivalent length of 45° elbow is
0.5 m
•Push the restrictor (1) into the flue
connection of the appliance (3)
•Connect the flue/elbow (2) into
the flue connection of the
appliance (3).
Note:
thermoCOMPACT 615 boilers do not
require a seperate restrictor ring and
are supplied without the restrictor.
The required restriction is designed
into the flue connection piece for
these boilers.
thermoCOMPACT
615/2 E
thermoCOMPACT
620/2 E
thermoCOMPACT
624/2 E
turboMAX plus
824/2 E
turboMAX
pro 24/2 E
thermoCOMPACT
628/2 E
turboMAX plus
828/2 E
turboMAX pro
28/2 E
Use restrictor A ---
Use restrictor D ---
No flue restrictor ---
< 6.3 m
---
---
---
---
---
---
< 2.3 m
> 2.3 m
Use restrictor C --- --- < 5.5 m ---
Total equivalent flue length
(incl. terminal any bends / elbows used)

PLANNING THE AIR/FLUE DUCT LAYOUT
10
Fig. 1.12: Flue restrictor rings
Flue restrictor rings
The flue restrictor ring marked F0 and
F1 is packed with the boiler
connection accessories. The restrictor
ring should be fitted as shown in the
diagram according to the equivalent
flue length in the table.
The total equivalent flue length is the
total length of the flue (including the
terminal assembly for vertical flues),
plus the resistance of any bends or
elbows used.
-equivalent length of 90° elbow is
1 m
-equivalent length of 45° elbow is
0.5 m
•Push the restrictor (1) into the flue
connection of the appliance (3)
•Connect the flue/elbow (2) into
the flue connection of the
appliance (3).
aquaPLUS thermoCOMPACT
637 E
turboMAX plus
837 E
Use restrictor F0 ---
Use restrictor F2 ---
No flue restrictor ---
< 2.5 m
---
> 3.3 m
< 2.5 m
---
> 3.3 m
< 2.5 m
---
> 3.3 m
Use restrictor F1 --- 2.5 - 3.3 m 2.5 - 3.3 m 2.5 - 3.3 m
Total equivalent flue length
(incl. terminal any bends / elbows used)