Vaillant 637 E Installation Instructions Manual Download Page 3

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CONTENTS: PART 2 CONCENTRIC 80/125

Planning the air/flue duct layout

Termination accessories available

Maximum flue lengths Ø 80/125

Flue restrictor rings

Preparation

Side flue installations

Fitting the appliance flue outlet
adapter to the boiler

Fitting air/flue duct extensions

Page

Fitting air/flue duct extensions
between two 90° elbows

Fitting air/flue duct extensions
between two 45° elbows

Installing the air/flue duct sliding
sleeve

Installation of the vertical
roof duct

Installation of the horizontal
air/flue with extensions

Preparation

Fitting extensions

Connect the flue assembly to the adaptor

Installation of the horizontal
air/flue duct and terminal
accessory (80/125)

Preparation

Pitched roof

Flat roof

Pitched and flat roof installation

Connect the flue assembly to the adaptor

Summary of Contents for 637 E

Page 1: ...aller 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 60 100 PART 2 Optional Concentric Syste...

Page 2: ...lation 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 elb...

Page 3: ...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...

Page 4: ...GI 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...

Page 5: ...Pack of 5 100 303 821 x x Air flue duct extension 1960 mm 60 100 303 803 x x Air flue duct 15 offset 60 100 303 820 Sliding sleeve 60 100 303 816 x x Adjustable roof tile 9076 Flat roof collar piece...

Page 6: ...extension 500 800 mm 60 100 Accy No 303 804 Air flue duct extension 500 mm 60 100 Accy No 303 801 Air flue duct extension 1000 mm 60 100 Accy No 303 802 Air flue duct extension 1960 mm 60 100 Accy No...

Page 7: ...U_LAZ 41 0 Fig 1 6 Sliding sleeve 60 100 Sliding sleeve 60 100 Accy No 303 816 LAS Euro B S 016 0 Fig 1 5 Flue support clip 100 Flue support clips 100 Pack of 5 Accy No 303 821 GU_LAZ 72 0 Use one cli...

Page 8: ...MPACT 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 leng...

Page 9: ...0 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 thermo...

Page 10: ...ncluding 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...

Page 11: ...te 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 templa...

Page 12: ...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...

Page 13: ...restrictor ring page 10 into the bottom of the boiler elbow Fit the elbow to the boiler by inserting the spigot of the flue elbow into the flue socket on the boiler and secure using the air duct clam...

Page 14: ...e 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 ens...

Page 15: ...Y Secure the boiler hanging bracket 1 to the wall using the screws provided 2 At this stage it is necessary to prepare and fit the boiler onto the hanging bracket refer to the boiler installation inst...

Page 16: ...d in the installation instructions supplied with the boiler Release the three clamps 1 and remove the combustion chamber cover 2 Loosen the screw 3 and remove the flue gas connector 4 from the fan Rem...

Page 17: ...d in the installation instructions supplied with the boiler Release the three clamps 1 and remove the combustion chamber cover 2 Remove the screw 3 Pull the two cables 8 and two tubes 9 from the fan a...

Page 18: ...cing outside Push the air flue duct assembly through the wall from outside the dwelling If the internal trim ring is to be used position it over the end of the air duct from inside the dwelling Engage...

Page 19: ...cure Reconnect the electrical cables to the fan Gently push the flue duct downwards to the left Slide the fan 2 into position on flue collector hood 3 Ensure that the flue gas connector 1 engages over...

Page 20: ...ages over the end of the flue duct and the flange on the back of the fan plate locks in to the collector hood Secure the fan to the flue collector hood using only one screw 4 Reconnect the air pressur...

Page 21: ...e centreline of the template is vertical using a plumbline or spirit level Top oulet flue exiting to rear For installations where the air flue duct is to be installed directly to the rear of the boile...

Page 22: ...s Length of flue duct Length of air duct 44 mm All flue sockets should point towards the terminal Ensure that the flue duct protrudes by 40 mm into the Se duct When cutting the air and flue ducts it i...

Page 23: ...o the boiler by inserting the spigot of the flue elbow into the flue socket on the boiler and secure using the air duct clamp provided Pull the air flue duct back through the se duct wall such that th...

Page 24: ...ntial that the roof tile collar is vertically aligned with the air flue duct of the boiler 48 1285 603 LAS Euro B S 036 0 Pitched roof Determine the point of termination of the vertical air flue duct...

Page 25: ...holes 3 mm through the air duct of the flue boiler clamp at the most convienient holes on the air duct clamp Ensure that the drill does not penetrate the inner flue duct Screw the clamp to the air duc...

Page 26: ...ace on the air duct After cutting the tubes to size insert the flue duct into the air duct and secure the air duct to the spacing bracket through the three pre drilled holes Lubricate the seals and in...

Page 27: ...410 625 415 630 420 635 425 640 430 645 435 650 440 655 445 660 450 665 455 670 460 675 465 680 470 685 475 690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515 Table 6 1 Length of surplus...

Page 28: ...399 290 276 404 295 283 409 300 290 414 305 297 419 310 304 424 Distance Length of Height between centres air duct in mm in mm in mm Distance Length of Height between centres air duct in mm in mm in m...

Page 29: ...eeve so that it engages into the socket of the boiler 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 d...

Page 30: ...n accessories Accy Part No 303 600 87 Elbow 80 125 303 610 Air flue duct extensions 500 mm 80 125 303 602 x x Air flue duct extensions 1000 mm 80 125 303 603 x x Air flue duct extensions 2000 mm 80 12...

Page 31: ...Fig 1 3 Elbow joints 80 125 87 Elbow 80 125 Accy No 303 610 2 x 45 Bends 80 125 Accy No 303 611 Air flue duct extensions 500 mm 80 125 Accy No 303 602 Air flue duct extensions 1000 mm 80 125 Accy No 3...

Page 32: ...tiles for pitched roof Adjustable roof tile Accy No 9076 GU_LAZ 41 0 164 120 Fig 1 5 Sliding sleeve 80 125 Sliding sleeve 80 125 Accy No 303 617 GU_LAZ 76 0 Fig 1 7 Flat roof penetration collar piece...

Page 33: ...3 600 Max permitted flue length L Max permitted flue length L 15 4 m 12 5 m 14 0 m thermoCOMPACT thermoCOMPACT 628 2 E turboMAX plus 615 620 624 2 E turboMAX plus 828 2 E 837 E turboMAX plus 824 2 E t...

Page 34: ...has a diameter of 100 mm An adaptor Accy No 303 814 is required to connect from the boiler outlet to the 125 mm diameter flue system This adaptor incorporates a condensate discharge connection which...

Page 35: ...e flue outlet adaptor 2 into the flue connection of the appliance 3 Note The flue outlet on the top of the boiler has a diameter of 100 mm An adaptor Accy No 303 814 is required to connect from the bo...

Page 36: ...ovided 7 Drill two holes 3 mm through the air duct clamp and secure the air duct clamp to the boiler using the screws provided Note Because of the high efficiency of turboMAX thermoCOMPACT and aquaPLU...

Page 37: ...mportant Ensure that there are no kinks in the condensate discharge pipe Position the trap 5 below the appliance and secure to the wall using the bracket and screws provided Connect the condensate dis...

Page 38: ...ust the location of the boiler installation template Please check that both the boiler installation site and flue termination are in accordance with these instructions prior to drilling any holes for...

Page 39: ...not shorten any air duct to a length of less than 100 mm If necessary shorten two adjacent extensions to achieve the overall required length Cut the air duct square and remove any burrs Refit the flu...

Page 40: ...ANT The flue hole should be cut with a slight rise to outside of 3 1 equivalent to 50mm 20mm rise per metre length 220 1 5 1 2 3 Fig 4 2 Installing the horizontal wall duct LAS Euro B S 013 0 Preparat...

Page 41: ...he inner flue duct Fix the duct using the screws provided Ensure that the flue assembly is adequately supported along its entire length Cut any air flue ducts to the required length as detailed on pag...

Page 42: ...t 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 plumbl...

Page 43: ...roof installations From above insert the air flue duct and terminal assembly 5 into the adjustable roof tile pitched roof or roof penetration collar flat roof until it is fully seated Adjust the vert...

Page 44: ...o 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...

Page 45: ...ping screws supplied Connect the flue assembly to the adaptor Slide the 125 mm dia x 88 mm long air duct clamp over the air duct Line up the air flue duct with the adaptor and insert the spigot of the...

Page 46: ...ny burrs Care should be taken not to scratch the white surface on the air duct After cutting the tubes to size insert the flue duct into the air duct and secure the air duct to the spacing bracket thr...

Page 47: ...670 460 675 465 680 470 685 475 690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515 Table 6 1 Length of surplus with 87 elbows 200 205 0 210 0 210 to not 310 mm possible 310 100 315 105 3...

Page 48: ...centres air duct in mm in mm in mm Distance Length of Height between centres air duct in mm in mm in mm Table 6 2 Length of surplus with 45 elbow Distance Length of Height between centres air duct in...

Page 49: ...et of the boiler 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 of the e...

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Page 52: ...31 70_31 GB 07 2003 M Subject to alteration Head Office Vaillant Ltd Service Solutions 0870 6060 777 Vaillant House Trident Close Medway City Estate Rochester Kent ME2 4EZ Technical Advice 01634 2923...

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