Vaillant ecoMAX 613/2 E Installation Instructions Manual Download

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For the installer

Flue installation instructions

Air flue duct for use with ecoMAX

ecoMAX 613/2 E

ecoMAX 618/2 E

ecoMAX 622/2 E

ecoMAX 824/2 E

ecoMAX 828/2 E

ecoMAX 835/2 E

ecoMAX pro 18 E

ecoMAX pro 28 E

2000225123A-10.02

Summary of Contents for ecoMAX 613/2 E

Page 1: ...taller Flue installation instructions Air flue duct for use with ecoMAX ecoMAX 613 2 E ecoMAX 618 2 E ecoMAX 622 2 E ecoMAX 824 2 E ecoMAX 828 2E ecoMAX 835 2E ecoMAX pro 18 E ecoMAX pro 28 E GB 2000225123A 10 02 ...

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Page 3: ...5 PART 1 Pages 4 20 Standard Concentric Systems Ø 60 100 Aluminium air duct plastic flue duct PART 2 Pages 21 40 Optional Concentric System Ø 80 125 Aluminium air duct plastic flue duct PART 2 CONCENTRIC 80 125 PART 1 CONCENTRIC 60 100 ...

Page 4: ...ions and standards Requirements Planning the air flue duct layout Regulations and standards to be observed 5 Alternative termination accessories available 6 Maximum flue lengths 9 Installation of the vertical roof duct 15 Installation of the horizontal air flue duct 11 Fitting air flue duct extensions Installation of the sliding sleeve How to add extensions 18 How to install elbows 19 10 ...

Page 5: ...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 ...

Page 6: ...ic 970 mm Ø 60 100 Air flue duct extensions concentric 1970 mm Ø 60 100 Bends PP concentric pack of 2 45 Ø 60 100 Elbow concentric 87 Ø 60 100 Flue support clips pack of 5 Ø 100 Sliding sleeve PP Ø 60 100 Adjustable roof tiles for pitched roof 303 900 Vertical air flue duct black 303 930 Horizontal air flue duct Accy No 303 930 303 900 303 919 303 906 303 902 x 303 903 x 303 905 x 303 911 x x 303 ...

Page 7: ... Fig 1 2 Elbow joints Ø 60 100 Elbow 87 Ø 60 100 Vaillant Accy No 303 910 Bends 45 pack of 2 Ø 60 100 Vaillant Accy No 303 911 Air flue duct extension 470 mm Ø 60 100 Vaillant Accy No 303 902 Air flue duct extension 970 mm Ø 60 100 Vaillant Accy No 303 903 Air flue duct extension 1970 mm Ø 60 100 Vaillant Accy No 303 905 GU_LAZ 70 0 GU_LAZ 72 0 440 690 Fig 1 4 Telescopic extension Ø 60 100 Telesco...

Page 8: ...74 33 56 Fig 1 5 Offset section Ø 60 100 Offset section Ø 60 100 Vaillant Accy No 303 919 303919_IAx Fig 1 8 Flat roof penetration collar GU_LAZ 42 0 Flat roof penetration collar Vaillant Accy No 009 056 Fig 1 7 Adjustable roof tile for pitched roof Adjustable roof tile for pitched roof Vaillant Accy No 009 076 black GU_LAZ 41 0 ...

Page 9: ... 87 828 2 E 835 2 E pro 18 E pro 28 E 10 0 m 7 0 m 10 0 m 8 0 m incl 1 elbow 87 4 0 m incl 1 elbow 87 10 0 m incl 1 elbow 87 824 2 E 9 0 m 7 0 m incl 1 elbow 87 613 2 E 618 2 E 622 2 E ecoMAX of which no more than 5 m lie in exposed position Maximum length of flue is reduced by 1 0 m for each additional 90 elbow Maximum length of flue is reduced by 0 5 m for each additional 45 elbow of which no mo...

Page 10: ...the air duct clamp 7 over the air duct Pull back the sliding sleeve so that it engages into the socket 3 of the boiler 4 Ensure that the sliding sleeve penetrates the socket such that there is at least 20 mm engagement at both ends of the sliding sleeve Fit the air duct clamp over the air ducts 5 and 6 of the extension terminal and boiler outlet Close the snap clamp Drill two holes 3 mm diameter t...

Page 11: ...w 1 x 70 mm air duct clamp 1 x 40 mm air duct clamp Internal trim ring Ø 100 External wall seal See page 6 et seq for details of air flue duct elements Fig 3 0 Horizontal air flue conduit Important The flue hole should be cut with a slight rise to outside of 3 1 equivalent to 50 mm 20 mm rise per metre length INSTALLATION OF THE HORIZONTAL AIR FLUE DUCT PART 1 CONCENTRIC 60 100 ...

Page 12: ... 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 install...

Page 13: ...s important to remove any burrs with a file this ensures easy fitting of the ducts and prevents any rough edges from damaging the flue seals Care should be taken not to scratch the white surface of the air duct If the installation requires the use of air flue duct extensions additional bends or elbows refer to the sections on pages 20 21 Secure the air duct sections together by drilling a 3 mm dia...

Page 14: ...iler installation instructions Fit the elbow to the boiler by inserting the spigot of the flue elbow into the flue socket on the boiler and secure using the air duct clamp provided Pull the air flue duct back through the wall such that the flue duct fully engages into the flue elbow socket Fit the air duct clamp ensuring that it is positioned centrally Drill two holes 3 mm Ø through the air duct o...

Page 15: ...mine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions Determine the point where the vertical air flue duct and terminal assembly will penetrate the roof Please note The vertical air f...

Page 16: ...This permits easy separation between the air flue duct and the appliance Drill two holes 3 mm Ø through the air duct of the flue boiler clamp at the most convienient holes on the air duct clamp Ensure that the drill does not penetrate the inner flue duct Screw the clamp to the air ducts of the flue assembly and the boiler using the screws supplied Ensure that any air duct clamps used are positione...

Page 17: ...he boiler See pages 19 et seq for further details on the installation of extensions and elbows Push the sliding sleeve 4 firmly into place on the extensionn Join the vertical roof duct 5 to the extension 7 Join the sliding sleeve 4 to the appliance s connection piece 8 This permits easy separation between the air flue duct and the appliance Drill two holes 3 mm Ø through the air duct of the flue b...

Page 18: ...nduit Lair length of air conduit Minimum length of air conduit extension 80 mm 1 2 13 2 70 L air Lexhaust 1 2 40 mm 27 1 Fig 9 1 Cutting tubes to size The seals are sensitive to mineral oil based grease products For this reason the seals must not be greased If the seals need wetting to aid in installation use water only De burr and file down any rough edges on the tubes before fitting in order to ...

Page 19: ...20 635 425 640 430 645 435 650 440 655 445 660 450 665 455 670 460 675 465 680 470 685 475 Table 10 1 Length of surplus with 87 elbows 190 to 210 mm 0 215 to not 265 mm possible 270 to 290 mm 80 295 85 300 90 305 95 310 100 315 105 320 110 325 115 330 120 335 125 340 130 345 135 350 140 355 145 360 150 365 155 370 160 375 165 380 170 385 175 390 180 395 185 400 190 405 195 410 200 415 205 420 210 ...

Page 20: ...t 420 mm Important This gives a corresponding exhaust conduit length of 284 40 324 mm cf page 19 GU_LAZ 103 2GB Fig 10 2 Installation of 45 bends 325 320 445 330 327 450 335 334 455 340 341 460 345 348 465 350 355 470 355 362 475 360 369 480 365 376 485 370 383 490 375 390 495 380 397 500 385 404 505 390 412 510 395 419 515 400 426 520 405 433 525 410 440 530 415 447 535 420 454 540 425 461 545 43...

Page 21: ...ements Planning the air flue duct layout Regulations and standards to be observed 22 Alternative termination accessories available 23 Maximum flue lengths 26 Changing the appliance connection piece 28 Installation of the vertical air flue duct 35 Installation of the horizontal air flue duct 30 Fitting air flue duct extensions Installation of the sliding sleeve How to add extensions 38 How to insta...

Page 22: ...on 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...

Page 23: ...ensions PPs concentric 470 mm Ø 80 125 303 202 x Air flue duct extensions PPs concentric 970 mm Ø 80 125 303 203 x Air flue duct extensions PPs concentric 1970 mm Ø 80 125 303 205 x Bends PPs concentric pack of 2 45 Ø 80 125 303 211 x Elbow PPs concentric 87 Ø 80 125 303 210 x Flue support clips pack of 5 Ø 125 303 616 x Sliding sleeve PPs Ø 80 125 303 215 x Adjustable roof tiles for pitched roof ...

Page 24: ...ow PPs 87 Ø 80 125 Vaillant Accy No 303 210 Bends PPs 45 pack of 2 Ø 80 125 Vaillant Accy No 303 211 Air flue duct extension PPs 470 mm Ø 80 125 Vaillant Accy No 303 202 Air flue duct extension PPs 970 mm Ø 80 125 Vaillant Accy No 303 203 Air flue duct extension PPs 1970 mm Ø 80 125 Vaillant Accy No 303 205 GU_LAZ 70 0 GU_LAZ 72 0 GU_LAZ 71 0 58 25 15 5 Fig 1 1 Appliance connection piece Appliance...

Page 25: ...ched roof Adjustable roof tiles for pitched roof Vaillant Accy No 009 076 black GU_LAZ 41 0 164 120 Fig 1 5 Sliding sleeve Ø 80 125 Sliding sleeve PPs Ø 80 125 Vaillant Accy No 303 215 GU_LAZ 76 0 Fig 1 7 Flat roof penetration collar GU_LAZ 42 0 Flat roof penetration collar Vaillant Accy No 009 056 ...

Page 26: ...in exposed position Maximum length of flue is reduced by 2 0 m for each additional 90 elbow Maximum length of flue is reduced by 1 0 m for each additional 45 elbow Accessories Accy No Vertical flue systems 303 200 Max permitted concentric flue length Horizontal flue systems 303 209 Max permitted concentric flue length 26 0 m 25 0 m incl 1 elbow 87 22 0 m 21 0 m incl 1 elbow 87 29 0 m 30 0 m incl 1...

Page 27: ...27 PART 2 CONCENTRIC 80 125 PLANNING THE AIR FLUE DUCT LAYOUT Maximum flue length Maximum flue length LAS Euro B S 074 0 LAS Euro B S 074 0 Fig 1 9 Fig 1 8 ...

Page 28: ... remove it Push the appliance connection piece with the selected connection diameter down from above inserting the push in end onto the sleeve of the flue collecting chamber Now push the appliance connection piece downwards until the flange comes into contact with the low pressure chamber Refit the fixing screws 2 The seals are sensitive to mineral oil based grease products For this reason the sea...

Page 29: ...2 Place the air duct clamp 7 over the air duct Pull back the sliding sleeve so that it engages into the socket 3 of the boiler 4 Ensure that the sliding sleeve penetrates the socket such that there is at least 20 mm engagement at both ends of the sliding sleeve Fit the air duct clamp over the air ducts 5 and 6 of the extension terminal and boiler outlet Close the snap clamp Drill two holes 3 mm di...

Page 30: ...rizontal air flue duct 87 elbow 2 x 70 mm air duct clamps 2 x internal trim rings Ø 125 See page 24 et seq for details of air flue duct elements Fig 4 1 Horizontal air flue conduit GU_LAZ 82 0 Important The flue hole should be cut with a slight rise to outside of 3 1 equivalent to 50 mm 20 mm rise per metre length Fig 4 2 Example of installation with horizontal air flue duct and inspection access ...

Page 31: ... and flue termination are in accordance with these instructions prior to drilling any holes for the boiler hanging bracket Once the position of the flue exit hole has been determined the hole should be cut through the wall using a core drill of 127 mm diameter The flue exit hole should be cut with a rise towards outside of 3 Measure the distance from the outside face of the wall to the centre of t...

Page 32: ...d and remove the 3 screws Separate the ducts Note For assembly reasons do not shorten any air duct to a length of less than 100 mm If necessary shorten two adjacent extensions to achieve the overall required length Cut the air duct square and remove any burrs Refit the flue duct into the air duct and secure using the 3 screws Cut the flue duct as detailed in fig 4 7 When cutting the air and flue d...

Page 33: ...al assembly through the flue exit hole until it protrudes 220 mm out from the outside wall Ensure that the terminal is correctly positioned with the air inlet grille at the bottom Slide one of the two trim rings over the air duct until it is flush with the internal wall face INSTALLATION OF THE HORIZONTAL AIR FLUE DUCT Ø 80 125 WITH EXTENSIONS ...

Page 34: ...elbow 5 to the appliance connection piece Push the sliding sleeve 7 firmly into place on the appropriate extensionns 6 Install the extensions and join the clutch sleeve to the 87 elbow This section functions subsequently as a separation point Join all separation points with the air conduit fixing collars 8 See pages 41 et seq for further details on the installation of extensions and elbows 750 mm ...

Page 35: ...ue Preparation Determine the installation site for the boiler with reference to the installation and servicing instructions supplied with the boiler Ensure that all installation and service clearances are available and that the boiler flue can be installed as detailed in these instructions Determine the point where the vertical air flue duct and terminal assembly will penetrate the roof Please not...

Page 36: ...ly into place on the extensionn Join the vertical roof duct 5 to the extension 7 Join the sliding sleeve 4 to the appliance s connection piece 8 This permits easy separation between the air flue duct and the appliance Drill two holes 3 mm Ø through the air duct of the flue boiler clamp at the most convienient holes on the air duct clamp Ensure that the drill does not penetrate the inner flue duct ...

Page 37: ...he boiler See pages 41 et seq for further details on the installation of extensions and elbows Push the sliding sleeve 4 firmly into place on the extensionn Join the vertical roof duct 5 to the extension 7 Join the sliding sleeve 4 to the appliance s connection piece 8 This permits easy separation between the air flue duct and the appliance Drill two holes 3 mm Ø through the air duct of the flue b...

Page 38: ...lue conduit Lair length of air conduit Minimum length of air conduit extension 100 mm 1 2 15 1 2 70 L air Lexhaust 1 2 40 mm 25 Fig 10 1 Cutting tubes to size The seals are sensitive to mineral oil based grease products For this reason the seals must not be greased If the seals need wetting to aid in installation use water only De burr and file down any rough edges on the tubes before fitting in o...

Page 39: ...5 415 630 420 635 425 640 430 645 435 650 440 655 445 660 450 665 455 670 460 675 465 680 470 685 475 690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515 Table 11 1 Length of surplus with 90 elbows 200 205 0 210 0 210 to not 310 mm possible 310 100 315 105 320 110 325 115 330 120 335 125 340 130 345 135 350 140 355 145 360 150 365 155 370 160 375 165 380 170 385 175 390 180 395 185 400...

Page 40: ...it 284 mm and the height 420 mm Important This gives a corresponding exhaust conduit length of 284 40 324 mm cf page 41 GU_LAZ 103 2GB Fig 11 2 Installation of 45 bends 335 334 455 340 341 460 345 348 465 350 355 470 355 362 475 360 369 480 365 376 485 370 383 490 375 390 495 380 397 500 385 405 505 390 412 510 395 419 515 400 426 520 405 433 525 410 440 530 415 447 535 420 454 540 425 461 545 430...

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Page 44: ... 44 49 GB 03 08 2002 Mü Subject to alteration Head Office Service Solutions 0870 6060 777 Vaillant Ltd Vaillant House Technical Advice 01634 292392 Medway City Estate Trident Close Rochester Kent ME2 4EZ ...

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Vaillant ecoMAX 613/2 E, Installation Instructions Manual

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