Vaillant turboMAX plus 2 E Series Installation Instructions Manual Download Page 1

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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

Summary of Contents for turboMAX plus 2 E Series

Page 1: ...ller 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 ...

Page 2: ...allation 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 1...

Page 3: ...e 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 P...

Page 4: ...RGI 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 boi...

Page 5: ...ips 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...

Page 6: ...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 Adjust...

Page 7: ...AZ 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 ...

Page 8: ...COMPACT 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 flu...

Page 9: ...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 thermoCOMPA...

Page 10: ...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 fl...

Page 11: ...late 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 posi...

Page 12: ...s 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 25 27 If us...

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 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...

Page 14: ...ure 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 The installation template details the position of the flue exit hole for rear outlet installations Ensure that...

Page 15: ...LY 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 instructions 3 402 171 174 5 12 5 1 1 2 Fig 3 3 LAS Euro B S 054 0GB PART 1 CONCENTRIC 60 100 ...

Page 16: ...ed 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 Remove the retaining spring 5 Pull the cables and two tubes 9 10 from the fan assembly Please ensure that you note the respective connection points for each tube Remove the complete fan assembly 11 from...

Page 17: ...ed 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 assembly Please ensure that you note the respective connection points for each tube Remove the fan 10 from the collector hood by pushing downwards to unlock Remove collector hood from the boiler Remov...

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 the end of the air duct into the air duct connection piece at the rear of the boiler Now from outside the dwelling push the entire air flue duct in towards the boiler such that the air duct completel...

Page 19: ...ecure 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 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 the two screws 4 Reconnect the air pressure tubes ...

Page 20: ...gages 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 pressure tubes to the fan ensuring that the air tubes are connected to the correct nipple Note Blue tube connects to the rear most fan outlet spigot On combustion chamber cover front swap top left hand rubb...

Page 21: ...he 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 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 instal...

Page 22: ...ws 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 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 t...

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 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 of both the elbow flue and elbow boiler...

Page 24: ...ential 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 and terminal assembly Install the adjustable pitched roof tile 1 fig 5 2 in position Fit the adjustable hood over the roof tile according to the roof pitch The adjustable hood is suitable for roof pi...

Page 25: ...oles 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 positioned centrally and fixed to the air duct using the self tapping screws supplied Note Th...

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 install the flue extension Ensure that the air duct clamps are centrally positioned over the 10 mm gap between the air duct sections Drill two holes 3 mm Ø through each air duct at either end of each cl...

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 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 1...

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 mm Distance Length of Height between centres air duct in mm in mm in mm 315 311 429 320 319 434 325 326 439 330 333 444 335 340 449 340 347 454 345 354 459 350 361 464 355 368 469 360 375 474 365 382 ...

Page 29: ...leeve 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 duct clamp over the air ducts 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 ...

Page 30: ...ssories Accy Part No 303 600 87 Elbow Ø 80 125 303 610 Air flue duct extensions 500 mm Ø 80 125 303 602 x x Air flue duct extensions 1000 mm Ø 80 125 303 603 x x Air flue duct extensions 2000 mm Ø 80 125 303 605 x 2 x 45 Bends Ø 80 125 303 611 x Flue support clips Pack of 5 Ø 125 303 616 x Sliding sleeve Ø 80 125 303 617 x Adjustable roof tile 9076 x Flat roof collar piece 9056 x 303 609 x x x x x...

Page 31: ... 1 3 Elbow joints Ø 80 125 87 Elbow Ø 80 125 Accy No 303 610 2 x 45 Bends Ø 80 125 Accy No 303 611 Air flue duct extensions 500 mm Ø 80 125 Accy No 303 602 Air flue duct extensions 1000 mm Ø 80 125 Accy No 303 603 Air flue duct extensions 2000 mm Ø 80 125 Accy No 303 604 GU_LAZ 70 0 GU_LAZ 72 0 GU_LAZ 71 0 Fig 1 1 Flue outlet adaptor Appliance flue outlet adaptor Ø 60 100 Ø 80 125 Accy No 303 814 ...

Page 32: ...tiles for pitched roof Adjustable roof tile Accy No 9076 GU_LAZ 41 0 164 120 Fig 1 5 Sliding sleeve Ø 80 125 Sliding sleeve Ø 80 125 Accy No 303 617 GU_LAZ 76 0 Fig 1 7 Flat roof penetration collar piece GU_LAZ 42 0 Flat roof penetration collar Accy No 9056 ...

Page 33: ...303 600 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 turboMAX pro 28 2 E thermoCOMPACT turboMAX pro 24 2 E 637 E aquaPLUS Tube length is reduced by 2 5 m for each 87 elbow Tube length is reduced by 1 0 m for each 45 elbow Tube length is reduced by 2 5 ...

Page 34: ...r 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 allows any condensate or water to drain away It is important that the condensate discharge connector is connected correctly Note thermoCOMPACT 615 boilers do not require a seperate restrictor ring an...

Page 35: ...he 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 boiler outlet to the 125 mm diameter flue system This adaptor incorporates a condensate discharge connection which allows any condensate or water to drain away It is important that the condensate disch...

Page 36: ...ided 7 Drill two holes 3 mm Ø 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 aquaPLUS boilers it is likely that condensate will form in the flue system when a long flue run is used A condensate discharge connection is provided on the adapter to remove any condensate that forms in the...

Page 37: ...Important 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 discharge tube to the top connection of the trap ensuring that the condensate discharge tube engages into the trap by a minimum of 90 mm Connect the outlet of the condensate trap 6 to a suitable drain p...

Page 38: ...djust 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 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 ...

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 flue duct into the air duct and secure using the 3 screws Cut the flue duct as detailed in fig 3 5 When cutting the air and flue ducts it is important to remove any burrs with a file this ensures easy fi...

Page 40: ...ORTANT 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 Preparation Push the assembled air flue duct and terminal 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 a...

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 page 45 Connect the flue assembly to the adaptor Slide the 125 mm dia x 88 mm long air duct clamp over the air duct Fit the 87 elbow to the last flue extension Line up the elbow with the adaptor and inse...

Page 42: ...at 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 Please note The vertical air flue duct and terminal accessory Accy 303 600 may be shortened The outer white duct should be shortened first then the inner flue duct cut so that it ...

Page 43: ...t 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 vertical alignment of the air flue duct and terminal assembly and secure the air duct with the fixing bracket provided 6 At this stage it is necessary to prepare and fit the boiler onto the hanging brack...

Page 44: ...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 45 47 Install the flue extensions by working from the installed air flue and t...

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 air flue duct in to the adaptor Locate the air duct clamps ensuring they are positioned centrally Drill two holes 3 mm Ø through the air duct through both the air duct clamps at the most convienient ...

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 through the three pre drilled holes Install the flue extension Ensure that the air duct clamps are centrally positioned over the 10 mm gap between the air duct sections Drill two holes 3 mm Ø through eac...

Page 47: ...5 670 460 675 465 680 470 685 475 690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515 Table 6 1 Length of surplus with 87 elbows 200 205 0 210 0 210 to not 310 mm possible 310 100 315 105 320 110 325 115 330 120 335 125 340 130 345 135 350 140 355 145 360 150 365 155 370 160 375 165 380 170 385 175 390 180 395 185 400 190 405 195 410 200 415 205 420 210 425 215 430 220 435 225 440 230 ...

Page 48: ...n 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 mm in mm in mm 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...

Page 49: ...ket 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 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 dri...

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Page 52: ... 31 70_31 GB 07 2003 Mü 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 292392 ...

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Vaillant turboMAX plus 2 E Series, Installation Instructions Manual

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