Vaillant Air flue duct Installation Instructions Manual Download

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For the installer

Flue installation instructions

Air flue duct for use with ecoTEC boilers

Standard Concentric

Systems Ø 60/100

(Galvanized steel air

duct/plastic flue duct)

Optional Concentric

System Ø 80/125

(Galvanized steel air

duct/plastic flue duct)

Summary of Contents for Air flue duct

Page 1: ...stallation instructions Air flue duct for use with ecoTEC boilers Standard Concentric Systems 60 100 Galvanized steel air duct plastic flue duct Optional Concentric System 80 125 Galvanized steel air...

Page 2: ...talling the deflector set 23 2 8 1 Contents included with delivery 23 2 8 2 Assembly of the deflector set before installing the flue gas pipe 23 2 8 3 Installation of the deflector set after installin...

Page 3: ...uirements Regulations and standards to be observed a Caution The air flue duct must be installed by a suita bly qualified service provider which is responsi ble for observing the relevant specificatio...

Page 4: ...Electricity at Work Regulations 1989 BS7671 IEE Wiring Regulations and the Water Supply Water Fitting Regulations 1999 or The Water Bylaws 2000 Scotland It should also be in accordance with the relev...

Page 5: ...duct extensions concentric 970 mm 60 100 303 903 X X X X Air flue duct extensions concentric 1970 mm 60 100 303 905 X X X X Bends PP concentric pack of 2 45 60 100 303 911 X X X X Elbow concentric 87...

Page 6: ...k 303 944 X X 45 bend for variable termination kit black 2 pieces 303 945 X X Variable termination kit white 303 946 X X Extension pipe for variable termination kit VTK 60 mm 1 m white 303 947 X X 87...

Page 7: ...o 303 936 140 100 Flue support clips 100 pack of 5 Accy No 303 821 250 Adjustable flue support clips 100 pack of 3 Accy No 303 935 Table 2 2 Elements 60 100 Element Description 155 37 23 Sliding sleev...

Page 8: ...on pipe for variable termination kit 60 mm 1 m white including 1 support clip Accy No 303 947 87 elbow for variable termi nation kit black including 1 support clip Accy No 303 944 87 elbow for variabl...

Page 9: ...th ecoTEC Accessories Accy Nr ecoTEC plus 612 plus 615 plus 618 plus 624 plus 824 plus 630 plus 831 plus 637 plus 837 plus 937 pro 24 pro 28 plus 415 plus 418 plus 428 plus 438 Horizontal flue systems...

Page 10: ...ontal flue systems Key A Maximum flue length A B Fig 2 2 Horizontal flue system installed with vertical termina tion kit Key A Concentric flue length B Flue length outside A Fig 2 3 Vertical flue syst...

Page 11: ...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...

Page 12: ...d directly to the rear of the boiler the installa tion template details the position of the flue exit hole for horizontal top outlet installation 2 4 4 Top outlet flue exiting to side Fig 2 7 Distance...

Page 13: ...ocation 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 87 13 1 3 Fig 2 10 Assembly of the horizo...

Page 14: ...e that condensate does not remain in the sleeve 30 13 405 610 48 65 Fig 2 11 Horizontal air flue conduit Horizontal telescopic air flue duct Accy No 303 936 Length 0 4 0 61 m Contents of the accessory...

Page 15: ...ow 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 t...

Page 16: ...1 is centred in the hole and the terminal is correctly positioned with the inlet grille at the bottom fig 2 12 and fig 2 16 Slide the internal trim ring 2 over the air duct until it is flush with the...

Page 17: ...her with the flue duct out of the air duct Fig 2 20 Unlocking the catch Unlock the catch between the terminal and the flue duct by twisting them against each other Pull the terminal off the flue duct...

Page 18: ...firmly seated and sealed 2 7 Installation of the variable termination kit VTK a Caution The flue outlet of the variable termination must face directly upwards Flue terminal clearances Minimum flue te...

Page 19: ...y twisting them against each other Pull the terminal out off the flue duct Push the variable terminal into the flue duct and click to lock Fig 2 28 Flue pipe a Caution The catch on the top of the term...

Page 20: ...duct behind the termi nal from the spacer Unlock the catch between the terminal and the flue duct by twisting them against each other fig 2 27 Pull the terminal out of the flue duct Push the new vari...

Page 21: ...fig 2 30 2 31 2 32 or 2 33 a Caution Pipe extensions must be fixed to the wall using support clips Use one clamp for each extension directly beside the sleeve Fit another clamp to the extension after...

Page 22: ...efects such as embrittlement or damage tight connection of the pipes dirt in the air intake and flue exits due to leaves insects etc 2 7 5 Routing around roof eaves min 400 mm min 100 mm Fig 2 34 Rout...

Page 23: ...0060585 Contents of the accessory White terminal 2 8 2 Assembly of the deflector set before install ing the flue gas pipe Fig 2 36 Releasing the catches Use an 8 mm screwdriver to bend the catches in...

Page 24: ...learances A B and C for the de flector are reduced to 150 mm from an opening such as a window This means that the terminal on the horizon tal flue gas pipe becomes the air inlet when a deflector is co...

Page 25: ...gas pipe must be at the top Fit the wall seal to the deflector 4 5 Fig 2 46 Angle of flue gas stream in centre position Setting the deflector in the centre position will direct the stream of flue gase...

Page 26: ...tion Determine the installation site for the boiler with ref erence to the installation and servicing instructions supplied with the boiler Ensure that all installation and service clearances are avai...

Page 27: ...he installa tion and servicing instructions supplied with the boil er h Note See section 2 11 for further details on the in stallation of extensions and elbows Push the sliding sleeve 4 firmly into pl...

Page 28: ...the appliance 2 with reference to the installa tion and servicing instructions supplied with the boil er hNote See section 2 11 for further details on the in stallation of extensions and elbows Push t...

Page 29: ...ure that all the clearances required for installation and maintenance are available and that the boiler flue gas pipe can be installed as detailed in these instruc tions Determine the point where the...

Page 30: ...elbows Drill two holes 3 mm in the air duct of the flue gas boiler clamp through the most convenient holes on the air duct clamp Ensure that the drill does not penetrate the inner flue gas pipe Screw...

Page 31: ...llation use water only Caution De burr and file down any rough edges on the tubes before fitting in order to prevent damage to the seals Remove all metal filings and other debris Caution Do not use da...

Page 32: ...fig 2 61 and fig 2 62 to avoid obstructions a Caution The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage h Note The elbow fitted to the top of the boiler 1 sh...

Page 33: ...530 320 720 510 345 135 535 325 725 515 350 140 540 330 730 520 355 145 545 335 735 525 360 150 550 340 740 530 365 155 555 345 745 535 370 160 560 350 750 540 375 165 565 355 755 545 380 170 570 360...

Page 34: ...157 330 410 440 530 610 723 730 215 164 335 415 447 535 615 730 735 220 171 340 420 454 540 620 737 740 225 178 345 425 461 545 625 744 745 230 185 350 430 468 550 630 751 750 235 192 355 435 475 555...

Page 35: ...e also that all legislation rules regula tions and directives mentioned in the installa tion instructions are observed Note The installation of the boiler and its flue must be carried out by a compete...

Page 36: ...80 125 303 202 X X Air flue duct extensions concentric 970 mm 80 125 303 203 X X Air flue duct extensions concentric 1970 mm 80 125 303 205 X X Bends PP concentric pack of 2 45 80 125 303 211 X X Elbo...

Page 37: ...15 25 1 5 2 5 Elbow PPs 87 80 125 Accy No 303 210 Bends PPs 45 80 125 pack of 2 Accy No 303 211 140 125 Flue support clips 125 pack of 5 Accy No 303 616 164 120 Sliding sleeve PPs 80 125 Accy No 303...

Page 38: ...4 Maximum flue lengths for use with ecoTEC Accessories Accy Nr ecoTEC plus 612 plus 615 plus 618 plus 624 plus 630 plus 824 plus 831 plus 637 plus 837 plus 937 pro 24 pro 28 plus 415 plus 418 plus 428...

Page 39: ...he four screws 2 and pull the appliance con nection piece 1 upwards to remove it Push the appliance connection piece with the selected connection diameter down from above inserting the push in end ont...

Page 40: ...amp 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 scre...

Page 41: ...TEC plus open vent 125 mm ecoTEC plus system combination 323 mm ecoTEC plus 937 Identify the correct measurement as shown in fig 3 7 carefully measure the distance from the bottom cen tre of the boile...

Page 42: ...ns are of a push fit type with the flue duct spigot insert ed into a socket containing a sealing ring For ease of installation lubricate the seal using soap solution prior to assembling Assemble the f...

Page 43: ...n 210 mm ecoTEC plus open vent from top holes on bracket 238 mm ecoTEC plus system combination 238 mm ecoTEC plus 937 Fit the wall mounting 4 Install the appliance 5 with reference to the installa tio...

Page 44: ...l penetrate the roof hPlease note The vertical air flue duct and ter minal accessory Accy No 303 200 may be shortened The outer white duct should be shortened first then the inner flue duct cut so tha...

Page 45: ...y to allow for any slight movement in the roof structure Ensure that at least one pipe clamp supports the air flue duct at each extension fitted 3 6 4 Flat roof installation 7 82 90 885 545 125 120 1...

Page 46: ...al air flue duct and termi nal accessory to allow for any slight movement in the roof structure Ensure that at least one pipe clamp supports the air flue duct at each extension fitted 3 7 Fitting air...

Page 47: ...Do not use damaged or dented tubes as they will not form an adequate seal Caution Ensure that the seals remain correctly aligned when installing the tubes Do not fit damaged seals Caution Secure the e...

Page 48: ...fig 3 22 and fig 3 23 to avoid obstructions a Caution The elbows must be correctly aligned to avoid undue stress on the joints and risk of leakage h Note The elbow fitted to the top of the boiler 1 sh...

Page 49: ...825 615 380 170 605 395 830 620 385 175 610 400 835 625 390 180 615 405 840 630 395 185 620 410 845 635 400 190 625 415 850 640 405 195 630 420 855 645 410 200 635 425 860 650 415 205 640 430 865 655...

Page 50: ...5 178 345 425 461 545 625 744 745 230 185 350 430 468 550 630 751 750 235 192 355 435 475 555 635 758 755 240 199 360 440 482 560 640 765 760 245 207 365 445 489 565 645 772 765 250 214 370 450 496 57...

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Page 52: ...834449_13 GB 052008...

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Vaillant Air flue duct, Installation Instructions Manual

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