Related Manuals for Vaillant turboMAX plus 2 E Series
Summary of Contents for Vaillant turboMAX plus 2 E Series
- Page 1 For the installer Flue installation instructions Air flue duct for use with PART 1: Standard Concentric Systems turboMAX plus .../2 E Ø 60/100 PART 2: turboMAX pro .../2 E Optional Concentric Systems Ø 80/125 thermoCOMPACT .../2 E aquaPLUS...
- Page 2 CONTENTS: PART 1 CONCENTRIC 60/100 Page Requirements § Planning the air/flue duct layout Alternative termination accessories available Maximum flue lengths Ø 60/100 Flue restrictor rings Installation of the horizontal Preparation Top outlet flue exiting to rear air/flue duct (top outlet) Top outlet flue exiting to side Installation of the horizontal Preparation...
- Page 3 CONTENTS: PART 2 CONCENTRIC 80/125 Page Planning the air/flue duct layout Termination accessories available Maximum flue lengths Ø 80/125 Flue restrictor rings Fitting the appliance flue outlet adapter to the boiler Installation of the horizontal Preparation Side flue installations air/flue with extensions Installation of the horizontal Preparation Fitting extensions...
- Page 4 § REQUIREMENTS ☞ Vaillant turboMAX, ☞ The air/flue duct operates at very thermoCOMPACT and aquaPLUS low temperatures therefore no boilers are certified as heating clearance is necessary between boilers with corresponding flue the air duct and adjacent systems according to EC Directive services.
- Page 5 PLANNING THE AIR/FLUE DUCT LAYOUT Alternative termination 303 807 = Horizontal air/flue duct with 90° elbow and terminal (750 mm) accessories available 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;...
- Page 6 PLANNING THE AIR/FLUE DUCT LAYOUT 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 Fig. 1.1: Extensions, Ø 60/100 Telescopic air/flue duct extension 500 –...
- Page 7 PLANNING THE AIR/FLUE DUCT LAYOUT ☞ Use one clip per extension to Flue support clips, Ø 100 (Pack of 5) support the air/flue duct. Accy. No.: 303 821 Fig. 1.5: Flue support clip, Ø 100 Sliding sleeve, Ø 60/100 Accy. No.: 303 816 Fig.
- Page 8 PLANNING THE AIR/FLUE DUCT LAYOUT Maximum flue lengths Ø 60/100 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...
- Page 9 PLANNING THE AIR/FLUE DUCT LAYOUT Flue restrictor rings Total equivalent flue length (incl. terminal any bends / elbows used) The flue restrictor ring marked A, C or D is packed with the boiler connection accessories. The restrictor thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT ring should be fitted as shown in the 620/2 E...
- Page 10 PLANNING THE AIR/FLUE DUCT LAYOUT Flue restrictor rings Total equivalent flue length (incl. terminal any bends / elbows used) 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 aquaPLUS thermoCOMPACT turboMAX plus...
- Page 11 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET) IMPORTANT: Horizontal air/flue duct The flue hole should be cut with a slight fall to outside of 1° to prevent Accy No.: 303 807 (Length 0.75 m) rain water entering the flue. Accy No.: 303 806 (telescopic, 0.45 –...
- Page 12 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET) • 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. Note: If access can be gained to the proposed flue exit point from outside the dwelling, the hole can be cut with a 107 mm core drill...
- Page 13 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET) • Push the air/flue duct assembly (1) including the flexible external seal (2) through the wall until the seal clears the outside face of the wall and pull air/flue duct back towards the boiler until the external seal touches the outside wall.
- Page 14 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) (TURBOMAX AND THERMOCOMPACT ONLY) IMPORTANT: Rear outlet flue accessory The flue hole should be cut with a Accy No: 303 817 slight fall to outside of 1° to prevent rain water entering the flue. Contents of the accessory Minimum top clearance for rear •...
- Page 15 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) (TURBOMAX AND THERMOCOMPACT ONLY) • Secure the boiler hanging bracket (1) to the wall using the screws 174,5 provided (2). • At this stage it is necessary to prepare and fit the boiler onto the hanging bracket –...
- Page 16 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) (TURBOMAX AND THERMOCOMPACT ONLY) Preparation of boiler for rear outlet air/flue duct For thermoCOMPACT 615, 637 and turboMAX plus 837: • Remove boiler case as detailed in the installation instructions supplied with the boiler. •...
- Page 17 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) (TURBOMAX AND THERMOCOMPACT ONLY) Preparation of boiler for rear outlet air/flue duct For thermoCOMPACT 620, 624, 628, turboMAX pro 24, 28 and turboMAX plus 824, 828: • Remove boiler case as detailed in the installation instructions supplied with the boiler.
- Page 18 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) • Remove the metal plate (1) covering the rear flue outlet point by pushing through the centre pins of the plastic fasteners as shown in the drawing. Now remove the metal plate by pulling on the foldedtag of the plate.
- Page 19 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) (TURBOMAX AND THERMOCOMPACT ONLY) For thermoCOMPACT 615, 637 and turboMAX plus 837: • Remove two screws (2) and separate the fan from the collector hood (4). • Swivel the collector hood (4) through 180°...
- Page 20 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET) (TURBOMAX AND THERMOCOMPACT ONLY) For thermoCOMPACT 620, 624, 628, turboMAX pro 24, 28, turboMAX plus 824, 828: • Refit the collector hood (1). Remove blank and refit funnel. • Reconnect the electrical cables to the fan.
- Page 21 INSTALLATION OF THE SE-DUCT FLUE IMPORTANT: Se-duct flue The flue hole should be cut with a Accy No.: 303 810 slight fall towards the Se-duct of 1°. Contents of the accessory: • Horizontal air/flue duct • 90°elbow • 2 x 48 mm air duct clamps •...
- Page 22 INSTALLATION OF THE SE-DUCT FLUE • Once the position of the flue exit hole has been determined, the hole should be cut through the wall using a core drill of 120 mm diameter. Ensure no debris enters the Se-duct. • Measure the distance from the wall face (inside of the duct) to the centre of the fan outlet on the boiler.
- Page 23 INSTALLATION OF THE SE-DUCT FLUE • Insert the end of the air/flue duct assembly through the se-duct wall. • Slide internal trim ring over the air duct until it is flush with the wall. • At this stage it is necessary to prepare and fit the boiler onto the hanging bracket –...
- Page 24 INSTALLATION OF THE VERTICAL AIR/FLUE DUCT Vertical air/flue duct Pitched roof Accy. Vaillant Part No.: 303 800 • Determine the point of termination Contents of the accessory: of the vertical air/flue duct and • Vertical air/flue duct and terminal terminal assembly. Install the assembly adjustable pitched roof tile (1, fig.
- Page 25 INSTALLATION OF THE VERTICAL AIR/FLUE DUCT • If the vertical air/flue duct and terminal assembly is to be connected directly to the boiler, it will be necessary to temporarily raise the flue slightly in order to mount the boiler. • Before connecting the flue on to the boiler flue outlet select and fit the correct restrictor ring into the bottom of the flue (as detailed in...
- Page 26 FITTING AIR/DUCT EXTENSIONS Fitting extensions • Measure and note the length of the air duct extension required for 10 mm 10 mm the installation. Use this measurement to calculate the length to cut the air and flue ducts: Length of Air duct Length of air duct •...
- Page 27 FITTING AIR/DUCT EXTENSIONS BETWEEN TWO 90° ELBOWS How to measure length Length of Air duct • Cut the length of the air duct as of air and flue ducts follows: Length of air duct as per table. Measure the distance between centres of the two flue pipes to be connected.
- Page 28 FITTING AIR/FLUE DUCT EXTENSIONS BETWEEN TWO 45° ELBOWS How to measure length Length of Air duct • Cut the length of the air duct as of air and flue ducts follows: Length of air duct as per table. Measure the distance between centres of the two flue pipes to be connected.
- Page 29 INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE How to fit sliding sleeves NOTE: For installations where there is insufficient movement to allow fitting of the flue into flue outlet, a sliding sleeve (Accy. No. 303 816) is available. When using the sliding sleeve both the air and flue ducts of the last extension must be shortened by a further 100 mm.
- Page 30 PLANNING THE AIR/FLUE DUCT LAYOUT Termination accessories 303 600 = Vertical roof duct(black) available 303 609 = Horizontal wall/roof duct 303 814 = Appliance flue outlet adaptor 303 600 303 609 Optional connection accessories Accy. Part No. Air/flue duct extensions 303 602 500 mm - Ø...
- Page 31 PLANNING THE AIR/FLUE DUCT LAYOUT Appliance flue outlet adaptor Ø 60/100 - Ø 80/125 Accy. No.: 303 814 (includes discharge tube and condensate trap) Fig. 1.1: Flue outlet adaptor Air/flue duct extensions 500 mm - Ø 80/125 Accy. No.: 303 602 Air/flue duct extensions 1000 mm - Ø...
- Page 32 PLANNING THE AIR/FLUE DUCT LAYOUT Sliding sleeve, Ø 80/125 Accy. No.: 303 617 Fig. 1.5: Sliding sleeve Ø 80/125 Adjustable roof tile Accy. No.: 9076 Fig. 1.6: Adjustable tiles for pitched roof Flat roof penetration collar Accy. No.: 9056 Fig. 1.7: Flat roof penetration collar-piece...
- Page 33 PLANNING THE AIR/FLUE DUCT LAYOUT Maximum flue lengths Ø 80/125 thermoCOMPACT thermoCOMPACT 628/2 E turboMAX plus 615, 620, 624/2 E turboMAX plus 828/2 E 837 E Accy. No. turboMAX plus 824/2 E turboMAX pro 28/2 E thermoCOMPACT turboMAX pro 24/2 E 637 E, aquaPLUS 303 609 Max.
- Page 34 PLANNING THE AIR/FLUE DUCT LAYOUT Flue restrictor rings Total equivalent flue length (incl. terminal any bends / elbows used) The flue restrictor ring marked A, or C / D is packed with the boiler connection accessories. The restrictor thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT ring should be fitted as shown in the...
- Page 35 PLANNING THE AIR/FLUE DUCT LAYOUT Flue restrictor rings Total equivalent flue length (incl. terminal any bends / elbows used) Two flue restrictor rings marked F0 to F2 are packed with the boiler connection accessories. The restrictor rings should be fitted as shown in the thermoCOMPACT turboMAX plus aquaPLUS...
- Page 36 FITTING THE APPLIANCE FLUE OUTLET ADAPTER TO THE BOILER Appliance flue outlet adaptor Accy. No.: 303 814 Ø 60/100 to Ø 80/125 Contents of the accessory: • Adaptor including condensate discharge connection • 48 mm Air duct clamp • Condensate trap •...
- Page 37 FITTING THE APPLIANCE FLUE OUTLET ADAPTER TO THE BOILER Connecting the condensate discharge system • A condensate discharge connection (3) is provided on the adaptor to remove any condensate or other water which may form in the flue system. • Connect the condensate discharge tube (2) to the condensate discharge connection point (4) on the adaptor and secure with the...
- Page 38 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITH EXTENSIONS Preparation IMPORTANT: Side flue installations The flue hole should be cut with a slight rise to outside of 3°±1° • Determine the installation site for • For installations where the air/flue (equivalent to 50mm±20mm rise per the boiler with reference to the duct is to be installed to the side,...
- Page 39 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITH EXTENSIONS • Taking each extension to be used, fit the flue duct into the air duct and secure using the 3 screws provided. • For ease of measuring and marking the air/flue duct extensions, assemble them loosely together with the air/flue duct and terminal assembly as shown (fig.
- Page 40 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT AND TERMINAL ACCESSORY (80/125 Ø) IMPORTANT: Horizontal air/flue duct and terminal The flue hole should be cut with a accessory slight rise to outside of 3°±1° Accy. No.: 303 609 (equivalent to 50mm±20mm rise per metre length) The set contains: •...
- Page 41 INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT AND TERMINAL ACCESSORY (80/125) Fitting extensions Connect the flue assembly to the adaptor • Install the flue extensions by working from the installed air/flue • Slide the 125 mm dia x 88 mm and terminal accessory back long air duct clamp over the air towards the boiler.
- Page 42 INSTALLATION OF THE VERTICAL ROOF DUCT Vertical air/flue duct and terminal accessory Accy. No.: 303 600 Contents of the accessory: • Vertical air/flue duct and terminal assembly • 70 mm Air duct clamp • Fixing bracket Fig. 5.1: Vertical Roof duct Preparation •...
- Page 43 INSTALLATION OF THE VERTICAL ROOF DUCT Pitched roof • Determine the point of termination of the vertical air/flue duct and terminal assembly. • Install the adjustable pitched roof tile (1) in position. • Fit the adjustable hood over the roof tile according to the roof pitch.
- Page 44 INSTALLATION OF THE VERTICAL ROOF DUCT • Assemble the flue such that there is a gap of about 10 mm between each air duct, which will ensure the correct flue duct penetration into the flue sockets of 30 mm. All flue sockets should point towards the flue terminal.
- Page 45 INSTALLATION OF THE VERTICAL ROOF DUCT • Drill two 3 mm diameter holes through the air duct (ensure that the drill does not pierce the inner flue duct). Fix the duct using the screws provided. • Ensure that the flue assembly is adequately supported along its entire length.
- Page 46 FITTING AIR/FLUE DUCT EXTENSIONS Cutting extensions • Measure and note the length of the air duct extension required for 10 mm 10 mm the installation (a). Note: Extensions should be assembled so there is a gap of 10 mm between each air duct. Use this measurement to calculate the Length of air duct length to cut the air and flue ducts:...
- Page 47 FITTING AIR/DUCT EXTENSIONS BETWEEN TWO 90° ELBOWS How to measure length Length of Air duct • Cut the length of the air duct as of air and flue ducts follows: Length of air duct as per table. Measure the distance between centres of the two flue pipes to be connected.
- Page 48 FITTING AIR/FLUE DUCT EXTENSIONS BETWEEN TWO 45° ELBOWS How to measure length Length of Air duct • Cut the length of the air duct as of air and flue ducts follows: Length of air duct as per table. Measure the distance between centres of the two flue pipes to be connected.
- Page 49 INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE How to fit sliding sleeves NOTE: For installations where there is insufficient movement to allow fitting of the flue into flue outlet, a sliding sleeve (Accy. No. 303 817) is available. When using the sliding sleeve both the air and flue ducts of the last extension must be shortened by a further 85 mm.
- Page 52 Head Office: Vaillant Ltd. Vaillant House Medway City Estate Trident Close Rochester Kent ME2 4EZ Service Solutions 0870 6060 777 Technical Advice 01634 292392...