Vaillant Air flue duct Installation Instructions Manual
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Vaillant Air flue duct Installation Instructions Manual

Air flue duct for use with ecotec boilers
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For the installer
Flue installation instructions
Air flue duct for use with ecoTEC boilers
GB
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)

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Summary of Contents for Vaillant Air flue duct

  • Page 1 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)

  • Page 2: Table Of Contents

    Contents Contents Notes on the documentation ......Installation of the vertical air/flue duct ..... 26 Storage of documents ..........2.9.1 Contents included with delivery ......26 Symbols used ............. 2.9.2 Preparation ..............26 Applicability of the manual ........2.9.3 Pitched roof installation .......... 27 2.9.4 Flat-roof installation ..........

  • Page 3: Notes On The Documentation 1

    Applicability of the manual Note This installation manual is only valid for the Vaillant The installation of the boiler and its flue must boilers referred to in the other applicable documents. be carried out by a competent person who is registered with CORGI (The Council for Regis- tered Gas Installers).

  • Page 4: Intended Use

    45 kW. The Vaillant flue pipes for ecoTEC may only be used Part 1 Fundamental and design consid- with the unit types named in this installation manual.

  • Page 5: Planning The Air/Flue Duct Layout

    Standard Concentric Systems Ø 60/100 2 Planning the air/flue duct layout 2.2.1 Alternative termination accessories available 0020060570 = Vertical air/flue duct (black) 0020060571 = Vertical air/flue duct (red) 0020065937 = Vertical air/flue duct (black) 303 982 = Ridge tile terminal 303 933 = Horizontal air/flue duct 303 936 = Horizontal telescopic air/flue duct 0020060570...
  • Page 6 2 Standard Concentric Systems Ø 60/100 0020060570 303 982 303 922 303 923 0020060571 0020065937 Optional connection accessories Accy. No. Variable termination kit - black *) 303 942 Extension pipe for variable termination kit VTK 303 943 Ø 60 mm 1 m - black *) 87°...

  • Page 7: Element Descriptions

    Standard Concentric Systems Ø 60/100 2 2.2.2 Element descriptions Element Description Element Description Air/flue duct extension, Sliding sleeve (PP), Ø 60/100 Ø 60/100 470 mm: Accy. No. 303 902 Accy. No.: 303 915 970 mm: Accy. No. 303 903 1970 mm: Accy. No. 303 905 Elbow, Ø...
  • Page 8 2 Standard Concentric Systems Ø 60/100 Element Description Element Description Offset section, Ø 60/100 45° bend for variable termi- Accy. No.: 303 919 nation kit - black Accy. No.: 303 945 45° bend for variable termi- nation kit - white Accy.

  • Page 9: Maximum Flue Lengths For Use With Ecotec Exclusive

    Standard Concentric Systems Ø 60/100 2 2.2.3 Maximum flue lengths for use with ecoTEC exclusive ecoTEC exclusive Accessories Accy.-Nr. Horizontal 303 933 Max. permitted 4.0 m flue systems 303 936 concentric incl. flue length 1 elbow 87° Maximum length of flue is reduced by 1.0 m for each additional 87° elbow Maximum length of flue is reduced by 0.5 m for each additional 45°...

  • Page 10: Horizontal/Vertical Flue Systems View

    2 Standard Concentric Systems Ø 60/100 Fig. 2.1 Horizontal flue systems A Maximum flue length Fig. 2.3 Vertical flue systems A Maximum flue length Fig. 2.2 Horizontal flue system installed with vertical termina- tion kit A Concentric flue length B Flue length outside Flue installation instructions ecoTEC 834449_13...

  • Page 11: Installing The Air/Flue Duct Sliding Sleeve

    The air/flue duct is not concentric and the air available. When using the sliding sleeve both duct has a slope of 1.5° (if the air flue duct is the air and flue ducts of the last extension not cut). The hole through the wall can there- must be shortened by a further 95 mm.

  • Page 12: Preparation

    2 Standard Concentric Systems Ø 60/100 2.4.2 Preparation 2.4.3 Top outlet flue exiting to rear • For installations where the air/flue duct is to be in- stalled directly to the rear of the boiler, the installa- tion template details the position of the flue exit hole for horizontal top outlet installation.
  • Page 13 Standard Concentric Systems Ø 60/100 2 • Cut the air duct and flue duct to the lengths shown in Note (fig. 2.9). If access can be gained to the proposed flue • All flue sockets should point towards the terminal. exit point from outside the dwelling, the hole •...

  • Page 14: Installation Of The Telescopic Horizontal Air/Flue Duct

    Contents included with delivery Caution! The air/flue duct is not concentric and the air duct has a slope of 1.5° (if the air flue duct is not cut). The hole through the wall can there- fore be drilled horizontally with no slope.

  • Page 15: Top Outlet Flue Exiting To Rear

    Standard Concentric Systems Ø 60/100 2 2.5.3 Top outlet flue exiting to rear • For installations where the air/flue duct is to be in- stalled directly to the rear of the boiler, the installa- tion template details the position of the flue exit hole for horizontal top outlet installation.
  • Page 16 2 Standard Concentric Systems Ø 60/100 secure using the 30 mm air duct clamp (3) provided (fig. 2.12). • Pull the air/flue duct back through the wall such that the flue duct fully engages into the flue elbow socket. • Fit the 48 mm air duct clamp (5) ensuring that it is positioned centrally (fig.

  • Page 17: Installation Of The Black Terminal Kit

    Standard Concentric Systems Ø 60/100 2 Installation of the black terminal kit 2.6.1 Contents included with delivery 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. Fig.

  • Page 18: Assembly Of The Black Terminal Kit After Installing The Flue Duct

    • Use an 8 mm screwdriver to bend the catches inwards facturer has received approval to quote smaller clear- (fig. 2.18). ances that are not safety critical. Vaillant have reduced • Pull the terminal together with the flue duct out of the flue terminal clearances approved and these are given air duct (fig.

  • Page 19: Assembly Of The Variable Terminal Kit Before Installing The Flue Pipe

    Standard Concentric Systems Ø 60/100 2 2.7.2 Assembly of the variable terminal kit before installing the flue pipe Fig. 2.27 Unlocking the catch • Unlock the catch between the terminal and the flue duct by twisting them against each other. •...

  • Page 20: Installing The Variable Terminal Kit After Installing The Flue Duct

    2 Standard Concentric Systems Ø 60/100 • Fit the rest of the variable termination kit as de- 2.7.4 Installing the pipes scribed in section 2.7.4. 2.7.3 Installing the variable terminal kit after in- stalling the flue duct Danger! Risk to life from escaping flue gas! Before starting work, shut down the appliance and prevent it from being switched on uninten- tionally.
  • Page 21 Standard Concentric Systems Ø 60/100 2 Fig. 2.31 Bird protection grille Fig. 2.33 Installation of basic kit with two additional 45° bends showing position of support clips • Fit the pipes and bends, working from the variable ter- minal to the selected location for the flue exit using support clips supplied fig.

  • Page 22: Routing Around Roof Eaves

    2 Standard Concentric Systems Ø 60/100 Caution! 2.7.5 Routing around roof eaves If installed near a light, insects may fly into the opening. Tell the home owner to clean the open- ing regularly. Danger! Before starting up the appliance, check that the entire flue pipe is firmly seated and sealed.

  • Page 23: Installing The Deflector Set

    Standard Concentric Systems Ø 60/100 2 Note If using the 87° elbow, use the seal from the pipe extension. • The final pipe extension must be fixed to the wall using two support clips with a minimum distance of 400 mm. •...

  • Page 24: Installation Of The Deflector Set After Installing The Flue Gas Pipe

    Do not twist the flue gas pipe when doing this. Vaillant have reduced the flue terminal clearances and Turning can cause the following flue gas pipe to these are given in the boiler installation instructions.
  • Page 25 Standard Concentric Systems Ø 60/100 2 Setting the deflector in the centre position will direct the stream of flue gases upwards at an angle of approx. 45°. 45° 45° Fig. 2.44 Flue pipe Caution! Fig. 2.47 Lateral setting options The catch on the top of the terminal must lock firmly into the notch in the flue duct.

  • Page 26: Installation Of The Vertical Air/Flue Duct

    If a 87° elbow is connected directly to the boil- er, use the 48 mm air duct clamp supplied with the vertical air flue duct at this position. Fig. 2.48 Vertical roof duct Vertical air/flue duct Accy. No.: 0020060570 (black) Accy.

  • Page 27: Pitched Roof Installation

    Standard Concentric Systems Ø 60/100 2 2.9.3 Pitched roof installation Note See section 2.11 for further details on the in- stallation of extensions and elbows. • Push the sliding sleeve (4) firmly into place on the ex- tension. • Join the vertical roof duct (5) to the extension (7). •...

  • Page 28: Flat-Roof Installation

    2 Standard Concentric Systems Ø 60/100 2.9.4 Flat-roof installation • Join the sliding sleeve (4) to the appliance’s connec- tion piece. 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.

  • Page 29: Installing The Ridge Tile Terminal

    • Determine the point where the ridge tile terminal is to pass through the ridge. Note If an 87° elbow is connected directly to the boiler, use the 40 mm air duct clamp supplied with the vertical air flue duct at this position. Flue installation instructions ecoTEC 834449_13...

  • Page 30: Installing The Ridge Tile Terminal

    2 Standard Concentric Systems Ø 60/100 2.10.4 Installing the ridge tile terminal Note See section 2.11 for further details on the in- stallation of extensions and elbows. • Connect the ridge tile terminal and the boiler using extensions and elbows. •...

  • Page 31: How To Install 2X 87° Elbows

    Standard Concentric Systems Ø 60/100 2 2.11.2 How to install 2x 87° elbows + 40 mm Fig. 2.57 Cutting tubes to size • Use a saw, tin-snips, etc. to cut tubes to size. • Start by measuring the required length of air conduit* ), and then calculate the corresponding length of Fig.
  • Page 32 2 Standard Concentric Systems Ø 60/100 90° * = 3° max. 5 m Fig. 2.61 Connecting extensions with 87° elbows 90° max. 5 m Fig. 2.62 Connecting extensions with 45° elbows When using elbows for long flue runs in a corner follow fig.

  • Page 33: How To Install 87° Elbows

    Standard Concentric Systems Ø 60/100 2 2.11.3 How to install 87° elbows A = Offset B = Length of air conduit Note The elbow delilvered with the flue kits 303 933 and 303 936 is not the same dimension as shown here.

  • Page 34: How To Install 45° Elbows

    2 Standard Concentric Systems Ø 60/100 2.11.4 How to install 45° elbows A = Offset B = Length of air conduit C = Height Caution! This gives a corresponding exhaust-conduit length of 284 + 40 = 324 mm. Example: An offset of 400 mm is measured. This value is then used, along with the table below, to determine the length of the air conduit (= 284 mm) and the height (= 420 mm).

  • Page 35: Optional Concentric System Ø 80/125

    Note Note Ensure while installation work is being carried Vaillant ecoTEC gas fired wall hung boilers are out that no debris such as swarf, filings or frag- certified as boiler systems with corresponding ments of mortar are allowed to remain in the flue gas systems according to the EU gas appli- air/flue duct.

  • Page 36: Planning The Air/Flue Duct Layout

    3 Optional Concentric System Ø 80/125 Planning the air/flue duct layout 3.2.1 Alternative termination accessories available 303 200 = Vertical air/flue duct (black) 303 926 =Appliance connection piece 303 209 = Horizontal air/flue duct 303 200 303 209 Optional connection accessories Accy.

  • Page 37: Element Descriptions

    Optional Concentric System Ø 80/125 3 3.2.2 Element descriptions Element Description Element Description Appliance connection piece Adjustable roof tiles for Ø 80/125 pitched roof Accy. No.: 303 926 Accy. No.: 009 076 (black) (with 2 measuring apertures) Air/flue duct extension (PPs) Flat roof penetration collar Ø...

  • Page 38: Maximum Flue Lengths For Use With Ecotec Exclusive

    3 Optional Concentric System Ø 80/125 3.2.3 Maximum flue lengths for use with ecoTEC exclusive ecoTEC exclusive Accessories Accy.-Nr. Horizontal 303 209 Max. permitted 21.0 m flue systems concentric incl. flue length 1 elbow 87° Maximum length of flue is reduced by 2.5 m for each additional 87° elbow Maximum length of flue is reduced by 1.0 m for each additional 45°...

  • Page 39: Changing The Appliance Connection Piece

    Optional Concentric System Ø 80/125 3 Changing the appliance connection piece Installation Accy No.: 303 926 Fig. 3.1 Horizontal flue systems A Maximum flue length Fig. 3.3 Fitting the appliance connection piece The appliance is supplied ready-fitted with the connec- tion piece for the 60/100 air/flue duct system.

  • Page 40: Installation Of The Sliding Sleeve

    Caution! The air/flue duct is not concentric and the air Note duct has a slope of 1.5° (if the air flue duct is For installations where there is insufficient not cut). The hole through the wall can there- movement to allow fitting of the flue into flue fore be drilled horizontally with no slope.

  • Page 41: Preparation

    Optional Concentric System Ø 80/125 3 * = 190 mm ecoTEC exclusive combination * = 176 mm ecoTEC 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 boiler hanging bracket (centreline of the two lower hanging bracket fixing holes).
  • Page 42 3 Optional Concentric System Ø 80/125 Note Note Due to the long lengths of flue possible and the The joints between the flue duct sections are of slope required, it may be necessary to adjust a push-fit type, with the flue duct spigot insert- the location of the boiler installation template.

  • Page 43: Indirect Installation

    Optional Concentric System Ø 80/125 3 • Change the appliance connection piece (3) as de- scribed in section 3.3. • Join the 87° elbow to the appliance connection piece. • Push the sliding sleeve (7) firmly into place on the ap- propriate extensions (6).

  • Page 44: Installation Of The Vertical Air/Flue Duct

    3 Optional Concentric System Ø 80/125 Installation of the vertical air/flue duct Please note: The vertical air/flue duct and ter- minal accessory (Accy. No. 303 200) may be Note shortened. The outer ‘white’ duct should be Observe the maximum flue lengths as detailed shortened first, then the inner flue duct cut so in sections 3.2.3 and 3.2.4.

  • Page 45: Flat-Roof Installation

    Optional Concentric System Ø 80/125 3 • Install the appliance (7) with reference to the installa- 3.6.4 Flat-roof installation tion and servicing instructions supplied with the boil- Note See section 3.7 for further details on the in- stallation of extensions and elbows. •...

  • Page 46: Fitting Air/Flue Duct Extensions

    3 Optional Concentric System Ø 80/125 • Push the sliding sleeve (7) firmly on to the vertical Fitting air/flue duct extensions roof duct (1) or, where appropriate, on to an exten- sion. 3.7.1 How to add extensions • Where appropriate, join the vertical roof duct (1) to an extension.

  • Page 47: How To Install 2X 87° Elbows

    Optional Concentric System Ø 80/125 3 Caution! You must fasten extensions to the ceiling or wall using pipe clamps. Use one clamp for each extension. Caution! * = 3° Where extensions are used, these must be in- stalled with a slope of 3° 1°...
  • Page 48 3 Optional Concentric System Ø 80/125 Note When using 87° elbow install with a slope of 3° between wall and air-flue pipe (fig. 3.22) or use 2 x 45° elbows (fig. 3.23). 90° * = 3° max. 5 m Fig. 3.22 Connecting extensions with 87° elbows 90°...

  • Page 49: How To Install 87° Elbows

    Optional Concentric System Ø 80/125 3 3.7.3 How to install 87° elbows A = Offset B = Length of air conduit Caution! This gives a corresponding exhaust-conduit length of 190 + 40 = 230 mm. Example: An offset of 400 mm is measured. This value is then used, along with the table below, to determine the length of the air conduit ( = 190 mm in this case).

  • Page 50: How To Install 45° Elbows

    3 Optional Concentric System Ø 80/125 3.7.4 How to install 45° elbows A = Offset B = Length of air conduit C = Height Caution! This gives a corresponding exhaust-conduit length of 284 + 40 = 324 mm. Example: An offset of 400 mm is measured. This value is then used, along with the table below, to determine the length of the air conduit (= 284 mm) and the height (= 420 mm).

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