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  5. Installation Instructions Manual

Vaillant Air flue duct Installation Instructions Manual

Manual is about: for use with ecoTEC boilers

Summary of 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) gb.

  • Page 2

    Flue installation instructions ecotec 834449_13 2 contents 1 notes on the documentation ........................... 3 1.1 storage of documents ............................................. 3 1.2 symbols used ............................................................. 3 1.3 applicability of the man...

  • Page 3

    3 flue installation instructions ecotec 834449_13 1 notes on the documentation the following instructions are intended to help you throughout the entire documentation. Further documents apply in combination with this instal- lation manual. We accept no liability for any damage caused by non-ob- serv...

  • Page 4

    Flue installation instructions ecotec 834449_13 4 h note two types of flue gas installation are available for ecotec boilers: - standard concentric flue gas installations (outer diameter 100 mm) - a concentric system with a larger diameter (outer diameter 125mm) which can be used to achieve longer a...

  • Page 5

    5 flue installation instructions ecotec 834449_13 2.2 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 ...

  • Page 6

    Flue installation instructions ecotec 834449_13 6 optional connection accessories accy. No. 0020060570 0020060571 0020065937 303 982 303 922 303 923 variable termination kit - black *) 303 942 x x extension pipe for variable termination kit vtk Ø 60 mm 1 m - black *) 303 943 x x 87° elbow for variab...

  • Page 7

    7 flue installation instructions ecotec 834449_13 2.2.2 element descriptions element description 60 air/flue duct extension, Ø 60/100 470 mm: accy. No. 303 902 970 mm: accy. No. 303 903 1970 mm: accy. No. 303 905 18 70 94 27 94 70 18 27 18 27 elbow, Ø 60/100 87°: accy. No. 303 910 45°: accy. No. 303...

  • Page 8

    Flue installation instructions ecotec 834449_13 8 element description 290 – 374 3 3 – 56 48 48 offset section, Ø 60/100 accy. No.: 303 919 black terminal kit for hori- zontal air/flue duct accy. No.: 303 934 for 303 933 and 303 936 only variable termination kit - black accy. No.: 303 942 for 303 933...

  • Page 9

    9 flue installation instructions ecotec 834449_13 2.2.3 maximum flue lengths for use with ecotec exclusive accessories accy.-nr. Ecotec exclusive 832 838 horizontal flue systems 303 933 303 936 max. Permitted concentric flue length 4.0 m incl. 1 elbow 87° maximum length of flue is reduced by 1.0 m f...

  • Page 10

    Flue installation instructions ecotec 834449_13 10 a fig. 2.1 horizontal 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 systems key a maximum flue length ...

  • Page 11

    11 flue installation instructions ecotec 834449_13 2.3 installing the air/flue duct sliding sleeve h note for installations where there is insufficient movement to allow fitting of the flue into flue outlet, a sliding sleeve (accy. No. 303 915) is available. When using the sliding sleeve both the ai...

  • Page 12

    Flue installation instructions ecotec 834449_13 12 2.4.2 preparation 4 * 87 3 2 1 5 fig. 2.6 assembly of the boiler and of the roof duct to buildings with pitched roofs key * = 190 mm ecotec exclusive combination * = 176 mm ecotec plus open vent * = 125 mm ecotec plus system & combination * = 323 mm...

  • Page 13

    13 flue installation instructions ecotec 834449_13 h 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 and the flue external wall seal fitted from outside the dwell- ing. 87 87 a a b 1. 2. Fig. 2.8 distance to externa...

  • Page 14

    Flue installation instructions ecotec 834449_13 14 the clamps to the air ducts of the flue assembly, the elbow and boiler using the screws supplied. • slide the internal trim ring back to the wall, securing in position with a small amount of sealant if required. A caution! If installed near a light,...

  • Page 15

    15 flue installation instructions ecotec 834449_13 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

    Flue installation instructions ecotec 834449_13 16 a + 22 mm 1 2 fig. 2.15 fixing the air pipe • adjust the air duct and flue duct to the lengths shown in (fig. 2.15). • secure the air duct sections together by drilling a 3 mm diameter hole through the location hole in the end of the outer air duct ...

  • Page 17

    17 flue installation instructions ecotec 834449_13 2.6 installation of the black terminal kit 2.6.1 contents included with delivery fig. 2.17 black terminal kit, accy.-no. 303 934 black terminal kit (accy. No. 303 934) contents of the accessory: - black terminal - external wall seal 2.6.2 assembly o...

  • Page 18

    Flue installation instructions ecotec 834449_13 18 2.6.3 assembly of the black terminal kit after in- stalling the flue duct d danger! Risk to life from escaping flue gas! Before starting work, shut down the appliance and prevent it from being switched on uninten- tionally. • remove the wall seal fr...

  • Page 19

    19 flue installation instructions ecotec 834449_13 2.7.2 assembly of the variable terminal kit before installing the flue pipe 55 fig. 2.24 wall clearance fig. 2.25 releasing the catches • use an 8 mm screwdriver to bend the catches in- wards. Fig. 2.26 pulling out the terminal • pull the terminal w...

  • Page 20

    Flue installation instructions ecotec 834449_13 20 • fit the rest of the variable termination kit as de- scribed in section 2.7.4. 2.7.3 installing the variable terminal kit after in- stalling the flue duct d danger! Risk to life from escaping flue gas! Before starting work, shut down the appliance ...

  • Page 21

    21 flue installation instructions ecotec 834449_13 fig. 2.31 bird protection grille fig. 2.32 installation of basic kit with two additional 87° bends showing position of support clips fig. 2.33 installation of basic kit with two additional 45° bends showing position of support clips • fit the pipes ...

  • Page 22

    Flue installation instructions ecotec 834449_13 22 a caution! If installed near a light, insects may fly into the opening. Tell the home owner to clean the open- ing regularly. D danger! Before starting up the appliance, check that the entire flue pipe is firmly seated and sealed. A caution! During ...

  • Page 23

    23 flue installation instructions ecotec 834449_13 h 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. • additional 45° bends may be required. 2.8 installing the deflector...

  • Page 24

    Flue installation instructions ecotec 834449_13 24 fig. 2.40 locking the catch • push the flue gas pipe and the deflector back into the air pipe and lock the two catches. A caution! The seam of the air duct must be at the top. • fit the horizontal air/flue duct as described in section 2.4 and 2.5. 2...

  • Page 25

    25 flue installation instructions ecotec 834449_13 fig. 2.44 flue pipe a caution! The catch on the top of the terminal must lock firmly into the notch in the flue duct. Caution! Make sure the seal fits tightly. Fig. 2.45 locking the catch • push the flue gas pipe with the terminal back into the air ...

  • Page 26

    Flue installation instructions ecotec 834449_13 26 2.9 installation of the vertical air/flue duct h note observe the maximum flue lengths as detailed in sections 2.2.3 and 2.2.4. 2.9.1 contents included with delivery 8 4 1456 542 901 fig. 2.48 vertical roof duct vertical air/flue duct accy. No.: 002...

  • Page 27

    27 flue installation instructions ecotec 834449_13 2.9.3 pitched roof installation 2 3 54 2 901 Ø 100 20 - 50 6 7 8 1 0-5 8 4 100- 110 5 fig. 2.49 fitting the appliance and the vertical roof duct to a building with a pitched roof key * = 190 mm ecotec exclusive combination * = 176 mm ecotec plus ope...

  • Page 28

    Flue installation instructions ecotec 834449_13 28 2.9.4 flat-roof installation 901 54 2 Ø 100 120 1 6 7 5 7 4 100 - 110 a b 2 * 3 fig. 2.50 fitting the appliance and vertical flue duct to a build- ing with a flat roof key a cold roof b warm roof * = 750 mm ecotec exclusive combination * = 530 mm ec...

  • Page 29

    29 flue installation instructions ecotec 834449_13 2.10 installing the ridge tile terminal h note observe the maximum flue gas pipe lengths as detailed in sections 2.2.3 and 2.2.4. 2.10.1 contents included with delivery 40 760 fig. 2.51 ridge tile terminal ridge tile terminal accessory no.: 303 982 ...

  • Page 30

    Flue installation instructions ecotec 834449_13 30 2.10.4 installing the ridge tile terminal 1 fig. 2.54 installing the ridge tile terminal • insert the ridge tile terminal into the ridge tile. • align the ridge tile terminal in such a way that the two fixing straps (1) are sitting across the run of...

  • Page 31

    31 flue installation instructions ecotec 834449_13 1. 2. A b + 40 mm 13 70 27 2 2 1 1 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* (l air ), and then calculate the corresponding length of flue conduit (l e...

  • Page 32

    Flue installation instructions ecotec 834449_13 32 1 2 max. 5 m max. 5 m * = 3° 90° * fig. 2.61 connecting extensions with 87° elbows 1 max. 5 m max. 5 m 90° fig. 2.62 connecting extensions with 45° elbows when using elbows for long flue runs in a corner follow fig. 2.61 and fig. 2.62 to avoid obstr...

  • Page 33

    33 flue installation instructions ecotec 834449_13 2.11.3 how to install 87° elbows 190 95 95 10 10 a b fig. 2.63 installation of 87° elbows, accy. No.: 303 910 offset [in mm] length of air conduit [in mm] offset [in mm] length of air conduit [in mm] offset [in mm] length of air conduit [in mm] > 19...

  • Page 34

    Flue installation instructions ecotec 834449_13 34 2.11.4 how to install 45° elbows c a b 10 10 fig. 2.64 installation of 45° bends, accy. No.: 303 911 offset [in mm] length of air conduit [in mm] height [in mm] offset [in mm] length of air conduit [in mm] height [in mm] offset [in mm] length of air...

  • Page 35

    35 flue installation instructions ecotec 834449_13 3 optional concentric system Ø 80/125 galvanized steel air duct/plastic flue duct. 3.1 requirements 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...

  • Page 36

    Flue installation instructions ecotec 834449_13 36 3.2 planning the air/flue duct layout 3.2.1 alternative termination accessories available 303 200 = vertical air/flue duct (black) 303 209 = horizontal air/flue duct optional connection accessories accy. No. 303 200 303 209 appliance connection piec...

  • Page 37

    37 flue installation instructions ecotec 834449_13 3.2.2 element descriptions element description appliance connection piece Ø 80/125 accy. No.: 303 926 (with 2 measuring apertures) 80 air/flue duct extension (pps) Ø 80/125 470 mm: accy. No.: 303 202 970 mm: accy. No.: 303 203 1970 mm: accy. No.: 30...

  • Page 38

    Flue installation instructions ecotec 834449_13 38 3.2.3 maximum flue lengths for use with ecotec exclusive accessories accy.-nr. Ecotec exclusive 832 838 horizontal flue systems 303 209 max. Permitted concentric flue length 21.0 m incl. 1 elbow 87° maximum length of flue is reduced by 2.5 m for eac...

  • Page 39

    39 flue installation instructions ecotec 834449_13 a fig. 3.1 horizontal flue systems key a maximum flue length a fig. 3.2 vertical flue systems key a maximum flue length 3.3 changing the appliance connection piece installation accy no.: 303 926 1 2 fig. 3.3 fitting the appliance connection piece th...

  • Page 40

    Flue installation instructions ecotec 834449_13 40 3.4 installation of the sliding sleeve installing the air/flue duct sliding sleeve h note for installations where there is insufficient movement to allow fitting of the flue into flue outlet, a sliding sleeve (accy. No. 303 215) is available. When u...

  • Page 41

    41 flue installation instructions ecotec 834449_13 a fig. 3.6 example of installation with horizontal air/flue duct 3.5.2 preparation • determine the installation site for the boiler with ref- erence to the installation and servicing instructions supplied with the boiler. • ensure that all installat...

  • Page 42

    Flue installation instructions ecotec 834449_13 42 h note due to the long lengths of flue possible and the slope required, it may be necessary to adjust the location of the boiler installation template. Please check that both the boiler installation site and flue termination are in accordance with t...

  • Page 43

    43 flue installation instructions ecotec 834449_13 220 15 3° 1 fig. 3.12 installing the horizontal wall duct • push the assembled air/flue duct and terminal assem- bly through the flue exit hole until it protrudes 220 mm out from the outside wall. • ensure that the terminal is correctly positioned w...

  • Page 44

    Flue installation instructions ecotec 834449_13 44 3.6 installation of the vertical air/flue duct h note observe the maximum flue lengths as detailed in sections 3.2.3 and 3.2.4. 3.6.1 contents included with delivery 1430 70 fig. 3.14 vertical roof duct vertical air/flue duct accy. No.: 303 200 (bla...

  • Page 45

    45 flue installation instructions ecotec 834449_13 • install the appliance (7) with reference to the installa- tion and servicing instructions supplied with the boil- er. H note see section 3.7 for further details on the in- stallation of extensions and elbows. • push the sliding sleeve (8) firmly i...

  • Page 46

    Flue installation instructions ecotec 834449_13 46 • push the sliding sleeve (7) firmly on to the vertical roof duct (1) or, where appropriate, on to an exten- sion. • where appropriate, join the vertical roof duct (1) to an extension. • join the sliding sleeve (7) to the appliance’s connec- tion pi...

  • Page 47

    47 flue installation instructions ecotec 834449_13 a caution! You must fasten extensions to the ceiling or wall using pipe clamps. Use one clamp for each extension. Caution! Where extensions are used, these must be in- stalled with a slope of 3° ± 1° to ensure that condensate does not remain in the ...

  • Page 48

    Flue installation instructions ecotec 834449_13 48 1 2 max. 5 m max. 5 m * = 3° 90° * fig. 3.22 connecting extensions with 87° elbows 1 max. 5 m max. 5 m 90° fig. 3.23 connecting extensions with 45° elbows when using elbows for long flue runs in a corner follow fig. 3.22 and fig. 3.23 to avoid obstr...

  • Page 49

    49 flue installation instructions ecotec 834449_13 3.7.3 how to install 87° elbows 190 95 95 10 10 a b fig. 3.24 installation of 87° elbows, accy. No.: 303 210 offset [in mm] length of air conduit [in mm] offset [in mm] length of air conduit [in mm] offset [in mm] length of air conduit [in mm] 200, ...

  • Page 50

    Flue installation instructions ecotec 834449_13 50 3.7.4 how to install 45° elbows c a b 10 10 fig. 3.25 installation of 45° bends, accy. No.: 303 211 offset [in mm] length of air conduit [in mm] height [in mm] offset [in mm] length of air conduit [in mm] height [in mm] offset [in mm] length of air ...

  • Page 52

    834449_13 gb 052008.