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  5. Installation Instructions Manual

Vaillant ecoMAX 613/2 E Installation Instructions Manual

Summary of ecoMAX 613/2 E

  • Page 1

    For the installer flue installation instructions air flue duct for use with ecomax ecomax 613/2 e ecomax 618/2 e ecomax 622/2 e ecomax 824/2 e ecomax 828/2 e ecomax 835/2 e ecomax pro 18 e ecomax pro 28 e gb 2000225123a-10.02.

  • Page 2

    2.

  • Page 3: Overview

    Overview 3 pa r t 2 concentric 80/125 part 1 pages 4 - 20 standard concentric systems Ø 60/100 (aluminium air duct/plastic flue duct) part 2 pages 21 - 40 optional concentric system Ø 80/125 (aluminium air duct/plastic flue duct) pa r t 2 concentric 80/125 pa r t 1 concentric 60/100

  • Page 4: Requirements

    4 contents: part 1 concentric 60/100 page the air/flue duct must be installed by a suitably qualified service provider, which is responsible for observing the relevant specifications, regulations and standards. Requirements planning the air/flue duct layout regulations and standards to be observed 5...

  • Page 5: Requirements

    5 pa r t 1 concentric 60/100 requirements regulations and standards to be observed § ☞ vaillant ecomax boilers are certified as heating boilers with corresponding flue systems according to ec directive 90/396/eec on gas-fired devices. This installation manual is covered by this certification and is ...

  • Page 6

    Optional connection accessories offset section telescopic extension 440 mm - 690 mm Ø 60/100 6 planning the air/flue duct layout alternative termination accessories available air/flue duct extensions, concentric 470 mm - Ø 60/100 air/flue duct extensions, concentric 970 mm - Ø 60/100 air/flue duct e...

  • Page 7

    7 pa r t 1 concentric 60/100 planning the air/flue duct layout fig. 1.1: extensions, Ø 60/100 fig. 1.3: flue support clips, Ø 100/Ø 80 flue support clips, Ø 100 (pack of 5) vaillant accy. No.: 303 921 ☞ use one clip per extension to support the air/flue duct. 18 27 18 27 18 27 fig. 1.2: elbow joints...

  • Page 8

    8 planning the air/flue duct layout 155 fig. 1.6: sliding sleeve, Ø 60/100 sliding sleeve (pp), Ø 60/100 vaillant accy. No.: 303 915 290 – 374 33 – 56 fig. 1.5: offset section, Ø 60/100 offset section, Ø 60/100 vaillant accy. No.: 303 919 303919_iax fig. 1.8: flat roof penetration collar gu_laz 42/0...

  • Page 9

    9 pa r t 1 concentric 60/100 planning the air/flue duct layout maximum flue lengths for use with ecomax maximum flue length maximum flue length las euro b/s 074/0 las euro b/s 074/0 fig. 1.5 fig. 1.6 accessories accy. No. Vertical flue systems 303 900 max. Permitted concentric flue length horizontal...

  • Page 10: Installing The

    10 installing the air/flue duct sliding sleeve fig. 2.0: installing the sliding sleeve 1 2 3 1 2 4 5 6 7 schiebemuffe_neu installing the air/flue duct sliding sleeve ☞ note: for installations where there is in- sufficient movement to allow fitting of the flue into flue outlet, a slid- ing sleeve (ac...

  • Page 11

    11 800 ☞ observe the maximum flue lengths as detailed in table on page 9 horizontal air/flue duct vaillant accy no.: 303 930 contents of the accessory: • horizontal air/flue duct • 87° elbow • 1 x 70 mm air duct clamp • 1 x 40 mm air duct clamp • internal trim ring Ø 100 • external wall seal ☞ see p...

  • Page 12: Preparation

    12 installation of the horizontal air/flue duct horizontal air/flue duct accy no.: 303 930 (length 0.8 m) contents of the accessory: • horizontal air/flue duct • 87° elbow • 2 x 70 mm air duct clamps • 1 x 40 mm air duct clamp • internal trim ring Ø 100 • external wall seal. Fig. 3.1: horizontal air...

  • Page 13

    13 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 125 mm diameter. Note: if access can be gained to the proposed flue exit point from outside the dwelling, the hole...

  • Page 14

    14 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 w...

  • Page 15

    15 pa r t 1 concentric 60/100 1530 880 70 vertical air/flue duct accy. Vaillant part no.: 303 900 (black) contents of the accessory: • vertical air/flue duct and terminal assembly • 70 mm air duct clamp • fixing bracket ☞ see page 6 et seq. For details of air/flue duct elements. ☞ observe the maximu...

  • Page 16: Pitched Roof Installation

    16 installation of the vertical air/flue duct pitched roof installation • determine the point where the vertical air/flue duct and terminal assembly will penetrate the roof. • fit the adjustable pitched roof tile (1). • working from above, insert the vertical roof duct (5) through the roofing tile a...

  • Page 17: Flat-Roof Installation

    17 installation of the vertical air/flue duct pa r t 1 concentric 60/100 880 warm roof cold roof 650 Ø100 ≥ 120 2 1 5 6 7 750 4 40 7 fig. 4.4: fitting the appliance and vertical flue duct to a building with a flat roof flat-roof installation • determine the point where the vertical air/flue duct and...

  • Page 18: How to Add Extensions

    18 fitting air/flue duct extensions how to add extensions use a saw, tin-snips, etc. To cut tubes to size. ☞ no tools are required when separating extensions for cutting to size air and flue tubes separately. When doing so, the flue conduit should be twisted into a position where the shoulders on th...

  • Page 19: How to Install Elbows

    19 pa r t 1 concentric 60/100 fitting air/flue duct extensions offset length of [in mm] air conduit [in mm] offset length of [in mm] air conduit [in mm] offset length of [in mm] air conduit [in mm] 690 480 695 485 700 490 705 495 710 500 715 505 720 510 725 515 730 520 735 525 740 530 745 535 750 54...

  • Page 20: How to Install Elbows

    20 fitting air/flue duct extensions 90 0 210 95 0 215 100 0 220 > 105 to not possible 160 86 280 165 93 285 170 100 290 175 107 295 180 115 300 185 122 305 190 129 310 195 136 315 200 143 320 205 150 325 210 157 330 215 164 335 220 171 340 225 178 345 230 185 350 235 192 355 240 199 360 245 206 365 ...

  • Page 21: Requirements

    21 contents: part 2 concentric 80/125 page the air/flue duct must be installed by a suitably qualified service provider, which is responsible for observing the relevant specifications, regulations and standards. Requirements planning the air/flue duct layout regulations and standards to be observed ...

  • Page 22: Requirements

    22 requirements regulations and standards to be observed § ☞ vaillant ecomax boilers are certified as heating boilers with corresponding flue systems according to ec directive 90/396/eec on gas-fired devices. This installation manual is covered by this certification and is referred to in the design ...

  • Page 23: Alternative Termination

    23 pa r t 2 concentric 80/125 planning the air/flue duct layout alternative termination accessories available 303 200 = vertical air/flue duct (black) 303 209 = horizontal air/flue duct 303 907 = appliance connection piece optional connection accessories accy. No. 303 200 air/flue duct extensions (p...

  • Page 24

    24 planning the air/flue duct layout fig. 1.2: extensions, Ø 80/125 fig. 1.4: flue support clips, Ø 125 or Ø 80 flue support clips, Ø 125 (pack of 5) vaillant accy. No.: 303 616 ☞ use one clip per extension to support the air/flue duct. 15 25 15 25 15 25 fig. 1.3: elbow joints, Ø 80/125 elbow (pps),...

  • Page 25

    25 pa r t 2 concentric 80/125 planning the air/flue duct layout fig. 1.6: adjustable roof tile for pitched roof adjustable roof tiles for pitched roof vaillant accy. No.: 009 076 (black) gu_laz 41/0 164 120 fig. 1.5: sliding sleeve, Ø 80/125 sliding sleeve (pps), Ø 80/125 vaillant accy. No.: 303 215...

  • Page 26

    26 planning the air/flue duct layout maximum flue lengths for use with ecomax accessories accy. No. Vertical flue systems 303 200 max. Permitted concentric flue length horizontal flue systems 303 209 max. Permitted concentric flue length 14.0 m 13.0 m incl. 1 elbow 87° 31.0 m 20.0 m 30.0 m incl. 1 e...

  • Page 27

    27 pa r t 2 concentric 80/125 planning the air/flue duct layout maximum flue length maximum flue length las euro b/s 074/0 las euro b/s 074/0 fig. 1.9 fig. 1.8.

  • Page 28: Installation

    28 changing the appliance connection-piece 1 2 fig. 2.0: fitting the appliance connection-piece installation the appliance is supplied ready-fitted with the connection-piece for the 60/100 air/flue duct system. • loosen the four screws (2) and pull the appliance connection- piece (1) upwards to remo...

  • Page 29: Installing The

    29 pa r t 2 concentric 80/125 installation of the sliding sleeve fig. 3.0: installing the sliding sleeve 1 2 3 1 2 4 5 6 7 schiebemuffe_neu installing the air/flue duct sliding sleeve ☞ note: for installations where there is in- sufficient movement to allow fitting of the flue into flue outlet, a sl...

  • Page 30

    30 installation of the horizontal air/flue duct ☞ observe the maximum flue lengths as detailed in table on page 27 70 1103 70 15 horizontal air/flue duct vaillant accy no.: 303 209 contents of the accessory: • horizontal air/flue duct • 87° elbow • 2 x 70 mm air duct clamps • 2 x internal trim rings...

  • Page 31: Side Flue Installations

    31 pa r t 2 concentric 80/125 important: the flue hole should be cut with a slight rise to outside of 3° ± 1° (equivalent to 50 mm ± 20 mm rise per metre length). Side flue installations • for installations where the air/flue duct is to be installed to the side, the position of the flue exit hole ca...

  • Page 32: Extensions

    32 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 ...

  • Page 33: Extensions

    33 pa r t 2 concentric 80/125 220 15 3 ° 1 fig. 4.8: installing the horizontal wall duct lgu_laz 384/0_it • 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 t...

  • Page 34: Accessory (80/125 Ø)

    34 installation of the horizontal air/flue duct and terminal accessory (80/125 Ø) 8 82 - 84 253 7 4 2 3 6 750 fig. 4.9: indirect installation indirect installation • fit the wall mounting (2). • install the appliance (3) with reference to the installation and servicing instructions supplied with the...

  • Page 35

    35 pa r t 2 concentric 80/125 1530 880 70 vertical air/flue duct accy. Vaillant part no.: 303 200 (black) contents of the accessory: • vertical air/flue duct and terminal assembly • adapter (air) for Ø 110/125 • 70 mm air duct clamp • fixing bracket ☞ see page 24 et seq. For details of air/flue duct...

  • Page 36: Pitched Roof Installation

    36 installation of the vertical air/flue duct 750 2 3 790 740 Ø125 20 – 50 ° 4 5 6 40 10 8 190 7 1 8 fig. 5.2: fitting the appliance and the vertical roof duct to a building with a pitched roof pitched roof installation • determine the point where the vertical air/flue duct and terminal assembly wil...

  • Page 37: Flat-Roof Installation

    37 pa r t 2 concentric 80/125 installation of the vertical air/flue duct 880 warm roof cold roof 650 Ø125 ≥ 120 2 1 5 6 7 750 4 40 7 fig. 5.3: fitting the appliance and vertical flue duct to a building with a flat roof flat-roof installation • determine the point where the vertical air/flue duct and...

  • Page 38: How to Add Extensions

    38 fitting air/flue duct extensions how to add extensions use a saw, tin-snips, etc. To cut tubes to size. ☞ no tools are required when removing previously-fitted extensions for cutting to size air and flue tubes separately. When doing so, the flue conduit should be twisted into a position where the...

  • Page 39: How to Install Elbows

    39 pa r t 2 concentric 80/125 fitting air/flue duct extensions offset length of [in mm] air conduit [in mm] offset length of [in mm] air conduit [in mm] offset length of [in mm] air conduit [in mm] 730 520 735 525 740 530 745 535 750 540 755 545 760 550 765 555 770 560 775 565 780 570 785 575 790 58...

  • Page 40: How to Install Elbows

    40 90 0 210 95 0 215 100 0 220 > 100 to not possible 170 100 290 175 108 295 180 115 300 185 122 305 190 129 310 195 136 315 200 143 320 205 150 325 210 157 330 215 164 335 220 171 340 225 178 345 230 185 350 235 192 355 240 199 360 245 207 365 250 214 370 255 221 375 260 228 380 265 235 385 270 242...

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  • Page 44

    83 44 4 9 gb 03 08 /2 00 2 mü s ubject t o alt er ation head office service solutions 0870 6060 777 vaillant ltd., vaillant house technical advice 01634 292392 medway city estate, trident close, rochester, kent me2 4ez.