83 31 70 GB31 24.07 - Orpington Plumbers - Orpington Boiler

For the installer

Flue installation instructions

Air flue duct for use with

turboMAX plus .../2 E

turboMAX pro .../2 E

thermoCOMPACT .../2 E

aquaPLUS

PART 1:

Standard Concentric Systems

Ø 60/100

PART 2:

Optional Concentric Systems

Ø 80/125

GB

2

CONTENTS: PART 1 CONCENTRIC 60/100

Requirements

Planning the air/flue duct layout

4

Alternative termination accessories available 5Maximum flue lengths Ø 60/100 9Flue restrictor rings 10

Preparation 11Top outlet flue exiting to rear 11Top outlet flue exiting to side 11

Preparation 14Preparation of boiler for rear outlet air/flue duct 16

Installation of the horizontal air/flue duct (top outlet)

Fitting air/flue duct extensions

Page

§

25

Fitting air/flue duct extensionsbetween two 90° elbows

26


27

Installing the air/flue duct slidingsleeve

28

Installation of the vertical roof duct

Installation of the horizontal air/flue duct (rear outlet)

Preparation 19Top outlet flue exiting to rear 19Top outlet flue exiting to side 19

Preparation 22Pitched roof 23Flat roof 23Pitched and flat roof installation 23

Installation of the Se-Duct flue

3

CONTENTS: PART 2 CONCENTRIC 80/125

Planning the air/flue duct layout Termination accessories available 29Maximum flue lengths Ø 80/125 32Flue restrictor rings 33

35

Preparation 37Side flue installations 37

Fitting the appliance flue outletadapter to the boiler

Fitting air/flue duct extensions

Page

45


46


47

Installing the air/flue duct slidingsleeve

48

Installation of the vertical roof duct

Installation of the horizontal air/flue with extensions

Preparation 39Fitting extensions 40Connect the flue assembly to the adaptor 40

Installation of the horizontal air/flue duct and terminalaccessory (80/125)

Preparation 41Pitched roof 42Flat roof 42Pitched and flat roof installation 42Connect the flue assembly to the adaptor 44

§ REQUIREMENTS

4

☞ Vaillant turboMAX,thermoCOMPACT and aquaPLUSboilers are certified as heatingboilers with corresponding fluesystems according to EC Directive90/396/EEC on gas-fireddevices. This installation manual iscovered by this certification and isreferred to in the design approvaltest certificate.

☞ These instructions should be readin conjunction with the instructionsfor installation and servicing supplied with the boiler.

☞ Ensure also that all legislation,rules, regulations and directivesmentioned in the installationinstructions are observed.

☞ The installation of the boiler andits flue must be carried out by acompetent person who is registered with CORGI (TheCouncil for Registered GasInstallers).

☞ The installation of the boiler andflue must be in accordance withthe Gas Safety (Installation andUse) Regulations 1998 and theBuilding Regulations and BS 5440 Part 1.

☞ The requirements for flue termination detailed in the boilerinstallation instructions must beobserved.

☞ Two types of flue system are available for turboMAX,thermoCOMPACT and aquaPLUSboilers. The standard concentricflue system (100 mm outsidediameter) and a larger diameterconcentric system (125 mmoutside diameter) which allowslonger air/flue duct lengths to beachieved.

☞ The air/flue duct operates at verylow temperatures therefore noclearance is necessary betweenthe air duct and adjacent services.

☞ Ensure while installation work isbeing carried out that no debrissuch as swarf, filings or fragmentsof mortar are allowed to remainin the air/flue duct.

Air/flue duct (adjustable) offset (33 -56 mm)Ø 60/100

5

PART

1 C

ONC

ENTR

IC 6

0/10

0

PLANNING THE AIR/FLUE DUCT LAYOUT

Alternative terminationaccessories available

Optional connection accessories Accy. No.

303 807 303 806

Air/flue duct extension500 mm - Ø 60/100 303 801 x x


Telescopic air/flue duct extension500 - 800 mm - Ø 60/100 303 804 x x

2 x 45° Bends Ø 60/100 303 809 x x

90° ElbowØ 60/100

303 808 x x

Flue support clips (Pack of 5), Ø 100 303 821 x x


Air/flue duct 15° offsetØ 60/100

303 820

Sliding sleeve Ø 60/100 303 816 x x

Adjustable roof tile 9076

Flat roof collar-piece 9056

x x

303 810

x

x

x

x

x

x

x

x

x

303 800

x

x

x

x

x

x

x

x

x

x

x

303 807 = Horizontal air/flue duct with 90° elbow andterminal (750 mm)

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; turboMAX and thermoCOMPACT only)

303 810 = Se-duct flue accessory

303 800 = Vertical air/flue duct and terminal accessory

x303 819 x x x

4

36

4

36

4

36

6


Fig. 1.1: Extensions, Ø 60/100

Fig. 1.3: Elbow joints, Ø 60/100

90° Elbow, Ø 60/100Accy. No.: 303 808

2 x 45° Bends, Ø 60/100Accy. No.: 303 809

Fig. 1.2: Telescopic extension

Telescopic air/flue duct extension500 – 800 mm Ø 60/100Accy. No.: 303 804

Air/flue duct extension 500 mm, Ø 60/100Accy. No.: 303 801



GU

_LA

Z 70

/0

LAS

Euro

B/S

015

/0Te

lesk

op_V

erlä

nger

ung

Air/flue duct 15° offset Ø 60/100Accy. No.: 303 820

Air/flue duct (adjustable) offset pipeØ 60/100Accy. No.: 303 819

33 - 56

Abb. 1.4: Adjustable offset pipe LAS

Euro

B/S

070

/0G

B

135

145

PART

1 C

ONC

ENTR

IC 6

0/10

0


7

Fig. 1.7: Tiles for pitched roofs

Adjustable roof tile Accy. No.: 9076

GU

_LA

Z 41

/0

Fig. 1.6: Sliding sleeve, Ø 60/100

Sliding sleeve, Ø 60/100 Accy. No.: 303 816

LAS

Euro

B/S

016

/0

Fig. 1.5: Flue support clip, Ø 100

Flue support clips, Ø 100 (Pack of 5)Accy. No.: 303 821

GU

_LA

Z 72

/0

☞ Use one clip per extension to support the air/flue duct.

Fig. 1.8: Flat roof penetration collar GU

_LA

Z 42

/0

Flat roof penetration collarAccy. No.: 9056

5.3 5.3 4.5 3.3 3.0


8

Horizontal fluesystems

303 807303 806303 810

Maximum flue lengths Ø 60/100

Maximum flue length

Max

imum

flue

leng

th

Fig. 1.9 Fig. 1.10LAS

Euro

B/S

074

/0

LAS

Euro

B/S

075

/0

Vertical fluesystems

303 800

thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT615/2 E 620/2 E 624/2 E 628/2 E 637 E

turboMAX pro 24/2 E turboMAX pro turboMAX plusturboMAX plus 28/2 E 837 E824/2 E turboMAX plus aquaPLUS

828/2 E

6.3 6.3 5.5 4.3 4.0

Max.permittedflue length(L)

Max.permittedflue length(L)

Maximum length of flue is reduced by 1.0 m for each additional 90° elbow.Maximum length of flue is reduced by 0.5 m for each additional 45° elbow.

Maximum length of flue is reduced by 1.0 m for each additional 90° elbow.Maximum length of flue is reduced by 0.5 m for each additional 45° elbow.

3

2

1

= B

= D

= A

= C

PART

1 C

ONC

ENTR

IC 6

0/10

0


9

Fig. 1.11: Flue restrictor rings

Flue restrictor ringsThe flue restrictor ring marked A, Cor D is packed with the boilerconnection accessories. The restrictorring should be fitted as shown in thediagram according to the equivalentflue length in the table.

The total equivalent flue length is thetotal length of the flue (including theterminal assembly for vertical flues),plus the resistance of any bends orelbows used.

- equivalent length of 90° elbow is1 m

- equivalent length of 45° elbow is0.5 m

• Push the restrictor (1) into the flueconnection of the appliance (3)

• Connect the flue/elbow (2) intothe flue connection of the appliance (3).

Note:thermoCOMPACT 615 boilers do notrequire a seperate restrictor ring andare supplied without the restrictor.The required restriction is designedinto the flue connection piece forthese boilers.

thermoCOMPACT615/2 E



turboMAX plus824/2 E

turboMAX pro 24/2 E



turboMAX pro 28/2 E

Use restrictor A ---

Use restrictor D ---

No flue restrictor ---

< 6.3 m

---

---

---

---

---

---

< 2.3 m

> 2.3 m

Use restrictor C --- --- < 5.5 m ---

Total equivalent flue length (incl. terminal any bends / elbows used)


10


Flue restrictor ringsThe flue restrictor ring marked F0 andF1 is packed with the boilerconnection accessories. The restrictorring should be fitted as shown in thediagram according to the equivalentflue length in the table.




• Push the restrictor (1) into the flueconnection of the appliance (3)

• Connect the flue/elbow (2) intothe flue connection of the appliance (3).

aquaPLUS thermoCOMPACT637 E

turboMAX plus 837 E

Use restrictor F0 ---



< 2.5 m

---

> 3.3 m

< 2.5 m

---

> 3.3 m

< 2.5 m

---

> 3.3 m

Use restrictor F1 --- 2.5 - 3.3 m 2.5 - 3.3 m 2.5 - 3.3 m


11

Horizontal air/flue duct

Accy No.: 303 807 (Length 0.75 m)Accy No.: 303 806 (telescopic,0.45 – 0.65 m; turboMAX andthermoCOMPACT only)

Contents of the accessory:• Horizontal air/flue duct• 90° elbow• 2 x 48 mm air duct clamps

(3x with telescopic accy.)• Internal trim ring Ø 100• External wall seal.Fig. 2.1: Horizontal air/flue conduit

IMPORTANT:The flue hole should be cut with aslight fall to outside of 1° to preventrain water entering the flue.

Preparation• Determine the installation site for

the boiler with reference to theinstallation and servicing instructions supplied with the boiler.

• Ensure that all installation and service clearances are availableand that the boiler flue can beinstalled as detailed in theseinstructions.

• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of the template is vertical using a plumbline or spirit level.

Top outlet flue exiting to rear• For installations where the air/flue

duct is to be installed directly tothe rear of the boiler, the installation template details theposition of the flue exit hole forhorizontal top outlet installation.

Top outlet flue exiting to side• For installations where the air/flue

duct is to be installed to the side,the position of the flue exit holecan be determined by carefullylevelling across the wall from thecentre line of the air/flue ducthole marked on the template.

• The position of the flue exit holeshould allow the flue to be installed with a slight downwardslope of about 1° (equivalent to10 to 15 mm per metre of flueduct). Calculate the required fallaccording to the flue length andmark the position of the flue exithole.

48

750

48

4

LAS

Euro

B/S

037

/0

110

1°

A

5

6

6

3

Fig. 2.2

LAS

Euro

B/S

072

/0G

B

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (TOP OUTLET)

turboMAX/thermoCOMPACT: A = 145 mmaquaPLUS: A = 310mm

PART

1 C

ONC

ENTR

IC 6

0/10

0

12


• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 127 mmdiameter.Note: If access can be gained tothe proposed flue exit point fromoutside the dwelling, the hole canbe cut with a 107 mm core drilland the flue external wall seal fitted from outside the dwelling.

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler.

This is dimension A.

• (Note: If using the top connectionspacer frame accessory with theboilers with a rear exit, make an additional 45 mm allowance forthe depth of the frame).

• Cut the air duct and flue duct tothe lengths shown in figure 2.4.

• All flue sockets should pointtowards the terminal.

• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.Care should be taken not toscratch the white surface of the airduct.

• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 25 – 27.

• If using the telescopic horizontalair/flue duct and terminal accy.303806 simply adjust the lengthas shown in Fig 2.4. Secure theair duct sections together bydrilling a 3 mm diameter holethrough the location hole in theend of the outer air duct. (Ensurethat the drill does not pierce theinner flue duct). Secure the airducts together using the screw provided.

1

2

*

* = 145 mm (TURBOmax/THERMOcompact)* = 310 mm (aquaPLUS)

Fig. 2.3 LAS

Euro

B/S

077

/1

110

A

B

A

110

Fig. 2.4 LAS

Euro

B/S

078

/0

A + 15 mm

4 mm

Fig. 2.5 LAS

Euro

B/S

076

/0Rear exit

Side exit

turboMAX: B = 145 mmaquaPLUS: B = 310 mm

13

PART

1 C

ONC

ENTR

IC 6

0/10

0

• Push the air/flue duct assembly(1) including the flexible externalseal (2) through the wall until theseal clears the outside face of thewall and pull air/flue duct backtowards the boiler until the external seal touches the outsidewall.

• Ensure that the air/flue duct (1) iscentred in the hole and the terminal is correctly positionedwith the inlet grille at the bottom.

• Slide the internal trim ring (3) overthe air duct until it is flush with thewall.

• At this stage it is necessary to prepare and fit the boiler onto thehanging bracket – refer to the boiler installation instructions.

• Before installing the flue elbowonto the boiler flue outlet selectand fit the correct restrictor ring(page 10) into the bottom of theboiler elbow.

• Fit the elbow to the boiler by inserting the spigot of the flueelbow into the flue socket on theboiler and secure using the airduct clamp provided.

• Pull the air/flue duct back throughthe wall such that the flue ductfully engages into the flue elbowsocket.

• Fit the air duct clamp ensuringthat it is positioned centrally.

• Drill two holes 3 mm Ø throughthe air duct of both the elbow/flueand elbow/boiler clamps at themost convienient holes on the airduct clamps. (Ensure that the drilldoes not penetrate the inner flueduct). Screw the clamps to the airducts of the flue assembly, theelbow and boiler using the screws supplied.

• Slide the internal trim ring back tothe wall, securing in position witha small amount of sealant if required.

110

123

1°

Fig. 2.6

LAS

Euro

B/S

001

/0G

B


14

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET)(TURBOMAX AND THERMOCOMPACT ONLY)

Rear outlet flue accessory Accy No: 303 817

Contents of the accessory• Rear air/flue duct• Flue securing collar Ø 100

including fixing screws and wallplugs

• Air duct connection piece and screws

• Flue cap• Rubber bung• Air pressure tube extension and

connecting nippleFig. 3.1: Horizontal wall duct LAS

Euro

B/S

073

/1G

B

IMPORTANT:The flue hole should be cut with aslight fall to outside of 1° to preventrain water entering the flue.Minimum top clearance for rearinstallation is 100 mm.

IMPORTANT:To install this accessory access mustbe available to the proposed flue exitpoint outside the dwelling.




• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of thetemplate is vertical using a plumbline or spirit level.

• The installation template detailsthe position of the flue exit holefor rear outlet installations.Ensure that the correct flue exithole has been identified.

• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 107 mmdiameter.

• Measure the thickness of the wallthrough which the flue will pass.This is dimension C.

• (Note: If using the top connectionspacer frame accessory make anadditional 45 mm allowance forthe depth of the frame).

• Cut the air duct and flue duct tothe lengths shown in figure 3.2.

• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts.

98C15 65

L 1 = C + 180 mm

Fig. 3.2

LAS

Euro

B/S

059

/1G

B

750

15


• Secure the boiler hanging bracket(1) to the wall using the screwsprovided (2).


3

402

171 174,5

12,5

1

1

2

Fig. 3.3 LAS

Euro

B/S

054

/0G

B

PART

1 C

ONC

ENTR

IC 6

0/10

0

16


1

2

5

43

Fig. 3.4 LAS

Euro

B/S

55/

0

11

12

8

6

7

10

9

13Fig. 3.5

LAS

Euro

B/S

056

/1

Preparation of boiler forrear outlet air/flue ductFor thermoCOMPACT 615, 637 andturboMAX plus 837:

• Remove boiler case as detailed inthe installation instructions supplied with the boiler.

• Release the three clamps (1) andremove the combustion chambercover (2).

• Loosen the screw (3) and removethe flue gas connector (4) from thefan.

• Remove the retaining spring (5).

• Pull the cables and two tubes (9,10) from the fan assembly. Pleaseensure that you note the respectiveconnection points for each tube.

• Remove the complete fan assembly(11) from the boiler.

• Remove the rubber funnel (12) andplace to side.

• Seal the hole with the rubber bung(13) provided.


17

1

3 99

8

11

a

b

c

d

12

13

2

10

LAS

Euro

B/S

55_

2.ep

s

Preparation of boiler forrear outlet air/flue ductFor thermoCOMPACT 620, 624, 628,turboMAX pro 24, 28 and turboMAXplus 824, 828:

• Remove boiler case as detailed inthe installation instructions supplied with the boiler.

• Release the three clamps (1) andremove the combustion chambercover (2).

• Remove the screw (3).• Pull the two cables (8) and two

tubes (9) from the fan assembly.Please ensure that you note therespective connection points foreach tube.

• Remove the fan (10) from thecollector hood by pushingdownwards to unlock.

• Remove collector hood from theboiler

• Remove the rubber funnel (12).• Seal the hole with the rubber bung

(13) provided.

PART

1 C

ONC

ENTR

IC 6

0/10

0Fig. 3.6

18

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT (REAR OUTLET)

3

1

2

Fig. 3.7

LAS

Euro

B/S

061

/0G

B

Fig. 3.8

LAS

Euro

B/S

060

/0

• Remove the metal plate (1)covering the rear flue outlet pointby pushing through the centre pinsof the plastic fasteners as shown inthe drawing. Now remove themetal plate by pulling on thefoldedtag of the plate.

• Fit the air duct connection piece(2) to the back of the boiler at therear flue outlet point with the fourscrews provided.

• Push the flue cap (3) firmly intoposition to seal the top flue outlet.

• From outside the dwelling locatethe flue securing collar centrallyover the flue exit hole, mark anddrill the three holes and insert thewall plugs provided.

• Push the flue securing collar on tothe flue at the opposite end to theterminal, ensure that the fluesecuring collar is fitted with theholes for securing the collar to theair duct facing outside.

• Push the air/flue duct assemblythrough the wall from outside thedwelling.

• If the internal trim ring is to beused, position it over the end of theair duct from inside the dwelling.

• Engage the end of the air duct intothe air duct connection piece atthe rear of the boiler. Now fromoutside the dwelling push theentire air/flue duct in towards theboiler such that the air ductcompletely engages all the wayinto the air duct connection on theboiler. Ensure that the flue terminalis correctly positioned with thehood at the top and the air inlet atthe bottom.

Important: • Fix the flue securing collar to the

wall with the three screwsprovided into the wall plugspreviously installed.

• Drill three 3mm Ø holes throughthe air duct using the pre drilledholes in the collar as a guide.Secure the collar to the air ductwith the three screws (1) provided.

• From inside the dwelling slide theinternal trim ring back to the walland secure in position.

• Fit the correct restrictor ring (page10 of the flue instructions providedwith the boiler) into the end of the

1°

1

19

PART

1 C

ONC

ENTR

IC 6

0/10

0


For thermoCOMPACT 615, 637 andturboMAX plus 837:

• Remove two screws (2) and separate the fan from the collectorhood (4).

• Swivel the collector hood (4)through 180° and locate back intoposition in the appliance.

• Extend the white air pressure tubewith the tube extension and nippleprovided.

• Refit the retaining spring clip (5)on the top of the collector hood (4)Remove blank and refit funnel.

• Loosen the screw (9) and removethe support bracket (8).

• Reconnect the bracket into position(b).

• Refit the flue gas connector (6) tothe fan (7) and secure.

• Reconnect the electrical cables tothe fan.

• Gently push the flue ductdownwards to the left.

• Slide the fan (2) into position onflue collector hood (3). Ensure thatthe flue gas connector (1) engagesover the end of the flue duct andthe flange on the back of the fanplate locks in to the collectorhood.

• Secure the fan to the flue collectorhood using the two screws (4).

• Reconnect the air pressure tubes tothe fan, ensuring that the air tubesare connected to the correctnipple.

Note: Blue tube connects to the rearmost fan outlet spigot.

• On combustion chamber coverfront swap top left hand rubberbung with the metal hole bung.

• Reassemble the boiler in reverseorder.

• Complete the installation asdetailed in the boiler Installationand Servicing instructions.

2

3

8

7

5

4

b

a

9

Fig. 3.9

LAS

Euro

B/S

057

/1

2

1

3

4

4

Fig. 3.10

LAS

Euro

B/S

058

/0


20

For thermoCOMPACT 620, 624, 628,turboMAX pro 24, 28, turboMAX plus824, 828:

• Refit the collector hood (1).Remove blank and refit funnel.

• Reconnect the electrical cables tothe fan.

• Gently push the flue ductdownwards to the left.

• Slide the fan (2) into position onflue collector hood (3). Ensure thatthe flue gas connector (5) engagesover the end of the flue duct andthe flange on the back of the fanplate locks in to the collectorhood.

• Secure the fan to the flue collectorhood using only one screw (4).

• Reconnect the air pressure tubes tothe fan, ensuring that the air tubesare connected to the correctnipple.

Note: Blue tube connects to the rearmost fan outlet spigot.

• On combustion chamber coverfront swap top left hand rubberbung with the metal hole bung.

• Reassemble the boiler in reverseorder.

• Complete the installation asdetailed in the boiler Installationand Servicing instructions.

2

5

3

4

4

1

Fig. 3.11 LAS

Euro

B/S

058

_2.e

ps

21

PART

1 C

ONC

ENTR

IC 6

0/10

0

INSTALLATION OF THE SE-DUCT FLUE

4848

Se-duct flueAccy No.: 303 810

Contents of the accessory:• Horizontal air/flue duct• 90°elbow • 2 x 48 mm air duct clamps • Internal trim ring• Screws

Fig. 4.1 LAS

Euro

B/S

022

/0

IMPORTANT:The flue hole should be cut with aslight fall towards the Se-duct of 1°.


the boiler with reference to theinstallation and servicing instructions supplied with the boiler and also any requirementsof the Se-duct manufacturer.



Top oulet flue exiting to rear• For installations where the air/flue

duct is to be installed directly tothe rear of the boiler, the installation template details theposition of the flue exit hole forhorizontal top outlet installation.

Top outlet flue exiting to side• For installations where the air/flue

duct is to be installed to the side,the position of the flue exit holecan be determined by carefullylevelling across the wall from thecentre line of the air/flue ducthole marked on the template.

• The position of the flue exit holeshould allow the flue to be installed with a slight downwardslope of about 1° (equivalent to10 to 15 mm per metre of flueduct). Calculate the required fallaccording to the flue length andmark the position of the flue exithole.

40

1°

A

5

6

6

3

Fig. 4.1a

LAS

Euro

B/S

072

/0G

B

turboMAX/thermoCOMPACT: A = 145 mmaquaPLUS: A = 310 mm

22


• Once the position of the flue exithole has been determined, thehole should be cut through thewall using a core drill of 120 mmdiameter. Ensure no debris entersthe Se-duct.

• Measure the distance from thewall face (inside of the duct) tothe centre of the fan outlet on theboiler.

This is dimension D.

• (Note: If using the top connectionspacer frame accessory with theboilers with a rear exit, make an additional 45 mm allowance forthe depth of the frame).

Length of Air duct:

• Cut the length of the air duct asfollows:Length of air duct = D - 95 mm

Length of Flue duct:

• Cut the length of the flue duct asfollows:Length of flue duct = Length of air duct + 44 mm

• All flue sockets should pointtowards the terminal.

• Ensure that the flue duct protrudesby 40 mm into the Se-duct.

• When cutting the air and flueducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.Care should be taken not toscratch the white surface of the airduct.

• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 25 – 27.

1

2

*


Fig. 4.2 LAS

Euro

B/S

077

/1

40

D

B

D

40

Fig. 4.3 LAS

Euro

B/S

078

/0SE

-Duc

tRear exit

Side exit

4 mm 40 mm

D - 95 mm

Fig. 4.4 LAS

Euro

B/S

079

/0SE

-Duc

t

This end of the flue will terminate in the Se-duct

turboMAX/thermoCOMPACT: B = 145 mmaquaPLUS: B = 310 mm

23

PART

1 C

ONC

ENTR

IC 6

0/10

0


• Insert the end of the air/flue ductassembly through the se-duct wall.

• Slide internal trim ring over the airduct until it is flush with the wall.


• Before installing the flue elbowonto the boiler flue outlet selectand fit the correct restrictor ring(page 10) into the bottom of theboiler elbow.

• Fit the elbow to the boiler by inserting the spigot of the flueelbow into the flue socket on theboiler and secure using the airduct clamp provided.

• Pull the air/flue duct back throughthe se-duct wall such that the flueduct fully engages into the flueelbow socket.

• Fit the air duct clamp ensuringthat it is positioned centrally.

• Drill two holes 3 mm Ø throughthe air duct of both the elbow/flueand elbow/boiler clamps at themost convienient holes on the airduct clamps. (Ensure that the drilldoes not penetrate the inner flueduct). Screw the clamps to the airducts of the flue assembly, theelbow and boiler using the screwssupplied.

• Slide the internal trim ring back tothe wall and seal and secure inposition.

24

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Vertical air/flue duct Accy. Vaillant Part No.: 303 800

Contents of the accessory:• Vertical air/flue duct and terminal

assembly• 48 mm air duct clamp• Fixing bracket

The air/flue duct assembly may beconnected directly to the flue outleton top of the boiler.

In addition to the vertical air/flueduct and terminal accessory, air/flueduct extensions can be added toincrease the length of the flue.

Fig. 5.1: Vertical Roof duct




• Determine the point where the vertical air/flue duct and terminalassembly will penetrate the roof.

Please note: The vertical air/flue ductand terminal accessory (Accy. No.303 800) may be shortened. Theouter ‘white’ duct should be shortened first, then the inner flueduct cut so that it protrudes 4 mm outof the air duct. In case of installationdirectly to the boiler without elbowsor bends, it is essential that the rooftile/collar is vertically aligned withthe air/flue duct of the boiler.

4812

85

603

LAS

Euro

B/S

036

/0

Pitched roof• Determine the point of termination

of the vertical air/flue duct andterminal assembly. Install the adjustable pitched roof tile (1, fig.5.2) in position.

• Fit the adjustable hood over theroof tile according to the roofpitch. The adjustable hood issuitable for roof pitches from 25°to 35°, or 35° to 45° byreversing.

Flat roof• Determine the point of termination

of the vertical air/flue duct andterminal assembly.

• Make a hole in the roof of 120 mm diameter. Secure the flatroof collar (1, fig. 5.2) to the roofcovering above the hole inaccordance with the codes ofpractice for flat roofs (CP 144) toensure a watertight seal.

Pitched and flat roofinstallations• From above insert the air/flue

duct and terminal assembly (5)into the adjustable roof tile (pitched roof) or roof penetrationcollar (flat roof) until it is fully seated. Adjust the vertical alignment of the air/flue duct andterminal assembly and secure theair duct with the fixing bracketprovided (6).


• If the installation requires the useof air/flue duct extensions, additional bends or elbows pleaserefer to the sections on pages 25 – 27.

25

PART

1 C

ONC

ENTR

IC 6

0/10

0

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

• If the vertical air/flue duct and terminal assembly is to be connected directly to the boiler, itwill be necessary to temporarilyraise the flue slightly in order tomount the boiler.

• Before connecting the flue on tothe boiler flue outlet select and fitthe correct restrictor ring into thebottom of the flue (as detailed inthese installation instructions).

• Fit the air duct clamp over the airduct.

• Connect the air/flue duct to theboiler by inserting the spigot of theair/flue duct into the flue socket onthe boiler and secure using the airduct clamp.

• Drill two holes 3 mm Ø throughthe air duct of the flue/boilerclamp at the most convienientholes on the air duct clamp.(Ensure that the drill does notpenetrate the inner flue duct).Screw the clamp to the air ducts ofthe flue assembly and the boilerusing the screws supplied.

• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.

• Note: The air/duct clamp must notbe screwed to the bottom of thevertical air/flue duct and terminalaccessory to allow for any slightmovement in the roof structure.

• Ensure that at least one pipeclamp supports the air/flue duct ateach extension fitted.

2

3

682

603

Ø100

25 –

45°

1

4

5

6

40

7

8

*

80 -

90

10

Fig. 5.2 LAS

Euro

B/S

011

/0G

B

603

682

Ø100

≥100

1

5

6

7

4

40

80 -

90

3

Fig. 5.3 LAS

Euro

B/S

012

/0G

B

*= 145 mm (turboMAX/thermoCOMPACT)* = 310 mm (aquaPLUS)

26

Fitting extensions• Measure and note the length of

the air duct extension required forthe installation.

Use this measurement to calculate thelength to cut the air and flue ducts:

Length of Air duct• Cut the length of the air duct as

follows:Length of air duct as shown in Fig.6.1

Note: Minimum length of air duct is100 mm.

Length of Flue duct• Cut the length of the flue duct as

follows:Length of flue duct =Length of air duct + 40 mm

• Cut the air and flue ducts squareand and remove any burrs. Careshould be taken not to scratch thewhite surface on the air duct.

• After cutting the tubes to size, insert the flue duct into the air ductand secure the air duct to the spacing bracket through the threepre-drilled holes.

• Lubricate the seals and install theflue extension.

• Ensure that the air duct clamps arecentrally positioned over the 10 mm gap between the air duct sections.

• Drill two holes 3 mm Ø througheach air duct (at either end ofeach clamp) at the most convienient holes in the air ductclamps and secure with screwsprovided. (Ensure that the drilldoes not penetrate the inner flueduct).

• Screw the clamp to the air ducts ofthe flue assembly and the boilerusing the sheet metal screws supplied.

10 mm

Length of air duct

10 mm

Fig. 6.1 LAS

Euro

B/S

081

/0

FITTING AIR/DUCT EXTENSIONS

27

FITTING AIR/DUCT EXTENSIONS BETWEEN TWO 90° ELBOWS

PART

1 C

ONC

ENTR

IC 6

0/10

0

730 520735 525740 530745 535750 540755 545760 550765 555770 560775 565780 570785 575790 580795 585800 590805 595810 600815 605820 610825 615830 620835 625840 630845 635850 640855 645860 650865 655870 660875 665880 670885 675890 680895 685900 690905 695910 700915 705920 710925 715930 720935 725940 730

Distance between Length ofcentres air duct[in mm] [in mm]



505 295510 300515 305520 310525 315530 320535 325540 330545 335550 340555 345560 350565 355570 360575 365580 370585 375590 380595 385600 390605 395610 400615 405620 410625 415630 420635 425640 430645 435650 440655 445660 450665 455670 460675 465680 470685 475690 480695 485700 490705 495710 500715 505720 510725 515

Table 6.1: Length of surplus with 90° elbows

200, 205 0210, 0

> 210 to not< 310 mm possible

310 100315 105320 110325 115330 120335 125340 130345 135350 140355 145360 150365 155370 160375 165380 170385 175390 180395 185400 190405 195410 200415 205420 210425 215430 220435 225440 230445 235450 240455 245460 250465 255470 260475 265480 270485 275490 280495 285500 290


follows:Length of air duct as per table.


follows:Length of flue duct = Length of airduct + 40 mm

How to measure lengthof air and flue ducts Measure the distance between centresof the two flue pipes to be connected.Using the table below identify andnote the air duct length to be cut(Length of air duct).

28


FITTING AIR/FLUE DUCT EXTENSIONS BETWEEN TWO 45° ELBOWS






80 0 19485 0 19990 0 20495 0 209

> 95 - not< 155 mm possible

155 85 269160 92 274165 99 279170 106 284175 113 289180 121 294185 128 299190 135 304195 142 309200 149 314205 156 319210 163 324215 170 329220 177 334225 184 339230 191 344235 198 349240 205 354245 212 359250 220 364255 227 369260 234 374265 241 379270 248 384275 255 389280 262 394285 269 399290 276 404295 283 409300 290 414305 297 419310 304 424

Distance Length of- Heightbetween centres air duct [in mm]

[in mm] [in mm]


[in mm] [in mm]


[in mm] [in mm]

315 311 429320 319 434325 326 439330 333 444335 340 449340 347 454345 354 459350 361 464355 368 469360 375 474365 382 479370 389 484375 396 489380 403 494385 410 499390 418 504395 425 509400 432 514405 439 519410 446 524415 453 529420 460 534425 467 539430 474 544435 481 549440 488 554445 495 559450 502 564455 509 569460 517 574465 524 579470 531 584475 538 589480 545 594485 552 599490 559 604495 566 609500 573 614505 580 619510 587 624

515 594 629520 601 634525 608 639530 616 644535 623 649540 630 654545 637 659550 644 664555 651 669560 658 674565 665 679570 672 684575 679 689580 686 694585 693 699590 700 704595 707 709600 715 714605 722 719610 729 724615 736 729620 743 734625 750 739630 757 744635 764 749640 771 754645 778 759650 785 764

29

INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE

PART

1 C

ONC

ENTR

IC 6

0/10

0

How to fit sliding sleevesNOTE:For installations where there is insufficient movement to allow fittingof the flue into flue outlet, a slidingsleeve (Accy. No. 303 816) is available. When using the slidingsleeve both the air and flue ducts ofthe last extension must be shortenedby a further 100 mm.

• Push the sliding sleeve over the cutend of the flue duct.

• Place the air duct clamp over theair duct.

• Pull back the sliding sleeve so thatit engages into the socket of theboiler. Ensure that the sliding sleeve penetrates the socket suchthat there is at least 20 mm engagement at both ends of thesliding sleeve.

• Fit the air duct clamp over the airducts of the extension/terminaland boiler outlet. Close the snapclamp.

• Drill two holes 3 mm diameterthrough the air duct clamp (thecentre of the holes should be 6mm from the edge of the clamp).Ensure that the drill does not penetrate the inner flue duct.Screw the air duct clamp to the airduct of the sleeve using the screws provided.

• Complete the installation of theflue as detailed in these instructions.

4

5

2

Fig. 7.1 LAS

Euro

B/S

087

/0G

B

Fig. 7.2 LAS

Euro

B/S

086

/0G

B

30


Termination accessoriesavailable

303 600 = Vertical roof duct(black)

303 609 = Horizontal wall/roof duct

303 814 = Appliance flue outlet adaptor

Optional connection accessories Accy. Part No.303 600

87° ElbowØ 80/125 303 610

Air/flue duct extensions500 mm - Ø 80/125 303 602 x

x


x


2 x 45° BendsØ 80/125 303 611 x

Flue support clips (Pack of 5), Ø 125 303 616 x

Sliding sleeve Ø 80/125 303 617 x

Adjustable roof tile 9076 x

Flat roof collar-piece 9056 x

303 609

x

x

x

x

x

x

31

PART

2 C

ONC

ENTR

IC 8

0/12

5


Fig. 1.2: Extensions, Ø 80/125

Fig. 1.4: Flue supporting clips, Ø 125 oder Ø 80

Flue support clips, Ø 125 (Pack of 5)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

87° Elbow Ø 80/125Accy. No.: 303 610

2 x 45° Bends, Ø 80/125Accy. No.: 303 611

Air/flue duct extensions500 mm - Ø 80/125 Accy. No.: 303 602



GU

_LA

Z 70

/0

GU

_LA

Z 72

/0

GU

_LA

Z 71

/0

Fig. 1.1: Flue outlet adaptor

Appliance flue outlet adaptor Ø 60/100 - Ø 80/125Accy. No.: 303 814 (includes discharge tube and condensate trap)

Ikon

_Kon

dens

was

sera

blau

f

32


Fig. 1.6: Adjustable tiles for pitched roof

Adjustable roof tile Accy. No.: 9076

GU

_LA

Z 41

/0

164

120

Fig. 1.5: Sliding sleeve Ø 80/125

Sliding sleeve, Ø 80/125 Accy. No.: 303 617

GU

_LA

Z 76

/0

Fig. 1.7: Flat roof penetration collar-piece GU

_LA

Z 42

/0

Flat roof penetration collar Accy. No.: 9056

33

PART

2 C

ONC

ENTR

IC 8

0/12

5


Maximum flue length

Max

imum

flue

leng

th

Fig. 1.8 Fig. 1.9LAS

Euro

B/S

074

/0

LAS

Euro

B/S

075

/0

Maximum flue lengths Ø 80/125

12.9 m 10.0 m 11.5 m

Vertical fluesystem

Horizontal fluesystem

Accy. No.

303 609

303 600 Max. permittedflue length (L)

Max. permittedflue length (L)

15.4 m 12.5 m 14.0 m

thermoCOMPACT thermoCOMPACT 628/2 E turboMAX plus615, 620, 624/2 E turboMAX plus 828/2 E 837 EturboMAX plus 824/2 E turboMAX pro 28/2 E thermoCOMPACT turboMAX pro 24/2 E 637 E, aquaPLUS

Tube length is reduced by 2.5 m for each 87° elbow.Tube length is reduced by 1.0 m for each 45° elbow.

Tube length is reduced by 2.5 m for each 87° elbow.Tube length is reduced by 1.0 m for each 45° elbow.

3

1

= B

= D

= A

= C

34


Flue restrictor ringsThe flue restrictor ring marked A, orC / D is packed with the boilerconnection accessories. The restrictorring should be fitted as shown in thediagram according to the equivalentflue length in the table.




• Push the restrictor (1) into the flueconnection of the appliance (3).

• Connect the flue outlet adaptor (2)into the flue connection of the appliance (3).

Note: The flue outlet on the top of theboiler has a diameter of 100 mm. Anadaptor (Accy. No. 303 814) is required to connect from the boileroutlet to the 125 mm diameter fluesystem. This adaptor incorporates acondensate discharge connectionwhich allows any condensate orwater to drain away. It is importantthat the condensate discharge connector is connected correctly.

Note:thermoCOMPACT 615 boilers do notrequire a seperate restrictor ring andare supplied without the restrictor. Therequired restriction is designed intothe flue connection piece for theseboilers.






turboMAX pro 24/2 E



turboMAX pro 28/2 E

Use restrictor A ---

Use restrictor D ---


< 15.4 m

---

---

---

9.2-12.0 m

> 12.0 m

---

< 6.0 m

> 6.0 m

Use restrictor C --- --- < 9.2 m ---



35

Flue restrictor ringsTwo flue restrictor rings marked F0 toF2 are packed with the boilerconnection accessories. The restrictorrings should be fitted as shown in thediagram according to the equivalentflue length in the table.




• Push the restrictor (1) into the flueconnection of the appliance (3).

• Connect the flue outlet adaptor (2)into the flue connection of the appliance (3).

Note: The flue outlet on the top of theboiler has a diameter of 100 mm. Anadaptor (Accy. No. 303 814) is required to connect from the boileroutlet to the 125 mm diameter fluesystem. This adaptor incorporates acondensate discharge connectionwhich allows any condensate orwater to drain away. It is importantthat the condensate discharge connector is connected correctly.


PART

2 C

ONC

ENTR

IC 8

0/12

5

thermoCOMPACT637 E

turboMAX plus 837 E

aquaPLUS




< 5.5 m

8.5 - 10.5 m

> 10.5 m

< 5.5 m

8.5 - 10.5 m

> 10.5 m

< 5.5 m

8.5 - 10.5 m

> 10.5 m

Use restrictor F1 --- 5.5 - 8.5 m 5.5 - 8.5 m 5.5 - 8.5 m


36

FITTING THE APPLIANCE FLUE OUTLET ADAPTER TO THE BOILER

• Before installing the adaptor ontothe boiler outlet select and fit thecorrect restrictor (page 33).For turboMAX boilers fit therestrictor into the bottom of theadaptor (page 34).For thermoCOMPACT boilers referto the installation instructions supplied with the boiler for detailson fitting the restrictor.

• Fit the adaptor to the boiler byinserting the spigot of the adaptor(1) into the flue socket on theboiler and secure using the airduct clamp provided (7).

• Drill two holes 3 mm Ø throughthe air duct clamp and secure theair duct clamp to the boiler usingthe screws provided.

Note: Because of the high efficiencyof turboMAX, thermoCOMPACT andaquaPLUS boilers it is likely thatcondensate will form in the fluesystem when a long flue run is used.A condensate discharge connection isprovided on the adapter to removeany condensate that forms in the flue.

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 • Condensate discharge tube • 2 Plastic rachet clips • Support clip

Fig. 2.1 GU

_LA

Z 11

2/0G

B

2

6

5

1

3 4

7

Fig. 2.2 LAS

Euro

B/S

066

/0G

B

37

FITTING THE APPLIANCE FLUE OUTLET ADAPTER TO THE BOILER

Connecting the condensate dischargesystem • A condensate discharge

connection (3) is provided on theadaptor to remove any condensate or other water whichmay form in the flue system.

• Connect the condensate dischargetube (2) to the condensate discharge connection point (4) onthe adaptor and secure with theplastic rachet clip provided.

Important: Ensure that there are nokinks in the condensate dischargepipe.

• Position the trap (5) below theappliance and secure to the wallusing the bracket and screws provided. Connect the condensatedischarge tube to the top connection of the trap ensuringthat the condensate dischargetube engages into the trap by aminimum of 90 mm.

• Connect the outlet of the condensate trap (6) to a suitabledrain point.

Important: Before operating the boilerthe condensate trap must be filledwith water.

• Use only the condensation hoseand condensate trap suppliedwith the accessory.

PART

2 C

ONC

ENTR

IC 8

0/12

5

38

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITHEXTENSIONS

IMPORTANT:The flue hole should be cut with aslight rise to outside of 3°±1°(equivalent to 50mm±20mm rise permetre length)

Side flue installations• For installations where the air/flue

duct is to be installed to the side,the position of the flue exit holecan be determined as follows:

• Identify the correct measurementas shown in fig. 3.2, carefullymeasure the distance from the bottom centre of the boiler hanging bracket (centreline of thetwo lower hanging bracket fixingholes). This gives the position ofthe centreline of the 125 mm flueelbow and adaptor when installed.

• The position of the flue exit holecan be determined by carefullylevelling across the wall from thismark.

• The position of the flue exit holeshould allow the flue to be installed with an upwards slopetowards the terminal of approximately 3°, equivalent to50 mm rise per 1 metre of fluelength. Calculate the required riseaccording to the flue length andmark the position of the flueexithole.

Note: Due to the long lengths of fluepossible and the slope required, itmay be necessary to adjust the location of the boiler installation template. Please check that both theboiler installation site and flue termination are in accordance withthese instructions prior to drilling anyholes for the boiler hanging bracket.• Once the position of the flue exit

hole has been determined, thehole should be cut through thewall using a core drill of 127 mmdiameter. The flue exit hole shouldbe cut with a rise towards outsideof 3°.

• Measure the distance from the outside face of the wall to the centre of the fan outlet on the boiler (fig. 3.3).This is dimension A.

• For installations where the measured distance dimension A(fig. 3.3) is greater than 960 mm,an air/flue extension accessorywill be required. The number ofair/flue duct extensions which canbe used depends on the boiler.





1

2

*


Fig. 3.1 LAS

Euro

B/S

077

/1

432 mm

Fig. 3.2 LAS

Euro

B/S

083

/2.e

ps

39

• Taking each extension to be used,fit the flue duct into the air ductand secure using the 3 screwsprovided.

• For ease of measuring and marking the air/flue duct extensions, assemble them looselytogether with the air/flue duct andterminal assembly as shown (fig.3.4).

Note: The joints between the flue ductsections are of a push- fit type, withthe flue duct spigot inserted into asocket containing a sealing ring. Forease of installation lubricate the sealusing soap solution prior to assembling.• Assemble the flue such that there

is a gap of about 10 mm betweeneach air duct, which will ensurethe correct flue duct penetrationinto the flue sockets of 30 mm. Allflue sockets should point towardsthe flue terminal.

• Measure from the flue terminaland mark the air duct to a lengthof:Dimension A + 50 mm

• Take the extension(s) to be shortened and remove the 3 screws. Separate the ducts.

Note: For assembly reasons do notshorten any air duct to a length ofless than 100 mm. If necessary shorten two adjacent extensions toachieve the overall required length.• Cut the air duct square and

remove any burrs.• Refit the flue duct into the air duct

and secure using the 3 screws.• Cut the flue duct as detailed in

fig. 3.5.• When cutting the air and flue

ducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.

• Care should be taken not toscratch the white surface of the airduct.

• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 45 - 47.

• At this stage it is necessary toprepare and fit the boiler onto thehanging bracket – refer to theboiler installation instructions.

• Fit the appliance flue outletadaptor to the boiler.

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT Ø 80/125 WITHEXTENSIONS

A

Fig. 3.3 LAS

Euro

B/S

082

/0

10 mm

Mark air duct here

Dimension A + 50 mm

Fig. 3.4 LAS

Euro

B/S

084

/0

25 mm

Mark flue duct here

15 mm

Fig. 3.5 LAS

Euro

B/S

080

/0

PART

2 C

ONC

ENTR

IC 8

0/12

5

40

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT AND TERMINALACCESSORY (80/125 Ø)

70

1103

70

15

Horizontal air/flue duct and terminalaccessoryAccy. No.: 303 609

The set contains:• Horizontal air/flue duct and

terminal assembly• 87° elbow• 2 x 70 mm air duct clamps• 2 trim rings Ø 125

Fig. 4.1: Horizontal air/flue duct

GU

_LA

Z 82

/0

IMPORTANT:The flue hole should be cut with aslight rise to outside of 3°±1°(equivalent to 50mm±20mm rise permetre length)

2201.5°

123

Fig. 4.2: Installing the horizontal wall duct LAS

Euro

B/S

013

/0

Preparation• Push the assembled air/flue duct

and terminal assembly through theflue exit hole until it protrudes 220 mm out from the outsidewall.

• Ensure that the terminal is correctly positioned with the airinlet grille at the bottom.

• Slide one of the two trim ringsover the air duct until it is flushwith the internal wall face.

41

PART

2 C

ONC

ENTR

IC 8

0/12

5

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT AND TERMINALACCESSORY (80/125)

Fitting extensions• Install the flue extensions by

working from the installed air/flueand terminal accessory backtowards the boiler.

• The joints between the flue ductsections are made by pushing theflue duct spigot into the socket ofthe flue duct extension by 30 mm.This is achieved when the gapbetween the air duct sections is10 mm.

• All sockets should point towardsthe flue terminal.

• The joints between the air ductsections should be clamped usingthe air duct clamps.

• Ensure that the air duct clampsare positioned centrally.

• Drill two 3 mm diameter holesthrough the air duct (ensure thatthe drill does not pierce the innerflue duct). Fix the duct using thescrews provided.

• Ensure that the flue assembly isadequately supported along itsentire length.

• Cut any air/flue ducts to the required length as detailed onpage 45.

Connect the flue assembly to the adaptor • Slide the 125 mm dia x 88 mm

long air duct clamp over the airduct.

• Fit the 87° elbow to the last flueextension.

• Line up the elbow with theadaptor and insert the spigot ofthe elbow in to the adaptor.

• Locate the air duct clamps ensuring they are positioned centrally.

• Drill two holes 3mm Ø throughthe air duct through both the airduct clamps at the most convienient holes on the air ductclamps. (Ensure that the drill doesnot penetrate the inner flue duct).Screw the clamps to the air ductsof the flue assembly, the elbowand boiler using the sheet metalscrews supplied.

• Slide the internal trim ring back tothe wall, securing in position witha small amount of sealant if required.

42

1170

670

70

Vertical air/flue duct and terminalaccessory 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 GU

_LA

Z 37

7/0G

B




• Fix the paper template, suppliedwith the boiler, to the wall ensuring that the centreline of the template is vertical using a plumbline or spirit level.

Please note: The vertical air/flue ductand terminal accessory (Accy. 303 600) may be shortened. Theouter ‘white’ duct should be shortened first, then the inner flueduct cut so that it protrudes 15 mmout of the air duct. In case of installation directly to the boiler without elbows or bends, it is essential that the roof tile/collar isvertically aligned with the air/flueduct of the boiler.

INSTALLATION OF THE VERTICAL ROOF DUCT

43

PART

2 C

ONC

ENTR

IC 8

0/12

5

2

3

640

520

Ø125

25 –

45°

1

5

6

7

8

10

Fig. 5.2: Fitting the device and the roof duct (pitched roof) LAS

Euro

B/S

002

/0

Pitched roof• Determine the point of termination


• Install the adjustable pitched rooftile (1) in position.

• Fit the adjustable hood over theroof tile according to the roofpitch. The adjustable hood is suitable for roof pitches from 25°to 35°, or 35° to 45° by reversing.

Flat roof• Determine the point of termination


• Make a hole in the roof of 135mm diameter. Secure the flat roofcollar (1) to the roof coveringabove the hole in accordancewith the codes of practice for flatroofs CP 144) to ensure a watertight seal.

Pitched and flat roofinstallations• From above insert the air/flue

duct and terminal assembly (5)into the adjustable roof tile (pitched roof) or roof penetrationcollar (flat roof) until it is fully seated.

• Adjust the vertical alignment ofthe air/flue duct and terminalassembly and secure the air ductwith the fixing bracket provided.(6).


• For installations where an air/flueextension accessory will be required. The number of air/flueduct extensions which can beused depends on the boiler.

Note: The joints between the flue ductsections are of a push- fit type, withthe flue duct spigot inserted into asocket containing a sealing ring. Forease of installation lubricate the sealusing soap solution prior to assembling.

670

500

Ø125

≥125

1

5

6

7

3

3

Fig. 5.3: Fitting the device and duct to a flat roof LAS

Euro

B/S

004

/0_G

B


44

• Assemble the flue such that thereis a gap of about 10 mm betweeneach air duct, which will ensurethe correct flue duct penetrationinto the flue sockets of 30 mm. Allflue sockets should point towardsthe flue terminal.

• Measure the air duct (from theend with the 3 fixing holes) andmark the air duct to this length.

• Take the extension(s) to be shortened and remove the 3 screws. Separate the ducts.

Note: For assembly reasons do notshorten any air duct to a length ofless than 100 mm. If necessary shorten two adjacent extensions toachieve the overall required length.• Cut the air duct square.• Refit the flue duct into the air duct

and secure using the 3 screws.• Cut the flue duct as detailed in

figure 5.5.• When cutting the air and flue

ducts it is important to remove anyburrs with a file, this ensures easyfitting of the ducts and preventsany rough edges from damagingthe flue seals.

• Care should be taken not toscratch the white surface of the airduct.

• If the installation requires the useof air/flue duct extensions, additional bends or elbows referto the sections on pages 45 - 47.

• Install the flue extensions by working from the installed air/flueand terminal accessory backtowards the boiler.

• The joints between the flue ductsections are made by pushing theflue duct spigot into the socket ofthe flue duct extension by 30 mm.This is achieved when the gapbetween the air duct sections is10 mm.

• All sockets should point towardsthe flue terminal.

• The joints between the air ductsections should be clamped usingthe air duct clamps.

• Ensure that the air duct clampsare positioned centrally.


10 mm

Length of air duct

10 mm

Fig. 5.4

25 mm

Mark flue duct here

15 mm

Fig. 5.5

45


• Drill two 3 mm diameter holesthrough the air duct (ensure thatthe drill does not pierce the innerflue duct). Fix the duct using thescrews provided.

• Ensure that the flue assembly isadequately supported along itsentire length.

• Fit the appliance flue outletadaptor to the boiler.

• Ensure that any air duct clampsused are positioned centrally andfixed to the air duct using the selftapping screws supplied.

Connect the flueassembly to the adaptor • Slide the 125 mm dia x

88 mm long air duct clamp overthe air duct.

• Line up the air/flue duct with theadaptor and insert the spigot of the air/flue duct in to theadaptor.

• Locate the air duct clampsensuring they are positionedcentrally.

• Drill two holes 3 mm Ø throughthe air duct through both the airduct clamps at the mostconvienient holes on the air ductclamps. (Ensure that the drill doesnot penetrate the inner flue duct).Screw the clamps to the air ductsof the flue assembly, the elbowand boiler using the sheet metal screws supplied.

PART

2 C

ONC

ENTR

IC 8

0/12

5

46

FITTING AIR/FLUE DUCT EXTENSIONS

Cutting extensions• Measure and note the length of

the air duct extension required forthe installation (a).Note: Extensions should be assembled so there is a gap of 10 mm between each air duct.

Use this measurement to calculate thelength to cut the air and flue ducts:


follows:Length of air duct as shown in fig. 6.1.


follows:Length of flue duct =length of air duct + 40 mm

• Cut the air and flue ducts squareand and remove any burrs. Careshould be taken not to scratch thewhite surface on the air duct.

• After cutting the tubes to size, insert the flue duct into the air ductand secure the air duct to the spacing bracket through the threepre-drilled holes.

• Install the flue extension. • Ensure that the air duct clamps are

centrally positioned over the 10 mm gap between the air ductsections.

• Drill two holes 3 mm Ø througheach air duct (at either end of theextension) at the most convienientholes in the air duct clamps andsecure with screws provided.

• Note: The air duct clamp must notbe screwed to the bottom theair/flue duct and terminal assembly, this will allow the clampto absord any slight movement inthe roof structure.

10 mm

Length of air duct

10 mm

Fig. 6.1 LAS

Euro

B/S

081

/0

47




730 520735 525740 530745 535750 540755 545760 550765 555770 560775 565780 570785 575790 580795 585800 590805 595810 600815 605820 610825 615830 620835 625840 630845 635850 640855 645860 650865 655870 660875 665880 670885 675890 680895 685900 690905 695910 700915 705920 710925 715930 720935 725940 730

505 295510 300515 305520 310525 315530 320535 325540 330545 335550 340555 345560 350565 355570 360575 365580 370585 375590 380595 385600 390605 395610 400615 405620 410625 415630 420635 425640 430645 435650 440655 445660 450665 455670 460675 465680 470685 475690 480695 485700 490705 495710 500715 505720 510725 515


200, 205 0210, 0


310 100315 105320 110325 115330 120335 125340 130345 135350 140355 145360 150365 155370 160375 165380 170385 175390 180395 185400 190405 195410 200415 205420 210425 215430 220435 225440 230445 235450 240455 245460 250465 255470 260475 265480 270485 275490 280495 285500 290






FITTING AIR/DUCT EXTENSIONS BETWEEN TWO 90° ELBOWS

PART

2 C

ONC

ENTR

IC 8

0/12

5

48

FITTING AIR/FLUE DUCT EXTENSIONS BETWEEN TWO 45° ELBOWS






90 0 21095 0 215100 0 220


170 100 290175 108 295180 115 300185 122 305190 129 310195 136 315200 143 320205 150 325210 157 330215 164 335220 171 340225 178 345230 185 350235 192 355240 199 360245 207 365250 214 370255 221 375260 228 380265 235 385270 242 390275 249 395280 256 400285 263 405290 270 410295 277 415300 284 420305 291 425310 298 430315 306 435320 313 440325 320 445330 327 450


[in mm] [in mm]


[in mm] [in mm]

Table 6.2: Length of surplus with 45° elbow


[in mm] [in mm]

335 334 455340 341 460345 348 465350 355 470355 362 475360 369 480365 376 485370 383 490375 390 495380 397 500385 405 505390 412 510395 419 515400 426 520405 433 525410 440 530415 447 535420 454 540425 461 545430 468 550435 475 555440 482 560445 489 565450 496 570455 504 575460 511 580465 518 585470 525 590475 532 595480 539 600485 546 605490 553 610495 560 615500 567 620505 574 625510 581 630515 588 635520 596 640525 603 645530 610 650

535 617 655540 624 660545 631 665550 638 670555 645 675560 652 680565 659 685570 666 690575 673 695580 680 700585 687 705590 695 710595 702 715600 709 720605 716 725610 723 730615 730 735620 737 740625 744 745630 751 750635 758 755640 765 760645 772 765650 779 770655 786 775660 794 780665 801 785670 808 790675 815 795680 822 800685 829 805690 836 810695 843 815700 850 820705 857 825710 864 830715 871 835720 878 840

49

4

5

2

1 4

How to fit sliding sleeves

INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE

NOTE:For installations where there is insufficient movement to allow fittingof the flue into flue outlet, a slidingsleeve (Accy. No. 303 817) is available. When using the slidingsleeve both the air and flue ducts ofthe last extension must be shortenedby a further 85 mm.

• Push the sliding sleeve over the cutend of the flue duct.

• Place the air duct clamp over theair duct.

• Pull back the sliding sleeve so thatit engages into the socket of theboiler. Ensure that the sliding sleeve penetrates the socket suchthat there is at least 20 mm engagement at both ends of thesliding sleeve.

• Fit the air duct clamp over the airducts of the extension/terminaland boiler outlet. Close the snapclamp.

• Drill two holes 3 mm diameterthrough the air duct clamp (thecentre of the holes should be 6mm from the edge of the clamp).Ensure that the drill does not penetrate the inner flue duct.Screw the air duct clamp to the airduct of the sleeve using the screw provided.

• Refer back to the Instructions forInstallation and Servicing suppliedwith the boiler to complete theinstallation.

Fig. 7.1 LAS

Euro

B/S

087

/0

Fig. 7.2 LAS

Euro

B/S

086

/0

PART

2 C

ONC

ENTR

IC 8

0/12

5

83

31

70

_31

GB

07/

200

3 M

üS

ub

ject

to

alt

erat

ion

Head Office: Vaillant Ltd.

Service Solutions 0870 6060 777

Vaillant House Trident CloseMedway City Estate

Rochester Kent ME2 4EZ

Technical Advice 01634 292392

83 31 70 GB31 24.07 - Orpington Plumbers - Orpington Boiler

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Transcript of 83 31 70 GB31 24.07 - Orpington Plumbers - Orpington Boiler