Vaillant TurboMAX plus 2 E Series Bedienungsanleitung

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

CONTENTS: PART 1 CONCENTRIC 60/100

Requirements

Planning the air/flue duct layout

Alternative termination accessories available 5

Maximum flue lengths Ø 60/100 9

Flue restrictor rings 10

Preparation 11

Top outlet flue exiting to rear 11

Top outlet flue exiting to side 11

Preparation 14

Preparation of boiler for rear outlet air/flue duct 16

Installation of the horizontal

air/flue duct (top outlet)

Fitting air/flue duct extensions

Page

Fitting air/flue duct extensions

between two 90° elbows

Fitting air/flue duct extensions

between two 45° elbows

Installing the air/flue duct sliding

sleeve

Installation of the vertical

roof duct

Installation of the horizontal

air/flue duct (rear outlet)

Preparation 19

Top outlet flue exiting to rear 19

Top outlet flue exiting to side 19

Preparation 22

Pitched roof 23

Flat roof 23

Pitched and flat roof installation 23

Installation of the Se-Duct flue

CONTENTS: PART 2 CONCENTRIC 80/125

Planning the air/flue duct layout Termination accessories available 29

Maximum flue lengths Ø 80/125 32

Flue restrictor rings 33

Preparation 37

Side flue installations 37

Fitting the appliance flue outlet

adapter to the boiler

Fitting air/flue duct extensions

Page

Fitting air/flue duct extensions

between two 90° elbows

Fitting air/flue duct extensions

between two 45° elbows

Installing the air/flue duct sliding

sleeve

Installation of the vertical

roof duct

Installation of the horizontal

air/flue with extensions

Preparation 39

Fitting extensions 40

Connect the flue assembly to the adaptor 40

Installation of the horizontal

air/flue duct and terminal

accessory (80/125)

Preparation 41

Pitched roof 42

Flat roof 42

Pitched and flat roof installation 42

Connect the flue assembly to the adaptor 44

REQUIREMENTS

☞Vaillant turboMAX,

thermoCOMPACT and aquaPLUS

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 approval

test certificate.

☞These instructions should be read

in conjunction with the instructions

for installation and servicing

supplied with the boiler.

☞Ensure also that all legislation,

rules, regulations and directives

mentioned in the installation

instructions are observed.

☞The installation of the boiler and

its flue must be carried out by a

competent person who is

registered with CORGI (The

Council for Registered Gas

Installers).

☞The installation of the boiler and

flue must be in accordance with

the Gas Safety (Installation and

Use) Regulations 1998 and the

Building Regulations and

BS 5440 Part 1.

☞The requirements for flue

termination detailed in the boiler

installation instructions must be

observed.

☞Two types of flue system are

available for turboMAX,

thermoCOMPACT and aquaPLUS

boilers. The standard concentric

flue system (100 mm outside

diameter) and a larger diameter

concentric system (125 mm

outside diameter) which allows

longer air/flue duct lengths to be

achieved.

☞The air/flue duct operates at very

low temperatures therefore no

clearance is necessary between

the air duct and adjacent

services.

☞Ensure while installation work is

being carried out that no debris

such as swarf, filings or fragments

of mortar are allowed to remain

in the air/flue duct.

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

Ø 60/100

PART 1 CONCENTRIC 60/100

PLANNING THE AIR/FLUE DUCT LAYOUT

Alternative termination

accessories available

Optional connection accessories Accy. No.

303 807 303 806

Air/flue duct extension

500 mm - Ø 60/100 303 801 x x

Air/flue duct extension

1000 mm - Ø 60/100 303 802 x x

Telescopic air/flue duct extension

500 - 800 mm - Ø 60/100 303 804 x x

2 x 45° Bends

Ø 60/100 303 809 x x

90° Elbow

Ø 60/100 303 808 x x

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

Air/flue duct extension

1960 mm - Ø 60/100 303 803 x x

Air/flue duct 15° offset

Ø 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

303 800

303 807 = Horizontal air/flue duct with 90° elbow and

terminal (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

PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.1: Extensions, Ø 60/100

Fig. 1.3: Elbow joints, Ø 60/100

90° Elbow, Ø 60/100

Accy. No.: 303 808

2 x 45° Bends, Ø 60/100

Accy. No.: 303 809

Fig. 1.2: Telescopic extension

Telescopic air/flue duct extension

500 – 800 mm Ø 60/100

Accy. No.: 303 804

Air/flue duct extension 500 mm,

Ø 60/100

Accy. No.: 303 801

Air/flue duct extension 1000 mm,

Ø 60/100

Accy. No.: 303 802

Air/flue duct extension 1960 mm,

Ø 60/100

Accy. No.: 303 803

GU_LAZ 70/0

LAS Euro B/S 015/0 Teleskop_Verlängerung

Air/flue duct 15° offset Ø 60/100

Accy. No.: 303 820

Air/flue duct (adjustable) offset pipe

Ø 60/100

Accy. No.: 303 819

33 - 56

Abb. 1.4: Adjustable offset pipe

LAS Euro B/S 070/0GB

135

145

PART 1 CONCENTRIC 60/100

PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.7: Tiles for pitched roofs

Adjustable roof tile

Accy. No.: 9076

GU_LAZ 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_LAZ 72/0

☞Use one clip per extension to

support the air/flue duct.

Fig. 1.8: Flat roof penetration collar

GU_LAZ 42/0

Flat roof penetration collar

Accy. No.: 9056

5.3 5.3 4.5 3.3 3.0

PLANNING THE AIR/FLUE DUCT LAYOUT

Horizontal flue

systems

303 807

303 806

303 810

Maximum flue lengths Ø 60/100

Maximum flue length

Fig. 1.9 Fig. 1.10

LAS Euro B/S 074/0

LAS Euro B/S 075/0

Vertical flue

systems

303 800

thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT

615/2 E 620/2 E 624/2 E 628/2 E 637 E

turboMAX pro 24/2 E turboMAX pro turboMAX plus

turboMAX plus 28/2 E 837 E

824/2 E turboMAX plus aquaPLUS

828/2 E

6.3 6.3 5.5 4.3 4.0

Max.

permitted

flue length

(L)

Max.

permitted

flue 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.

= B

= D

= A

= C

PART 1 CONCENTRIC 60/100

PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.11: Flue restrictor rings

Flue restrictor rings

The flue restrictor ring marked A, C

or D is packed with the boiler

connection accessories. The restrictor

ring should be fitted as shown in the

diagram according to the equivalent

flue length in the table.

The total equivalent flue length is the

total length of the flue (including the

terminal assembly for vertical flues),

plus the resistance of any bends or

elbows used.

-equivalent length of 90° elbow is

1 m

-equivalent length of 45° elbow is

0.5 m

•Push the restrictor (1) into the flue

connection of the appliance (3)

•Connect the flue/elbow (2) into

the flue connection of the

appliance (3).

Note:

thermoCOMPACT 615 boilers do not

require a seperate restrictor ring and

are supplied without the restrictor.

The required restriction is designed

into the flue connection piece for

these boilers.

thermoCOMPACT

615/2 E

thermoCOMPACT

620/2 E

thermoCOMPACT

624/2 E

turboMAX plus

824/2 E

turboMAX

pro 24/2 E

thermoCOMPACT

628/2 E

turboMAX plus

828/2 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)

PLANNING THE AIR/FLUE DUCT LAYOUT

Fig. 1.12: Flue restrictor rings

Flue restrictor rings

The flue restrictor ring marked F0 and

F1 is packed with the boiler

connection accessories. The restrictor

ring should be fitted as shown in the

diagram according to the equivalent

flue length in the table.

The total equivalent flue length is the

total length of the flue (including the

terminal assembly for vertical flues),

plus the resistance of any bends or

elbows used.

-equivalent length of 90° elbow is

1 m

-equivalent length of 45° elbow is

0.5 m

•Push the restrictor (1) into the flue

connection of the appliance (3)

•Connect the flue/elbow (2) into

the flue connection of the

appliance (3).

aquaPLUS thermoCOMPACT

637 E

turboMAX plus

837 E

Use restrictor F0 ---

Use restrictor F2 ---

No flue restrictor ---

< 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

Total equivalent flue length

(incl. terminal any bends / elbows used)

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