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Seite 1

For the installer

Flue installation instructions

Air flue duct for use with ecoMAX

and ecoTEC boilers

ecoMAX 613/2 E
ecoMAX 618/2 E
ecoMAX 622/2 E
ecoMAX 635/ E
ecoMAX 824/2 E
ecoMAX 828/2 E
ecoMAX 835/ E
ecoMAX pro 18 E
ecoMAX pro 28 E
ecoTEC plus 612
ecoTEC plus 615
ecoTEC plus 618
ecoTEC plus 624
ecoTEC plus 824
ecoTEC plus 630
ecoTEC plus 831
ecoTEC plus 637
ecoTEC plus 837
ecoTEC pro 28

GB

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Seite 2

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Seite 3

Pages 4 - 38

Standard Concentric Systems 60/100

(Galvanized steel air duct/plastic flue duct)

PART 2

Pages 39 - 61

Optional Concentric System 80/125

(Galvanized steel air duct/plastic flue duct)

PART 2 CONCENTRIC 80/125

PART 1

PART 1 CONCENTRIC 60/100

OVERVIEW

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Seite 4

CONTENTS: PART 1 CONCENTRIC 60/100

The air/flue duct must be installed by a suitably
qualified service provider, which is responsible
for observing the relevant specifications,
regulations and standards.
Page

Requirements

Regulations and standards to be observed

Planning the air/flue duct

layout

Alternative termination accessories available

Maximum flue lengths for ecoMAX
Maximum flue lengths for ecoTEC

6
11
12

Installing the air/flue duct sliding sleeve

14

Installation of the horizontal air/flue duct

15

Installation of the black terminal kit

24

Installation of the variable termination kit

26

Installation of the vertical air/flue duct

31

Fitting air/flue duct extensions

34
35

How to add extensions

How to install elbows

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Seite 5

REQUIREMENTS
Regulations and
standards to be
observed

Vaillant ecoMAX/ecoTEC 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.

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.

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 ecoMAX/ecoTEC
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.

PART 1 CONCENTRIC 60/100

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PLANNING THE AIR/FLUE DUCT LAYOUT

Alternative termination accessories available
303 900 = Vertical air/flue duct (black)

303 930 = Horizontal air/flue duct (only ecoMAX)

303 933 = Horizontal air/flue duct
303 936 = Horizontal telescopic air/flue duct
303 900 303 930 303 933 303 936

Optional connection accessories

Accy. No.

Air/flue duct extensions, concentric

470 mm - 60/100

303 902

Air/flue duct extensions, concentric

970 mm - 60/100

303 903

Air/flue duct extensions, concentric

1970 mm - 60/100

303 905

Bends (PP), concentric (pack of 2)

45 - 60/100

303 911

Elbow, concentric
87 - 60/100

303 910

Flue support clips (pack of 5), 100

303 821

Adjustable flue support clips (pack of 3); 100

303 935

Sliding sleeve (PP) 60/100

303 915

009076 black

Flexible pitched roof seal

303 980

Flat roof penetration collar

009 056

Telescopic extension
440 mm - 690 mm 60/100

303 906

Telescopic offset section

303 919

Black terminal kit for horizontal air/flue duct

303 934

Variable termination kit - black *)

303 942

Extension pipe for variable termination kit VTK

60 mm 1 m - black *)

303 943

87 elbow for variable termination kit - black *)

303 944

45 bend for variable termination kit - black (2 pieces)

303 945

Variable termination kit - white *)

303 946

Extension pipe for variable termination kit VTK

60 mm 1 m - white *)

303 947

87 elbow for variable termination kit - white *)

303 949

45 bend for variable termination kit - white (2 pieces)

303 948

Adjustable roof tiles for pitched roof

*) delivered with support clips

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PLANNING THE AIR/FLUE DUCT LAYOUT

PART 1 CONCENTRIC 60/100

Air/flue duct extension 470 mm

60/100
Vaillant Accy. No.: 303 902
Air/flue duct extension 970 mm,
60/100
Vaillant Accy. No.: 303 903

GU_LAZ 70/0

Air/flue duct extension 1970 mm,

60/100
Vaillant Accy. No.: 303 905

Fig. 1.1: Extensions, 60/100

Elbow, 87, 60/100

Vaillant Accy. No.: 303 910
27

27

18

27

18

18

Bends, 45 (pack of 2),

60/100
Vaillant Accy. No.: 303 911

Fig. 1.2: Elbow joints, 60/100

Elbow, 87, 60/100

Only Part of:
Vaillant Accy. No.: 303 933
Vaillant Accy. No.: 303 936

Fig. 1.3: Elbow joints, 60/100

GU_LAZ 72/0

13

65

Flue support clips, 100 (pack of 5)

Vaillant Accy. No.: 303 821

Fig. 1.4: Flue support clips, 100/ 80

GU_LAZ 72/0

Use one clip per extension to

support the air/flue duct.

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PLANNING THE AIR/FLUE DUCT LAYOUT

250

Adjustable flue support clips, 100

(pack of 3)
Vaillant Accy. No.: 303 935

Fig. 1.5: Flue support clips, 100

Telescopic extension (PP), 60/100

440 mm - 690 mm
Vaillant Accy. No.: 303 906
440 690

Fig. 1.6: Telescopic extension, 60/100

33 56

Offset section, 60/100

Vaillant Accy. No.: 303 919

Fig. 1.7: Offset section, 60/100

303919_IAx

290 374

155

Sliding sleeve (PP), 60/100

Vaillant Accy. No.: 303 915

Fig. 1.8: Sliding sleeve, 60/100

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PLANNING THE AIR/FLUE DUCT LAYOUT

Adjustable roof tile for pitched roof
Vaillant Accy. No.: 009 076 (black)

132

PART 1 CONCENTRIC 60/100

25

8
GU_LAZ 41/0

49

Fig. 1.9: Adjustable roof tile for pitched roof

Flexible pitched roof seal (black)

Vaillant Accy. No.: 303 980

495

132

495
Fig. 1.10: Flexible pitched roof seal

Flat roof penetration collar

Vaillant Accy. No.: 009 056

130

153

834449_08GB_022006.qxd

390
Fig. 1.11: Flat roof penetration collar

Black terminal kit for horizontal

air/flue duct
Vaillant Accy. No.: 303 934
For 303 933 and 303 936 only

Fig. 1.12: Black terminal kit

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PLANNING THE AIR/FLUE DUCT LAYOUT

Variable termination kit - black
Vaillant Accy. No.: 303 942
For 303 933 and 303 936 only
Variable termination kit - white
Vaillant Accy. No.: 303 946
For 303 933 and 303 936 only

Fig. 1.13: Variable termination kit

Extension pipe for variable

termination kit 60 mm 1 m - black
including 1 support clip
Vaillant Accy. No.: 303 943
Extension pipe for variable
termination kit 60 mm 1 m - white
including 1 support clip
Vaillant Accy. No.: 303 947

Fig. 1.14: Extension 60 1 m pipe

87 elbow for variable termination kit

- black
including 1 support clip
Vaillant Accy. No.: 303 944
87 elbow for variable termination kit
- white
including 1 support clip
Vaillant Accy. No.: 303 949

Fig. 1.15: 87 elbow

45 bend for variable termination kit

- black
Vaillant Accy. No.: 303 945
45 bend for variable termination kit
- white
Vaillant Accy. No.: 303 948

Fig. 1.16: 45 bend

10

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PLANNING THE AIR/FLUE DUCT LAYOUT

60

PART 1 CONCENTRIC 60/100

Flue support clip, 60 mm

delivered with kits

Fig. 1.17: Flue support clip, 60 mm

Maximum flue lengths for use with ecoMAX

ecoMAX
Accessories

613/2 E
618/2 E
622/2 E

824/2 E

828/2 E

635/ E
835/ E

pro 18 E
pro 28 E

8.0 m
incl.
1 elbow 87

7.0 m
incl.
1 elbow 87

8.0 m
incl.
1 elbow 87

4.0 m
incl.
1 elbow 87

10.0 m
incl.
1 elbow 87

Accy. No.

Horizontal
303 930 Max. permitted
flue systems 303 933 concentric
flue length
Fig. 1.17

Maximum length of flue is reduced by 1.0 m for each additional 87 elbow

Maximum length of flue is reduced by 0.5 m for each additional 45 elbow

Variable
termination
kit

Vertical
flue systems

303 942 Max. permitted

303 946 concentric
flue length
only in Fig. 1.19
combination with
303 933

The maximum permitted concentric flue length given above is reduced as

follows:
-

Reduced
Reduced
Reduced
Reduced

by
by
by
by

0.5
0.5
0.5
0.5

m
m
m
m

for
for
for
for

the variable terminal

every 1 m VTK pipe
every 87 bend
2 x 45 bend

10.0 m
7.0 m
10.0 m
9.0 m
303 900 Max. permitted
12.0 m
concentric
flue length
Fig. 1.18
Maximum length of flue is reduced by 1.0 m for each additional 87 elbow
Maximum length of flue is reduced by 0.5 m for each additional 45 elbow

11

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PLANNING THE AIR/FLUE DUCT LAYOUT

Maximum flue lengths for use with ecoTEC
ecoTEC
Accessories

Accy. No.

Horizontal
flue systems

303 933 Max. permitted

concentric
flue length
Fig. 1.17

plus 612
plus 615
plus 618

plus 624
plus 824

plus 630
plus 831

plus 637
plus 837

pro 28

8.0 m
incl.
1 elbow 87

8.0 m
incl.
1 elbow 87

8.0 m
incl.
1 elbow 87

5.5 m
incl.
1 elbow 87

8.0 m
incl.
1 elbow 87

Maximum length of flue is reduced by 1.0 m for each additional 87 elbow

Maximum length of flue is reduced by 0.5 m for each additional 45 elbow

Variable
termination
kit

Vertical
flue systems

303 942 Max. permitted

303 946 concentric
flue length
only in Fig. 1.19
combination with
303 933

The maximum permitted concentric flue length given above is reduced as

follows:
-

Reduced
Reduced
Reduced
Reduced

by
by
by
by

0.5
0.5
0.5
0.5

m
m
m
m

for
for
for
for

the variable terminal

every 1 m VTK pipe
every 87 bend
2 x 45 bend

303 900 Max. permitted

12.0 m
12.0 m
12.0 m
8.0 m
12.0 m
concentric
flue length
Fig. 1.18
Maximum length of flue is reduced by 1.0 m for each additional 87 elbow
Maximum length of flue is reduced by 0.5 m for each additional 45 elbow

12

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Seite 13

Maximum flue length

Fig. 1.19: Vertical flue systems

Flue length outside

Fig. 1.18: Horizontal flue systems

LAS Euro B/S 074/0

LAS Euro B/S 074/0

Maximum flue length

PART 1 CONCENTRIC 60/100

PLANNING THE AIR/FLUE DUCT LAYOUT

Concentric flue length

Fig. 1.20: Horizontal flue system installed with vertical termination kit

13

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INSTALLING THE AIR/FLUE DUCT SLIDING SLEEVE

5
Fig. 2.0: Installing the sliding sleeve

14

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 air and flue ducts
of the last extension must be
shortened by a further 95 mm.

Schiebemuffe_neu

INSTALLING THE
AIR/FLUE DUCT SLIDING
SLEEVE

Push the sliding sleeve (1) over the

cut end of the flue duct (2).
Place the air duct clamp (7) over
the air duct.
Pull back the sliding sleeve so that
it engages into the socket (3) of
the boiler (4). Ensure that the
sliding sleeve penetrates the
socket such that there is at least
20 mm engagement at both ends
of the sliding sleeve.
Fit the air duct clamp over the air
ducts (5 and 6) of the
extension/terminal and boiler
outlet. Close the snap clamp.
Drill two holes 3 mm diameter
through the air duct clamp (the
centre of the holes should be 6
mm from the edge of the clamp).
Ensure that the drill does not
penetrate the inner flue duct.
Screw the air duct clamp to the
air duct of the sleeve using the
screws provided.
Complete the installation of the
flue as detailed in these
instructions.

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INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT

Accy No.: 303 930

for ecoMAX only
(Length 0.8 m)

95

Fig. 3.1: Horizontal air/flue conduit

LAS Euro B/S 037/0

13

70

40

IMPORTANT:
The flue hole should be cut with a
slight rise to outside if 3 1
(equivalent to 50 mm 20 mm rise
per metre length).

Horizontal air/flue duct

800

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 100
External wall seal

Preparation
**

Determine the installation site for

the boiler with reference to the
installation and servicing
instructions supplied with the
boiler.
Ensure that all installation and
service clearances are available
and that the boiler flue can be
installed as detailed in these
instructions.
Fix the paper template, supplied
with the boiler, to the wall
ensuring that the centreline of the
template is vertical using a
plumbline or spirit level.

150

5
3
4
1
2

Top outlet flue exiting to rear

* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro

For installations where the air/flue

duct is to be installed directly to
the rear of the boiler, the
installation template details the
position of the flue exit hole for
horizontal top outlet installation.

Fig. 3.2

LAS Euro B/S 072/0GB

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 hole
can be determined by carefully
levelling across the wall from the
centre line of the air/flue duct hole
marked on the template (fig. 3.3).
The position of the flue exit hole
should allow the flue to be
installed with a slight upward
slope of about 3 1 (equivalent
to 50 mm 20 mm per metre of
flue duct). Calculate the required
rise according to the flue length
and mark the position of the flue
exit hole.
15

PART 1 CONCENTRIC 60/100

Observe the maximum flue

lengths as detailed in table on
page 11.

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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 can
be cut with a 107 mm core drill
and the flue external wall seal
fitted from outside the dwelling.

* = 190 mm ecoMAX combination and system boilers

* = 176 mm ecoMAX pro

Fig. 3.3

LAS Euro B/S 077/1

This is dimension A.
Cut the air duct and flue duct to
the lengths shown in (fig. 3.5).

Rear exit

All flue sockets should point

towards the terminal.

* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro

When cutting the air and flue

ducts it is important to remove any
burrs with a file, this ensures easy
fitting of the ducts and prevents
any rough edges from damaging
the flue seals.
Care should be taken not to
scratch the white surface of the air
duct.

150

Fig. 3.4

LAS Euro B/S 078/0

150

Side exit

A + 45 mm

Fig. 3.5

LAS Euro B/S 076/0

13 mm

16

Measure the distance from the

outside face of the wall to the
centre of the fan outlet on the
boiler (fig. 3.4).

If the installation requires the use

of air/flue duct extensions,
additional bends or elbows refer
to the sections on pages 34 - 38.
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. (Ensure that the drill does
not pierce the inner flue duct).
Secure the air ducts together using
the screw provided.

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Seite 17

Push the air/flue duct assembly

(1) including the flexible external
seal 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
wall (fig. 3.2 and fig. 3.6).

150

1
13
Fig. 3.6

LAS Euro B/S 001/0GB

Ensure that the air/flue duct (1) is

centred in the hole and the
terminal is correctly positioned
with the inlet grille at the bottom
(fig. 3.2).
Slide the internal trim ring (2) over
the air duct until it is flush with the
wall (fig. 3.2).
At this stage it is necessary to
prepare and fit the boiler onto the
hanging bracket refer to the
boiler installation instructions.
Fit the elbow (3) to the boiler by
inserting the spigot of the flue
elbow into the flue socket on the
boiler and secure using the 40
mm air duct clamp (4) provided
(fig. 3.2).
Pull the air/flue duct back through
the wall such that the flue duct
fully engages into the flue elbow
socket.
Fit the 70 mm air duct clamp (5)
ensuring that it is positioned
centrally (fig. 3.2).
Drill two holes 3 mm through
the air duct of both the elbow/flue
and elbow/boiler clamps at the
most convienient holes on the air
duct clamps. (Ensure that the drill
does not penetrate the inner flue
duct). Screw 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.
Caution!
If installed near a light, insects may
fly into the opening. Tell the
homeowner to clean the opening
regularly.

17

PART 1 CONCENTRIC 60/100

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

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Seite 18

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT

IMPORTANT:
The air/flue duct is not concentric
and the air duct has a slope of 1.5
(if the air flue duct is not cut). The
hole through the wall can therefore
be drilled horizontally with no slope.

Horizontal air/flue duct

754

Accy No.: 303 933

(Length 0.75 m)
65

Contents of the accessory:

Horizontal air/flue duct
87 elbow
1 x 48 mm air duct clamp
1 x 30 mm air duct clamp
Internal trim ring 100
External wall seal.

30

13

Where extensions are used, these

must be installed with a slope at 3
1 (equivalent to 50 mm 20 mm
rise per metre length) to ensure that
condensate dows not remain in the
sleeve.

48

Fig. 3.7: Horizontal air/flue conduit

Preparation
**

Determine the installation site for

the boiler with reference to the
installation and servicing
instructions supplied with the
boiler.
Ensure that all installation and
service clearances are available
and that the boiler flue can be
installed as detailed in these
instructions.
Fix the paper template, supplied
with the boiler, to the wall
ensuring that the centreline of the
template is vertical using a
plumbline or spirit level.

87

5
3
4

Top outlet flue exiting to rear

For installations where the air/flue

duct is to be installed directly to
the rear of the boiler, the
installation template details the
position of the flue exit hole for
horizontal top outlet installation.

* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

Fig. 3.8

18

LAS Euro B/S 072/0GB

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 hole
can be determined by carefully
levelling across the wall from the
centre line of the air/flue duct hole
marked on the template (fig. 3.9).
The position of the flue exit hole
should allow the flue to be
installed with a slight upward
slope of about 3 1 (equivalent
to 50 mm 20 mm per metre of
flue duct). Calculate the required
rise according to the flue length
and mark the position of the flue
exit hole.

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Seite 19

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 can
be cut with a 107 mm core drill
and the flue external wall seal
fitted from outside the dwelling.

Fig. 3.9

* = 190 mm ecoMAX combination and system boilers

* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

LAS Euro B/S 077/1

Measure the distance from the

outside face of the wall to the
centre of the fan outlet on the
boiler (fig. 3.10).
This is dimension A.
Cut the air duct and flue duct to
the lengths shown in (fig. 3.11).
All flue sockets should point
towards the terminal.

Rear exit

When cutting the air and flue

ducts it is important to remove any
burrs with a file, this ensures easy
fitting of the ducts and prevents
any rough edges from damaging
the flue seals.
Care should be taken not to
scratch the white surface of the air
duct.

87

*
* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

A
Fig. 3.10

LAS Euro B/S 078/0

87

Side exit

If the installation requires the use

of air/flue duct extensions,
additional bends or elbows refer
to the sections on pages 34 - 38.
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. (Ensure that the drill does
not pierce the inner flue duct).
Secure the air ducts together using
the screw provided.

A + 22 mm

Fig. 3.11

LAS Euro B/S 076/0

13 mm

19

PART 1 CONCENTRIC 60/100

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

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Seite 20

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

Push the air/flue duct assembly
(1) including the flexible external
seal 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
wall (fig. 3.8 and fig 3.12).

87

13

Fig. 3.12

LAS Euro B/S 001/0GB

Ensure that the air/flue duct (1) is

centred in the hole and the
terminal is correctly positioned
with the inlet grille at the bottom
(fig 3.8 and fig 3.12).
Slide the internal trim ring (2) over
the air duct until it is flush with the
wall (fig. 3.8).
At this stage it is necessary to
prepare and fit the boiler onto the
hanging bracket refer to the
boiler installation instructions.
Fit the elbow (3) to the boiler by
inserting the spigot of the flue
elbow into the flue socket on the
boiler and secure using the 30
mm air duct clamp (4) provided
(fig. 3.8).
Pull the air/flue duct back through
the wall such that the flue duct
fully engages into the flue elbow
socket.
Fit the 48 mm air duct clamp (5)
ensuring that it is positioned
centrally (fig. 3.8).
Drill two holes 3 mm through
the air duct of both the elbow/flue
and elbow/boiler clamps at the
most convienient holes on the air
duct clamps. (Ensure that the drill
does not penetrate the inner flue
duct). Screw 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.
Caution!
If installed near a light, insects may
fly into the opening. Tell the
homeowner to clean the opening
regularly.

20

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Seite 21

INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT

Horizontal telescopic air/flue duct

405 - 610

Accy No.: 303 936

(Length 0.4 - 0.61 m)
48

65

Fig. 3.13: Horizontal air/flue conduit

LAS Euro B/S 037/0

30

13

Where extensions are used, these

must be installed with a slope at 3
1 (equivalent to 50 mm 20 mm
rise per metre length) to ensure that
condensate dows not remain in the
sleeve.

Contents of the accessory:

Horizontal telescopic air/flue duct
87 elbow
1 x 48 mm air duct clamp
1 x 30 mm air duct clamp
Internal trim ring 100
External wall seal.

Preparation
**

Determine the installation site for

the boiler with reference to the
installation and servicing
instructions supplied with the
boiler.
Ensure that all installation and
service clearances are available
and that the boiler flue can be
installed as detailed in these
instructions.
Fix the paper template, supplied
with the boiler, to the wall
ensuring that the centreline of the
template is vertical using a
plumbline or spirit level.

87

5
3
4

1
2

Top outlet flue exiting to rear

* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

For installations where the air/flue

duct is to be installed directly to
the rear of the boiler, the
installation template details the
position of the flue exit hole for
horizontal top outlet installation.

Fig. 3.14

LAS Euro B/S 072/0GB

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 hole
can be determined by carefully
levelling across the wall from the
centre line of the air/flue duct hole
marked on the template (fig. 3.15).
The position of the flue exit hole
should allow the flue to be
installed with a slight upward
slope of about 3 1 (equivalent
to 50 mm 20 mm per metre of
flue duct). Calculate the required
rise according to the flue length
and mark the position of the flue
exit hole.
21

PART 1 CONCENTRIC 60/100

IMPORTANT:
The air/flue duct is not concentric
and the air duct has a slope of 1.5
(if the air flue duct is not cut). The
hole through the wall can therefore
be drilled horizontally with no slope.

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Seite 22

INSTALLATION OF THE TELESCOPIC 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 can
be cut with a 107 mm core drill
and the flue external wall seal
fitted from outside the dwelling.

Fig. 3.15

* = 190 mm ecoMAX combination and system boilers

* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

LAS Euro B/S 077/1

Rear exit

*
A
* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

A + 22 mm
Fig. 3.17

22

LAS Euro B/S 078/0

Adjust the air duct and flue duct

to the lengths shown in (fig.
3.17).

All flue sockets should point

towards the terminal.

87

Fig. 3.16

This is dimension A.

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 (1). (Ensure that the drill does
not pierce the inner flue duct).
Secure the air ducts together using
the screw (1) provided. Place the
adhesive tape (2) across the gap
in the telescopic extensions.
(fig. 3.17)

87

Side exit

Measure the distance from the

outside face of the wall to the
centre of the fan outlet on the
boiler (fig. 3.16).

Care should be taken not to

scratch the white surface of the air
duct.
If the installation requires the use
of air/flue duct extensions,
additional bends or elbows refer
to the sections on pages 34 - 38.

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Seite 23

Push the air/flue duct assembly

(1) including the flexible external
seal 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
wall (fig. 3.14 and fig. 3.18).

87

13

Fig. 3.18

LAS Euro B/S 001/0GB

Ensure that the air/flue duct (1) is

centred in the hole and the
terminal is correctly positioned
with the inlet grille at the bottom
(fig. 3.14 and fig. 3.18).
Slide the internal trim ring (2) over
the air duct until it is flush with the
wall (fig. 3.14).
At this stage it is necessary to
prepare and fit the boiler onto the
hanging bracket refer to the
boiler installation instructions.
Fit the elbow (3) to the boiler by
inserting the spigot of the flue
elbow into the flue socket on the
boiler and secure using the 30
mm air duct clamp (4) provided
(fig. 3.14).
Pull the air/flue duct back through
the wall such that the flue duct
fully engages into the flue elbow
socket.
Fit the 48 mm air duct clamp (5)
ensuring that it is positioned
centrally (fig. 3.14).
Drill two holes 3 mm through
the air duct of both the elbow/flue
and elbow/boiler clamps at the
most convienient holes on the air
duct clamps. (Ensure that the drill
does not penetrate the inner flue
duct). Screw 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.
Caution!
If installed near a light, insects may
fly into the opening. Tell the
homeowner to clean the opening
regularly.

23

PART 1 CONCENTRIC 60/100

INSTALLATION OF THE TELESCOPIC HORIZONTAL AIR/FLUE DUCT

(TOP OUTLET)

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Seite 24

INSTALLATION OF THE BLACK TERMINAL KIT

Black terminal kit
Accy. No.: 303 934
Contents of the accessory:
Black terminal
External wall seal

Fig. 3.19: Black kit

Assembly
Before installing the flue
duct

Fig. 3.20: Releasing the catches

Use an 8 mm screwdriver to bend

the catches inwards (fig. 3.20).
Pull the terminal together with the
flue duct out of the air duct (fig.
3.21).
Unlock the catch between the
terminal and the flue duct by
twisting them against each other
(fig. 3.22).
Pull the terminal off the flue duct.
Push the new terminal into the flue
duct and click to lock.
Please note: The catch on the top
of the terminal must lock firmly
into the notch in the flue duct
(fig. 3.23).
Please note: Make sure the seal
fits tightly.

Fig. 3.21: Pulling out the terminal

Push the flue duct and the terminal

back into the air duct and lock the
two catches (fig. 3.24).
Caution!
The seam of the air duct must be at
the top.
Fit the horizontal air/flue duct as
described on pages 18 and 21.

Fig. 3.22: Unlocking the catch

24

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Seite 25

INSTALLATION OF THE BLACK TERMINAL KIT

Assembly
After installing the flue
duct
Danger!
Before starting work, shut down the
appliance and prevent it from being
switched on unintentionally.

Fig. 3.23: Flue duct

Remove the wall seal from the

terminal.
Use an 8 mm screwdriver to bend
the catches inwards (fig. 3.20).
Pull the terminal together with the
flue duct out of the air duct (fig.
3.21).
Caution!
Do not twist the flue duct, because
this might detach the following flue
duct behind the terminal from the
spacer.

Fig. 3.24: Locking the catch

Unlock the catch between the

terminal and the flue duct by
twisting them against each other
(fig. 3.22).
Pull the terminal off the flue duct.
Push the new terminal into the flue
duct and click to lock.
Please note: The catch on the top
of the terminal must lock firmly
into the notch in the flue duct (fig.
3.23).
Please note: Make sure the seal
fits tightly.
Push the flue duct with the
terminal back in the air duct.
Carefully push the flue duct back
into the sleeve of the pipe or bend
behind it. Lock the two catches
(fig. 3.24).
Fit the wall seal.
Danger!
Before starting up the appliance,
check that the entire flue pipe is
firmly seated and sealed.

25

PART 1 CONCENTRIC 60/100

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Seite 26

INSTALLATION OF THE VARIABLE TERMINATION KIT

Variable termination kit
Accy. No.:
303 942 (black)
303 946 (white)

Important:
The flue outlet of the variable termination must face directly upwards.
Flue Terminal Clearances
Minimum flue terminal clearances
are defined in BS5440, and these
must apply unless the boiler manufacturer has received approval to
quote smaller clearances that are
not safety critical. Vaillant have reduced flue terminal clearances
approved and these are given in the
boiler installation instructions. These
are the minimum clearances that
must apply to all installations, except
when a Variable Termination Kit
(VTK) is fitted.

Contents of the kit:

Variable terminal
2 x 1m pipe
3 x pipe support clips
87 bend with bird protection
grille
Fig. 4.1: Variable termination kit

55

When a VTK is fitted to the horizontal flue, the terminal clearances for
the air inlet are reduced. The terminal clearances for the new flue
outlet at the end of the VTK do not
change.
The minimum terminal clearances A,
B & C for the air inlet of the VTK are
reduced to 50 mm from an opening
such as a window, and 25mm from
an opening such as an airbrick. This
means that the terminal on the
horizontal flue becomes the air inlet
when a VTK is fitted, and hence can
be located less than 300mm from
an opening window or airbrick.

Fig. 4.2

Assembly
Before installing the flue
pipe
Use an 8 mm screwdriver to bend
the catches inwards (fig. 4.3).
Pull the terminal with the flue duct
out of the air duct (fig. 4.4).
Fig. 4.3: Releasing the catch

Fig. 4.4: Pulling out the variable terminal

26

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Seite 27

Unlock the catch between the

terminal and the flue duct by
twisting them against each other
(fig. 4.5).
Pull the terminal out of the flue
duct.
Push the variable terminal onto the
flue duct.
Please note: The catch on the top
of the variable terminal must lock
firmly into the notch in the flue
duct (fig. 4.6).
Fig. 4.5: Unlocking the catch

Caution!
Make sure the seal fits tightly.
Push the flue duct and the variable
terminal back into the air duct
and lock the two catches
(fig. 4.7).
Please note: The seam of the air
duct must be at the top.
Fit the horizontal ait/flue duct as
described on pages 18 and 21.
Caution!
It cannot be fitted from inside.

Fig. 4.6: Flue pipe

Fig. 4.7: Locking the catch

Fit the rest of the variable

termination kit as described on
page 28.

Assembly
After installing the flue
duct
Danger!
Before starting work, shut down the
appliance and prevent it from being
switched on unintentionally.
Remove the wall seal from the
terminal.
Use an 8 mm screwdriver to bend
the catches inwards (fig. 4.3).
Pull the terminal with the flue duct
out of the air duct (fig. 4.4).
Caution!
Do not twist the flue duct, because
this might detach the following flue
duct behind the terminal from the
spacer.
Unlock the catch between the
terminal and the flue duct by
twisting them against each other
(fig. 4.5).
Pull the terminal out of the flue
duct.
Push the new variable terminal
onto the flue duct.
Please note: The catch on the top
of the variable terminal must lock
firmly into the notch in the flue
duct (fig. 4.6).
Please note: Make sure the seal
fits tightly.
Push the flue duct with the
variable terminal back in the air
duct. Carefully push the flue duct
back into the sleeve of the duct or
bend behind it. Lock the two
catches (fig. 4.7).
Fit the wall seal on the variable
terminal.
Fit the rest of the VTK as
described on page 28.

27

PART 1 CONCENTRIC 60/100

INSTALLATION OF THE VARIABLE TERMINATION KIT

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Seite 28

INSTALLATION OF THE VARIABLE TERMINATION KIT

Fit the pipes and bends, working
from the variable terminal to the
selected location for the flue exit
using support clips supplied fig
4.8, 4.9, 4.10 or 4.11.
Caution!
Pipe extensions must be fixed to the
wall using pipe clamps. Use one
clamp for each extension directly
beside the sleeve. Fit another clamp
to the extension after each 87 bend
(fig. 4.9).
Caution!
The extension pipe expands when
heated.
Leave 1 cm expansion space in each
sleeve.
Please note: The maximum flue
lengths where the variable
termination kit is installed are
shown in the tables on pages 11
and 12.
Please note: The parts are simply
pushed together (not bolted).
Caution!
Fasten the 87 bend with bird
protection grille using a separate
pipe clamp (fig. 4.9).
Caution!
If installed near a light, insects may
fly into the opening. Tell the
homeowner to clean the opening
regularly.
Danger!
Before starting up the appliance,
check that the entire flue pipe is
firmly seated and sealed.
Fig. 4.8: Installation of basic kit showing position of support clips

Caution!
During annual maintenance, check
the flue system for
- visible defects, such as
embrittlement or damage
-

Fig. 4.9: Bird protection grille

28

tight connection of the pipes

dirt in the air intake and flue exits
due to leaves, insects etc.

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PART 1 CONCENTRIC 60/100

INSTALLATION OF THE VARIABLE TERMINATION KIT

Fig. 4.10: Installation of basic kit with two additional 87 bends showing position of support clips

Fig. 4.11: Installation of basic kit with two additional 45 bends showing position of support clips

29

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Seite 30

INSTALLATION OF THE VARIABLE TERMINATION KIT

min 400 mm

min 100 mm

Routing around roof

eaves
When routing the variable
termination kit around the roof eaves,
additional lengths of M8 threaded
bar will be required for the support
brackets. Threaded bar can be
purchased from most local merchants.
Change the bird protection grille
from the 87 elbow to the
extension installed at the end.
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.

Fig. 4.12: Routing around roof eaves

30

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Seite 31

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Vertical air/flue duct
Accy. No.: 303 900 (black)

40

880

1435

550

Contents of the accessory:

Vertical air/flue duct and terminal
assembly
40 mm air duct clamp
Fixing bracket
See page 6 et seq. for details of
air/flue duct elements.

Fig. 5.1: Vertical roof duct

The air/flue duct assembly may be

connected directly to the flue outlet
on top of the boiler.
In addition to the vertical air/flue
duct and terminal accessory, air/flue
duct extensions can be added to
increase the length of the flue.
Preparation
Determine the installation site for
the boiler with reference to the
installation and servicing
instructions supplied with the
boiler.
Ensure that all installation and
service clearances are available
and that the boiler flue can be
installed as detailed in these
instructions.
Determine the point where the
vertical air/flue duct and terminal
assembly will penetrate the roof.
Please note: The vertical air/flue
duct and terminal accessory
(Accy. No. 303 900) may be
shortened. The outer white duct
should be shortened first, then the
inner flue duct cut so that it
protrudes 13 mm out of the air
duct. In case of installation
directly to the boiler without
elbows or bends, it is essential
that the roof tile/collar is vertically
aligned with the air/flue duct of
the boiler.
Please note: If a 87 elbow is
connected directly to the boiler,
use the 40 mm air duct clamp
supplied with the vertical air flue
duct at this position.
31

PART 1 CONCENTRIC 60/100

Observe the maximum flue

lengths as detailed in table on
page 11.

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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Pitched roof installation

550

20

885

0-5

100

750

100- 110

3
8
* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 125 mm ecoTEC
Fig. 5.2: Fitting the appliance and the vertical roof duct to a building with a pitched roof

32

750 mm ecoMAX
combination and system boilers
530 mm ecoMAX pro
(top holes of bracket)
622 mm ecoTEC

Determine the point where the

vertical air/flue duct and terminal
assembly will penetrate the roof.
Fit the flexible pitched roof (Accy.
No. 303 980) tile (1).
Working from above, insert the
vertical roof duct (5) through the
roofing tile and push it firmly into
place.
Vertically align the roof duct and
attach it to the roof structure with
the fixing bracket (6) supplied.
Fit the boiler hanging bracket (2).
Install the appliance (3) with
reference to the installation and
servicing instructions supplied with
the boiler.
See pages 34 et seq. for further
details on the installation of
extensions and elbows.
Push the sliding sleeve (4) firmly
into place on the extension.
Join the vertical roof duct (5) to
the extension (7).
Join the sliding sleeve (4) to the
appliances connection piece (8).
Using the sliding sleeve allows the
appliance to be easily removed
and replaced without dismantling
the flue.
Drill two holes 3 mm through
the air duct of the flue/boiler
clamp at the most convienient
holes on the air duct clamp.
(Ensure that the drill does not
penetrate the inner flue duct).
Screw the clamp to the air ducts
of the flue assembly and the boiler
using the screws supplied.
Ensure that any air duct clamps
used are positioned centrally and
fixed to the air duct using the self
tapping screws supplied.
Note: The air/duct clamp must not
be screwed to the bottom of the
vertical air/flue duct and terminal
accessory to allow for any slight
movement in the roof structure.
Ensure that at least one pipe
clamp supports the air/flue duct
at each extension fitted.

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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

550

5
cold roof

warm roof

885

1
120

Fig. 5.3: Fitting the appliance and vertical flue duct to a building with a flat roof

100- 110

750

750 mm ecoMAX
combination and system boilers
530 mm ecoMAX pro
(top holes of bracket)
622 mm ecoTEC

100

Determine the point where the

vertical air/flue duct and terminal
assembly will penetrate the roof.
Fit the flat roof penetration collar
(1).
Stick the flat roof penetration
collar firmly into place with
adhesive in accordance with the
codes of practice for flat roofs
(CP 144) to ensure a watertight
seal.
Working from above, insert the
vertical roof duct (5) through the
flat roof collar and push it firmly
into place.
Vertically align the roof duct and
attach it to the roof structure with
the fixing bracket (6) supplied.
Fit the boiler hanging bracket (2).
Install the appliance (3) with
reference to the installation and
servicing instructions supplied with
the boiler.
See pages 34 et seq. for further
details on the installation of
extensions and elbows.
Push the sliding sleeve (4) firmly
into place on the extension.
Join the vertical roof duct (5) to
the extension (7).
Join the sliding sleeve (4) to the
appliances connection piece (8).
This permits easy separation
between the air/flue duct and the
appliance.
Drill two holes 3 mm through
the air duct of the flue/boiler
clamp at the most convienient
holes on the air duct clamp.
(Ensure that the drill does not
penetrate the inner flue duct).
Screw the clamp to the air ducts
of the flue assembly and the boiler
using the screws supplied.
Ensure that any air duct clamps
used are positioned centrally and
fixed to the air duct using the self
tapping screws supplied.
Note: The air/duct clamp must not
be screwed to the bottom of the
vertical air/flue duct and terminal
accessory to allow for any slight
movement in the roof structure.
Ensure that at least one pipe
clamp supports the air/flue duct
at each extension fitted.
33

PART 1 CONCENTRIC 60/100

Flat-roof installation

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Seite 34

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 the plastic
tube can be pushed through the
spacer-piece. After cutting to size,
refit the flue conduit and secure it
to the air conduit.

70

L air

1.

L exhaust

27

2.

1
+ 40 mm

13

Fig. 6.1: Cutting tubes to size

The seals are sensitive to mineral

oil-based grease products. For this
reason, the seals must not be
greased. If the seals need wetting
to aid in installation, use water
only.

Tip:
Start by measuring the required
length of air conduit* (Lair), and then
calculate the corresponding length of
flue conduit (Lexhaust) as follows:
Lexhaust

= Lair + 40 mm

Lexhaust
Lair

= length of flue conduit

= length of air conduit

* Minimum length of air-conduit

extension: 80 mm.

De-burr and file down any rough

edges on the tubes before fitting in
order to prevent damage to the
seals. Remove all metal filings and
other debris.
Fig. 6.2: Loosening the flue conduit

Important:
You must fasten extensions to the
ceiling or wall using pipe clamps.
Use one clamp for each extension.

Important:
Where extensions are used, these
must be installed with a slope of 3
1 to ensure that condensate does
not remain in the sleeve (equivalent
to 50 mm 20 mm rise per metre
length).
34

Do not use damaged or dented

tubes, as they will not form an
adequate seal.
Ensure that the seals remain
correctly aligned when installing
the tubes. Do not fit damaged
seals.
Secure the exhaust conduit with
the fixing device in order to ensure
that it is correctly centred relative
to the air conduit.

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FITTING AIR/FLUE DUCT EXTENSIONS

Fig. 6.1: Arrangement of 2 x 87 elbows View from above

When using 2 x 87 elbows

follow fig. 6.1 to fig. 6.3 to avoid
obstructions on outer wall.
Note: The elbows must be
correctly aligned to avoid undue
stress on the joints and risk of
leakage.
The elbow fitted to the top of the
boiler (1) should be twisted by 3
to ensure that the second 87 elbow (2) exits the wall perpendicular.
When using elbows for long flue
runs in a corner follow fig. 6.4
and fig. 6.5 to avoid obtrsuctions.
Note: The elbows must be
correctly aligned to avoid undue
stress on the joints an risk of
leakage.
The elbow fitted to the top of the
boiler (1) should be twisted by 3
to ensure that the second 87 elbow (2) exits the wall perpendicular.
When using 87 elbow install with
a slope of 3 between wall and
air-flue pipe (fig. 6.4) or use 2 x
45 elbows (fig. 6.5).

2
1
*
* = 3

Fig. 6.2: Arrangement of 2 x 87 elbows View from front

*
* = 3

Fig. 6.3: Arrangement of 2 x 87 elbows View from side

35

PART 1 CONCENTRIC 60/100

How to install
2x 87 elbows

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FITTING AIR/FLUE DUCT EXTENSIONS

max. 5 m

When using elbows for long flue

runs in a corner follow fig. 6.4
and fig. 6.5 to avoid obtrsuctions.

90

*
2
1

max. 5 m

* = 3

max. 5 m

Fig. 6.4: Long flue runs using 87 elbow

90

max. 5 m

Fig. 6.5: Long flue elbow Using 45 elbows

36

Note: The elbows must be

correctly aligned to avoid undue
stress on the joints an risk of
leakage.
The elbow fitted to the top of the
boiler (1) should be twisted by 3
to ensure that the second 87 elbow (2) exits the wall perpendicular.
When using 87 elbow install with
a slope of 3 between wall and
air-flue pipe (fig. 6.4) or use 2 x
45 elbows (fig. 6.5).

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FITTING AIR/FLUE DUCT EXTENSIONS

How to install 87 elbows
Note: The elbow delilvered with
the flue kits 303 933 and
303 936 is not the same
dimension as shown here.

190

Accy. No.: 303 910

An offset of 400 mm is measured.

This value is then used, along with the
table below, to determine the length
of the air conduit ( = 190 mm in this
case).
Important:
This gives a corresponding
exhaust-conduit length of
190 + 40 = 230 mm.

Length of air conduit

95
10

GU_LAZ 102/2GB

Example:

95
10

Fig. 6.3: Installation of 87 elbows

Table 6.1: Length of surplus with 87 elbows

Offset
[in mm]

Length of
air conduit
[in mm]

> 190 to
< 210 mm

> 215 to
< 265 mm

not
possible

> 270 to
< 290 mm
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435

80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225

Offset
[in mm]

Length of
air conduit
[in mm]

Offset
[in mm]

Length of
air conduit
[in mm]

440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625

230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415

630
635
640
645
650
655
660
665
670
675
680
685
690
695
700
705
710
715
720
725
730
735
740
745
750
755
760
765
770
775
780
785
790
795
800

420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590

37

PART 1 CONCENTRIC 60/100

Offset

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FITTING AIR/FLUE DUCT EXTENSIONS

How to install 45 elbows

Offset

Accy. No.: 303 911

Example:

on

du

it

10

Height

An offset of 400 mm is measured.

This value is then used, along with the
table below, to determine the length
of the air conduit (= 284 mm) and the
height (= 420 mm).

10

Fig. 6.4: Installation of 45 bends

GU_LAZ 103/2GB

Le
ng

th

of

ai

rc

Important:
This gives a corresponding
exhaust-conduit length of
284 + 40 = 324 mm.

Table 6.2: Length of surplus with 45 bends

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 conduit
[in mm]

Height
[in mm]

90
95
100

0
0
0

210
215
220

325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520

320
327
334
341
348
355
362
369
376
383
390
397
404
412
419
426
433
440
447
454
461
468
475
482
489
496
503
511
518
525
532
539
546
553
560
567
574
581
588
595

445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640

525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650
655
660
665
670
675
680

602
610
617
624
631
638
645
652
659
666
673
680
687
694
701
709
716
723
730
737
744
751
758
765
772
779
786
793
800
808
815
822

645
650
655
660
665
670
675
680
685
690
695
700
705
710
715
720
725
730
735
740
745
750
755
760
765
770
775
780
785
790
795
800

not
possible

> 105 to
< 155 mm
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320

38

86
93
100
107
115
122
129
136
143
150
157
164
171
178
185
192
199
206
214
221
228
235
242
249
256
263
270
277
284
291
298
306
313

280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440

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Seite 39

CONTENTS: PART 2 CONCENTRIC 80/125

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

Regulations and standards to be observed

40

Planning the air/flue duct

layout

Alternative termination accessories available

Maximum flue lengths for ecoMAX
Maximum flue lengths for ecoTEC

41
44
45

Changing the appliance

connection piece

47

Installation of the sliding sleeve

48

Installation of the horizontal air/flue duct

49

Installation of the vertical air/flue duct

54

Fitting air/flue duct extensions

How to add extensions

How to install elbows

57
58

39

PART 2 CONCENTRIC 80/125

Page

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Seite 40

REQUIREMENTS

Regulations and
standards to be
observed

Vaillant ecoMAX/ecoTEC 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.

40

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.

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Seite 41

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 for ecoMAX only
303 926 = Appliance connection piece for ecoTEC and ecoMAX

303 200 303 209

Accy. No.

Air/flue duct extensions (PPs), concentric

470 mm - 80/125

303 202

Air/flue duct extensions (PPs), concentric

970 mm - 80/125

303 203

Air/flue duct extensions (PPs), concentric

1970 mm - 80/125

303 205

Bends (PPs), concentric (pack of 2)

45 - 80/125

303 211

Elbow (PPs), concentric

87 - 80/125

303 210

Flue support clips (pack of 5), 125

303 616

Sliding sleeve (PPs) 80/125

303 215

009076 black

Flat roof penetration collar

009 056

Flexible pitched roof seal

303 980

Adjustable roof tiles for pitched roof

PART 2 CONCENTRIC 80/125

Optional connection accessories

41

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Seite 42

PLANNING THE AIR/FLUE DUCT LAYOUT

18

58

25

Appliance connection piece

80/125
Vaillant Accy. No.: 303 926
(with 2 measuring apertures)

Fig. 1.1: Appliance connection piece

Air/flue duct extension (PPs) 470 mm,

80/125
Vaillant Accy. No.: 303 202
Air/flue duct extension (PPs) 970 mm,
80/125
Vaillant Accy. No.: 303 203

GU_LAZ 70/0

Air/flue duct extension (PPs) 1970 mm,

80/125
Vaillant Accy. No.: 303 205

Fig. 1.2: Extensions, 80/125

Elbow (PPs), 87, 80/125

Vaillant Accy. No.: 303 210
Bends (PPs), 45 (pack of 2),
80/125
Vaillant Accy. No.: 303 211

Fig. 1.3: Elbow joints, 80/125

GU_LAZ 71/0

15

25

15

15

25

25

Flue support clips, 125 (pack of 5)

Vaillant Accy. No.: 303 616

Fig. 1.4: Flue support clips, 125 or 80

42

GU_LAZ 72/0

Use one clip per extension to

support the air/flue duct.

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Seite 43

PLANNING THE AIR/FLUE DUCT LAYOUT

Sliding sleeve (PPs), 80/125
Vaillant Accy. No.: 303 215
164

GU_LAZ 76/0

120

Fig. 1.5: Sliding sleeve, 80/125

Adjustable roof tiles for pitched roof

Vaillant Accy. No.: 009 076 (black)

132
25

PART 2 CONCENTRIC 80/125

8
GU_LAZ 41/0

49

Fig. 1.6: Adjustable roof tile for pitched roof

Flexible pitched roof seal (black)

Vaillant Accy. No.: 303 980

495

132

495
Fig. 1.7: Flexible pitched roof seal

Flat roof penetration collar

Vaillant Accy. No.: 009 056

153

130

390
Fig. 1.8: Flat roof penetration collar

GU_LAZ 42/0

834449_08GB_022006.qxd

43

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Seite 44

PLANNING THE AIR/FLUE DUCT LAYOUT

Maximum flue lengths for use with ecoMAX

ecoMAX
Accessories

Accy. No.

Horizontal
flue systems

303 209 Max. permitted

concentric
flue length

613/2 E

618/2 E

622/2 E

pro 18 E
pro 28 E

13.0 m
incl.
1 elbow 87

25.0 m
incl.
1 elbow 87

30.0 m
incl.
1 elbow 87

20.0 m
incl.
1 elbow 87

Maximum length of flue is reduced by 2.5 m for each additional 90 elbow.

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

Vertical
flue systems

303 200 Max. permitted

concentric
flue length

14.0 m

27.0 m

31.0 m

20.0 m

Maximum length of flue is reduced by 2.5 m for each additional 90 elbow

Maximum length of flue is reduced by 1.0 m for each additional 45 elbow

ecoMAX
Accessories

Accy. No.

Horizontal
flue systems

303 209 Max. permitted

concentric
flue length

824/2 E

828/2 E

635/ E
835/ E

25.0 m
incl.
1 elbow 87

30.0 m
incl.
1 elbow 87

21.0 m
incl.
1 elbow 87

Maximum length of flue is reduced by 2.5 m for each additional 87 elbow.

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

Vertical
flue systems

303 200 Max. permitted

concentric
flue length

26.0 m

29.0 m

22.0 m

Maximum length of flue is reduced by 2.5 m for each additional 90 elbow

Maximum length of flue is reduced by 1.0 m for each additional 45 elbow

44

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PLANNING THE AIR/FLUE DUCT LAYOUT

Maximum flue lengths for use with ecoTEC

ecoTEC

Accessories

Accy. No.

303 209 Max. permitted

Horizontal
concentric
flue systems
flue length

plus
plus
plus
plus
plus

plus 612
plus 615

13.0 m
incl.
1 elbow 87

618
624
630
824
831

25.0 m
incl.
1 elbow 87

Maximum length of flue is reduced by 2.5 m for each additional 90 elbow.

303 200 Max. permitted

Vertical
concentric
flue systems
flue length

14.0 m

27.0 m

Maximum length of flue is reduced by 2.5 m for each additional 90 elbow

Maximum length of flue is reduced by 1.0 m for each additional 45 elbow

ecoTEC
Accessories

Accy. No.

Horizontal
flue systems

303 209 Max. permitted

concentric
flue length

plus 637
plus 837

pro 28

21.0 m
incl.
1 elbow 87

25.0 m
incl.
1 elbow 87

Maximum length of flue is reduced by 2.5 m for each additional 87 elbow.

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

Vertical
flue systems

303 200 Max. permitted

concentric
flue length

23.0 m

27.0 m

Maximum length of flue is reduced by 2.5 m for each additional 90 elbow

Maximum length of flue is reduced by 1.0 m for each additional 45 elbow

45

PART 2 CONCENTRIC 80/125

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

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Seite 46

PLANNING THE AIR/FLUE DUCT LAYOUT

LAS Euro B/S 074/0

Maximum flue length

Fig. 1.10

46

LAS Euro B/S 074/0

Maximum flue length

Fig. 1.9

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Seite 47

CHANGING THE APPLIANCE CONNECTION-PIECE

Installation
2
1

Accy No.: 303 907 for ecoMAX

only
Accy No.: 303 926 for ecoTEC and
ecoMAX
The appliance is supplied ready-fitted
with the connection-piece for the
60/100 air/flue duct system.

Push the appliance connectionpiece with the selected connection

diameter down from above,
inserting the push-in end onto the
sleeve of the flue collecting
chamber. Now push the
appliance connection-piece
downwards until the flange comes
into contact with the low-pressure
chamber.
Refit the fixing screws (2).

Fig. 2.0: Fitting the appliance connection-piece

The seals are sensitive to

mineral oil-based grease
products.
For this reason, the seals must
not be greased. If the seals
need wetting to aid in
installation, use water only.

47

PART 2 CONCENTRIC 80/125

Loosen the four screws (2) and

pull the appliance connectionpiece (1) upwards to remove it.

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Seite 48

INSTALLATION OF THE SLIDING SLEEVE

5
Fig. 3.0: Installing the sliding sleeve

48

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 using the sliding
sleeve both the air and flue ducts
of the last extension must be
shortened by a further 85 mm.

Schiebemuffe_neu

INSTALLING THE
AIR/FLUE DUCT SLIDING
SLEEVE

Push the sliding sleeve (1) over the

cut end of the flue duct (2).
Place the air duct clamp (7) over
the air duct.
Pull back the sliding sleeve so that
it engages into the socket (3) of
the boiler (4). Ensure that the
sliding sleeve penetrates the
socket such that there is at least
20 mm engagement at both ends
of the sliding sleeve.
Fit the air duct clamp over the air
ducts (5 and 6) of the
extension/terminal and boiler
outlet. Close the snap clamp.
Drill two holes 3 mm diameter
through the air duct clamp (the
centre of the holes should be 6
mm from the edge of the clamp).
Ensure that the drill does not
penetrate the inner flue duct.
Screw the air duct clamp to the
air duct of the sleeve using the
screws provided.
Complete the installation of the
flue as detailed in these
instructions.

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Seite 49

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT

70

70

15

IMPORTANT:
The air/flue duct is not concentric
and the air duct has a slope of 1.5
(if the air flue duct is not cut). The
hole through the wall can therefore
be drilled horizontally with no slope.

Vaillant Accy No.: 303 209

Contents of the accessory:
Horizontal air/flue duct
87 elbow
2 x 70 mm air duct clamps
1 x internal plastic ring 125
1 x external metal plate
See page 41 et seq. for details of
air/flue duct elements.

Fig. 4.1: Horizontal air/flue conduit

PART 2 CONCENTRIC 80/125

Where extensions are used, these

must be installed with a slope at 3
1 (equivalent to 50 mm 20 mm
rise per metre length) to ensure that
condensate dows not remain in the
sleeve.

Horizontal air/flue duct

1103

GU_LAZ 82/0

Observe the maximum flue

lengths as detailed in table on
page 44.

Fig. 4.2: Example of installation with horizontal air/flue duct

49

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Seite 50

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT 80/125 WITH

EXTENSIONS
IMPORTANT:
The air/flue duct is not concentric
and the air duct has a slope of 1.5
(if the air flue duct is not cut). The
hole through the wall can therefore
be drilled horizontally with no slope.
Where extensions are used, these
must be installed with a slope at 3
1 (equivalent to 50 mm 20 mm
rise per metre length) to ensure that
condensate dows not remain in the
sleeve.

Preparation

Side flue installations

Determine the installation site for

the boiler with reference to the
installation and servicing
instructions supplied with the
boiler.
Ensure that all installation and
service clearances are available
and that the boiler flue can be
installed as detailed in these
instructions.
Fix the paper template, supplied
with the boiler, to the wall
ensuring that the centreline of the
template is vertical using a
plumbline or spirit level.

For installations where the air/flue

duct is to be installed to the side,
the position of the flue exit hole
can be determined as follows:
Identify the correct measurement
as shown in fig. 4.3, carefully
measure the distance from the
bottom centre of the boiler
hanging bracket (centreline of the
two lower hanging bracket fixing
holes). This gives the position of
the centreline of the 127 mm flue
elbow and adaptor when
installed.
The position of the flue exit hole
can be determined by carefully
levelling across the wall from this
mark.
The position of the flue exit hole
should allow the flue to be
installed with an upwards slope
towards the terminal of
approximately 3 1, equivalent
to 50 mm 20 mm rise per metre
of flue length. Calculate the
required rise according to the flue
length and mark the position of
the flue exithole (fig 4.4).

Fig. 4.3

* = 190 mm ecoMAX combination and system boilers

* = 176 mm ecoMAX pro
* = 125 mm ecoTEC

LAS Euro B/S 077/1

* = 253 mm ecoMAX
combination and system boilers
* = 210 mm ecoMAX pro
(from top holes on bracket)
* = 238 mm ecoTEC

Fig. 4.4

50

LAS Euro B/S 083/1

*
253

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
these instructions prior to drilling any
holes for the boiler hanging bracket.
Once the position of the flue exit
hole has been determined, the
hole should be cut through the
wall using a core drill of 127 mm
diameter. The flue exit hole should
be cut with a rise towards outside
of 3.
Measure the distance from the
outside face of the wall to the
centre of the fan outlet on the
boiler (fig. 4.5).
This is dimension A.
For installations where the
measured distance dimension A
(fig. 4.5) is greater than 960 mm,
an air/flue extension accessory
will be required. The number of
air/flue duct extensions which can
be used depends on the boiler.

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Seite 51

Fig. 4.5

Mark air duct here

10 mm

LAS Euro B/S 084/0

Dimension A + 20
Dimension
60 mm
mm

Fig. 4.6

15 mm

25 mm

Fig. 4.7

LAS Euro B/S 080/0

Mark flue duct here

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 duct and
terminal assembly as shown
(fig. 4.6).
Note: The joints between the flue duct
sections are of a push-fit type, with
the flue duct spigot inserted into a
socket containing a sealing ring. For
ease of installation lubricate the seal
using soap solution prior to
assembling.
Assemble the flue such that there
is a gap of about 10 mm between
each air duct, which will ensure
the correct flue duct penetration
into the flue sockets of 30 mm.
All flue sockets should point
towards the flue terminal.
Measure from the flue terminal
and mark the air duct to a length
of:
Dimension A + 60 mm
Take the extension(s) to be
shortened and remove the
3 screws. Separate the ducts.
Note: For assembly reasons do not
shorten any air duct to a length of
less than 100 mm. If necessary
shorten two adjacent extensions to
achieve 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. 4.7.
When cutting the air and flue
ducts it is important to remove any
burrs with a file, this ensures easy
fitting of the ducts and prevents
any rough edges from damaging
the flue seals.
Care should be taken not to
scratch the white surface of the air
duct.
If the installation requires the use
of air/flue duct extensions,
additional bends or elbows refer
to the sections on pages 57 - 61.
At this stage it is necessary to
prepare and fit the boiler onto the
hanging bracket refer to the
boiler installation instructions.
Fit the appliance flue outlet
adaptor to the boiler.
51

PART 2 CONCENTRIC 80/125

LAS Euro B/S 082/0

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT 80/125 WITH

EXTENSIONS

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Seite 52

INSTALLATION OF THE HORIZONTAL AIR/FLUE DUCT 80/125 WITH

EXTENSIONS

220
3

15
Fig. 4.8: Installing the horizontal wall duct

52

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 the air
inlet grille at the bottom.
Slide one of the two trim rings
over the air duct until it is flush
with the internal wall face.

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Seite 53

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

Indirect installation
Fit the wall mounting (2).
6

Install the appliance (3) with

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

253

**

82 - 90

Join the 87 elbow to the

appliance connection piece.

750

* = 750 mm ecoMAX
combination and system boilers
* = 530 mm ecoMAX pro
(from top holes on bracket)
* = 622 mm ecoTEC
** = 253 mm ecoMAX
combination and system boilers
** = 210 mm ecoMAX pro
(from top holes on bracket)
* * = 238 mm ecoTEC
Fig. 4.9: Indirect installation

Change the appliance connectionpiece (4) as described on

page 47.

Push the sliding sleeve (7) firmly

into place on the appropriate
extensions (6).
Install the extensions and join the
sliding sleeve to the 87 elbow.

This section functions

subsequently as a separation
point.

Join all separation points with the

air-conduit fixing collars (8).
See pages 57 et seq. for further
details on the installation of
extensions and elbows.
For horizontal flue installations
through sloping roofs, please
order the Horizontal Flue Flashing
from Ubbink (Nothants,
Tel: 01280 700211)

53

PART 2 CONCENTRIC 80/125

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Seite 54

INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Vertical air/flue duct
Accy. No.: 303 200 (black)
Contents of the accessory:
Vertical air/flue duct and terminal
assembly
Adapter (air) for 110/125
70 mm air duct clamp
Fixing bracket

Fig. 5.1: Vertical roof duct

GU_LAZ 81/0

880

70

1530

650

Observe the maximum flue

lengths as detailed in table on
page 42.

See page 41 et seq. for details of

air/flue duct elements.

The air/flue duct assembly may be

connected directly to the flue outlet
on top of the boiler.
In addition to the vertical air/flue
duct and terminal accessory, air/flue
duct extensions can be added to
increase the length of the flue.
Preparation
Determine the installation site for
the boiler with reference to the
installation and servicing
instructions supplied with the
boiler.
Ensure that all installation and
service clearances are available
and that the boiler flue can be
installed as detailed in these
instructions.
Determine the point where the
vertical air/flue duct and terminal
assembly will penetrate the roof.
Please note: The vertical air/flue
duct and terminal accessory (Accy.
No. 303 200) may be shortened.
The outer white duct should be
shortened first, then the inner flue
duct cut so that it protrudes 15 mm
out of the air duct. In case of
installation directly to the boiler
without elbows or bends, it is
essential that the roof tile/collar is
vertically aligned with the air/flue
duct of the boiler.

54

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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

790

740

20

0-5

125

8
2

82 - 90

750

3
8

750 mm ecoMAX combination and system boilers

530 mm ecoMAX pro
(top holes of bracket)
622 mm ecoTEC

* = 190 mm ecoMAX
combination and system boilers
* = 176 mm ecoMAX pro
* = 125 mm ecoTEC
Fig. 5.2: Fitting the appliance and the vertical roof duct to a building with a pitched roof

Determine the point where the

vertical air/flue duct and terminal
assembly will penetrate the roof.
Fit the flexible pitched roof seal (1).
Working from above, insert the
vertical roof duct (5) through the
roofing tile and push it firmly into
place.
Vertically align the roof duct and
attach it to the roof structure with
the fixing bracket (6) supplied.
Fit the boiler hanging bracket (2).
Install the appliance (3) with
reference to the installation and
servicing instructions supplied with
the boiler.
See pages 57 et seq. for further
details on the installation of
extensions and elbows.
Push the sliding sleeve (4) firmly
into place on the extension.
Join the vertical flue duct (5) to the
extension (7).
Join the sliding sleeve (4) to the
appliances connection piece (8).
Using the sliding sleeve allows the
appliance to be easily removed
and replaced without dismantling
the flue.
Drill two holes 3 mm through
the air duct of the flue/boiler
clamp at the most convienient
holes on the air duct clamp.
(Ensure that the drill does not
penetrate the inner flue duct).
Screw the clamp to the air ducts
of the flue assembly and the boiler
using the screws supplied.
Ensure that any air duct clamps
used are positioned centrally and
fixed to the air duct using the self
tapping screws supplied.
Note: The air/duct clamp must not
be screwed to the bottom of the
vertical air/flue duct and terminal
accessory to allow for any slight
movement in the roof structure.
Ensure that at least one pipe
clamp supports the air/flue duct
at each extension fitted.

55

PART 2 CONCENTRIC 80/125

Pitched roof installation

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INSTALLATION OF THE VERTICAL AIR/FLUE DUCT

Flat-roof installation
650

cold roof

warm roof

880

1
120

125

Fig. 5.3: Fitting the appliance and vertical flue duct to a building with a flat roof

56

82 - 90

750 mm ecoMAX combinatin

and system boilers
530 mm ecoMAX pro
(top holes of bracket)
622 mm ecoTEC
750

Determine the point where the

vertical air/flue duct and terminal
assembly will penetrate the roof.
Fit the flat roof penetration collar
(1).
Stick the flat roof penetration
collar firmly into place with
adhesive in accordance with the
codes of practice for flat roofs
(CP 144) to ensure a watertight
seal.
Working from above, insert the
vertical flue duct (5) through the
flat roof collar and push it firmly
into place.
Vertically align the roof duct and
attach it to the roof structure with
the fixing bracket (6) supplied.
Fit the boiler hanging bracket (2).
Install the appliance (3) with
reference to the installation and
servicing instructions supplied with
the boiler.
See pages 57 et seq. for further
details on the installation of
extensions and elbows.
Push the sliding sleeve (4) firmly
into place on the extension.
Join the vertical roof duct (5) to
the extension (7).
Join the sliding sleeve (4) to the
appliances connection piece (8).
This permits easy separation
between the air/flue duct and the
appliance.
Drill two holes 3 mm through
the air duct of the flue/boiler
clamp at the most convienient
holes on the air duct clamp.
(Ensure that the drill does not
penetrate the inner flue duct).
Screw the clamp to the air ducts
of the flue assembly and the boiler
using the screws supplied.
Ensure that any air duct clamps
used are positioned centrally and
fixed to the air duct using the self
tapping screws supplied.
Note: The air/duct clamp must not
be screwed to the bottom of the
vertical air/flue duct and terminal
accessory to allow for any slight
movement in the roof structure.
Ensure that at least one pipe
clamp supports the air/flue duct
at each extension fitted.

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FITTING AIR/FLUE DUCT EXTENSIONS

How to add extensions

Use a saw, tin-snips, etc. to cut tubes

to size.
L air

1.

25

2.

15

+ 40 mm

Fig. 6.1: Cutting tubes to size

The seals are sensitive to mineral

oil-based grease products. For this
reason, the seals must not be
greased. If the seals need wetting
to aid in installation, use water
only.

Lexhaust
Lair

= length of flue conduit

= length of air conduit

* Minimum length of air-conduit

extension: 100 mm.

Fig. 6.2: Loosening the flue conduit

Important:
You must fasten extensions to the
ceiling or wall using pipe clamps.
Use one clamp for each extension.

Important:
Where extensions are used, these
must be installed with a slope of 3
1 to ensure that condensate does
not remain in the sleeve (equivalent
to 50 mm 20 mm rise per metre
length).

GU_LAZ 290/1

= Lair + 40 mm

L exhaust

Tip:
Start by measuring the required
length of air conduit* (Lair), and then
calculate the corresponding length of
flue conduit (Lexhaust) as follows:
Lexhaust

De-burr and file down any rough

edges on the tubes before fitting in
order to prevent damage to the
seals. Remove all metal filings and
other debris.
Do not use damaged or dented
tubes, as they will not form an
adequate seal.
Ensure that the seals remain
correctly aligned when installing
the tubes. Do not fit damaged
seals.
Secure the exhaust conduit with
the fixing device in order to ensure
that it is correctly centred relative
to the air conduit.

57

PART 2 CONCENTRIC 80/125

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 shoulders on the plastic tube
can be pushed through the spacerpiece. After cutting to size, refit
the flue conduit and secure it to
the air conduit.

70

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FITTING AIR/FLUE DUCT EXTENSIONS

How to install
2x 87 elbows

Fig. 6.1: Arrangement of 2 x 87 elbows View from above

2
1
*
* = 3

Fig. 6.2: Arrangement of 2 x 87 elbows View from front

*
* = 3

Fig. 6.3: Arrangement of 2 x 87 elbows View from side

58

When using 2 x 87 elbows

follow fig. 6.1 to fig. 6.3 to avoid
obstructions on outer wall.
Note: The elbows must be
correctly aligned to avoid undue
stress on the joints and risk of
leakage.
The elbow fitted to the top of the
boiler (1) should be twisted by 3
to ensure that the second 87 elbow (2) exits the wall perpendicular.

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FITTING AIR/FLUE DUCT EXTENSIONS

max. 5 m

When using elbows for long flue

runs in a corner follow fig. 6.4
and fig. 6.5 to avoid obtrsuctions.

90

Note: The elbows must be

correctly aligned to avoid undue
stress on the joints an risk of
leakage.
The elbow fitted to the top of the
boiler (1) should be twisted by 3
to ensure that the second 87 elbow (2) exits the wall perpendicular.
When using 87 elbow install with
a slope of 3 between wall and
air-flue pipe (fig. 6.4) or use 2 x
45 elbows (fig. 6.5).

*
1

max. 5 m

PART 2 CONCENTRIC 80/125

2
* = 3

max. 5 m

Fig. 6.4: Long flue runs using 87 elbow

90

max. 5 m

Fig. 6.5: Long flue elbow Using 45 elbows

59

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FITTING AIR/FLUE DUCT EXTENSIONS

How to install 87 elbows

Offset

Important:
This gives a corresponding
exhaust-conduit length of
190 + 40 = 230 mm.

Length of air conduit

95
10

GU_LAZ 102/2GB

An offset of 400 mm is measured.

This value is then used, along with the
table below, to determine the length
of the air conduit (= 190 mm in this
case).

190

Accy. No.: 303 210

Example:

95
10

Fig. 6.3: Installation of 90 elbows

Table 6.1: Length of surplus with 90 elbows

60

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, 205
210,

0
0

> 210 to
< 310 mm

not
possible

310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500

100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290

505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650
655
660
665
670
675
680
685
690
695
700
705
710
715
720
725

295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515

730
735
740
745
750
755
760
765
770
775
780
785
790
795
800
805
810
815
820
825
830
835
840
845
850
855
860
865
870
875
880
885
890
895
900
905
910
915
920
925
930
935
940

520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650
655
660
665
670
675
680
685
690
695
700
705
710
715
720
725
730

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FITTING AIR/FLUE DUCT EXTENSIONS

How to install 45 elbows

Offset

Accy. No.: 303 211

Example:

du

it

10

Height

An offset of 400 mm is measured.

This value is then used, along with the
table below, to determine the length
of the air conduit (= 284 mm) and the
height (= 420 mm).

10

Fig. 6.4: Installation of 45 bends

GU_LAZ 103/2GB

Le
ng

th

of

ai

rc

on

Important:
This gives a corresponding
exhaust-conduit length of
284 + 40 = 324 mm.

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 conduit
[in mm]

Height
[in mm]

90
95
100

0
0
0

210
215
220

335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530

334
341
348
355
362
369
376
383
390
397
405
412
419
426
433
440
447
454
461
468
475
482
489
496
504
511
518
525
532
539
546
553
560
567
574
581
588
596
603
610

455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650

535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650
655
660
665
670
675
680
685
690
695
700
705
710
715
720

617
624
631
638
645
652
659
666
673
680
687
695
702
709
716
723
730
737
744
751
758
765
772
779
786
794
801
808
815
822
829
836
843
850
857
864
871
878

655
660
665
670
675
680
685
690
695
700
705
710
715
720
725
730
735
740
745
750
755
760
765
770
775
780
785
790
795
800
805
810
815
820
825
830
835
840

not
possible

> 100 to
< 170 mm
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330

100
108
115
122
129
136
143
150
157
164
171
178
185
192
199
207
214
221
228
235
242
249
256
263
270
277
284
291
298
306
313
320
327

290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450

PART 2 CONCENTRIC 80/125

Table 6.2: Length of surplus with 45 bends

61

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