Vaillant aquaPlus, aquaPLUS VUI 362-7, AQUAPLUS SERIES Instructions For Installation And Servicing

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VUI 362-7

Gas fired room sealed fan assisted combination boiler with integrated 15 litre power store

For the installer

Instructions for installation and servicing

aquaPLUS

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Table of Contents

Instructions for installation and servicing aquaPLUS VUI 362-72

Page

1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Contents included with boiler . . . . . . . . . . . . . . 3

1.2 Installation accessories . . . . . . . . . . . . . . . . . . . 3

2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 General Information . . . . . . . . . . . . . . . . . . . . . 4

2.2 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Showers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Boiler Specification . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Boiler connections . . . . . . . . . . . . . . . . . . . . . . 6

3.3 Functional Diagram . . . . . . . . . . . . . . . . . . . . . . 7

4 General Requirements . . . . . . . . . . . . . . . . . . . . 8

4.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . 8

4.2 Related Documents . . . . . . . . . . . . . . . . . . . . . . 8

4.3 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.4 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.5 Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.5.1 Top outlet flue system (100 mm outside

diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.5.2 Extended top outlet flue system (125 mm

outside diameter) . . . . . . . . . . . . . . . . . . . . . . . 9

4.5.3 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . 10

4.6 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.7 Cupboard or compartment ventilation . . . . . . 11

4.8 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.9 Guide to system requirements . . . . . . . . . . . . . 11

4.9.1 Water circulation system . . . . . . . . . . . . . . . . . . 11

4.9.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . . 11

4.9.3 Pressure relief valve (central heating) . . . . . . . 11

4.9.4 Pressure relief valve (hot water) . . . . . . . . . . . 11

4.9.5 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.9.6 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 12

4.9.7 Pump specifications . . . . . . . . . . . . . . . . . . . . . 12

4.9.8 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 12

4.9.9 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.9.10 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Boiler Installation Sequence . . . . . . . . . . . . . . . 13

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.1.1 Preparation of boiler location . . . . . . . . . . . . . . 13

5.1.2 Selecting position of boiler . . . . . . . . . . . . . . . . 13

5.2 Using boiler template . . . . . . . . . . . . . . . . . . . . 14

5.3 Fitting the boiler hanging bracket . . . . . . . . . . 15

5.4 Install the flue system . . . . . . . . . . . . . . . . . . . . 15

5.5 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . 15

5.6 Removing boiler casing . . . . . . . . . . . . . . . . . . . 15

5.7 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.8 Cold water mains inlet and hot water outlet . . 16

5.9 Central heating flow and return pipework . . . 17

5.10 Connect the flue system to the boiler . . . . . . . 17

5.11 Electrical installation . . . . . . . . . . . . . . . . . . . . . 18

5.12 Connection to the main supply . . . . . . . . . . . . 18

5.13 Electronic board layout . . . . . . . . . . . . . . . . . . . 20

5.14 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.15 Thermostatic radiator valves . . . . . . . . . . . . . . 22

Page

5.16 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.17 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 22

5.18 Anti-cycling ‘economiser’ control . . . . . . . . . . . 22

5.19 Automatic pump spin control (APS) . . . . . . . . 22

5.20 Anti legionella protection . . . . . . . . . . . . . . . . . 22

6 Commissioning Part I . . . . . . . . . . . . . . . . . . . . 23

6.1 Preliminary electrical checks . . . . . . . . . . . . . . 23

6.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.3 Cold water supply . . . . . . . . . . . . . . . . . . . . . . . 23

6.4 Filling the heating system . . . . . . . . . . . . . . . . . 23

6.5 Initial system flush ("cold") . . . . . . . . . . . . . . . . 23

7 Gas supply adjustments

(Commissioning Part II) . . . . . . . . . . . . . . . . . . . 24

7.1 Gas inlet working pressure . . . . . . . . . . . . . . . . 24

7.2 Main burner pressure . . . . . . . . . . . . . . . . . . . . 25

7.3 Adjusting to the maximum heat load

(nominal load) . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.4 Adjusting the ignition rate . . . . . . . . . . . . . . . . 27

7.5 Adjusting the central heating output (range

rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.6 Checking the gas valve mid setting point . . . . 30

7.7 Burner pressure and gas rate . . . . . . . . . . . . . . 30

7.8 Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . 31

8 Functional checks (Commissioning Part III) . . . 32

8.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . 32

8.2 Hot-water supply . . . . . . . . . . . . . . . . . . . . . . . . 32

8.3 Power store filling mode . . . . . . . . . . . . . . . . . 32

8.4 Heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.5 Adjusting pump speed . . . . . . . . . . . . . . . . . . . . 33

8.6 Final system flush ("Hot") . . . . . . . . . . . . . . . . . 33

8.7 Handing over to the user . . . . . . . . . . . . . . . . . 34

8.8 Anti legionella protection . . . . . . . . . . . . . . . . . 34

9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.1 Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.2 Functional check of boiler operation . . . . . . . . 34

9.3 Cleaning the burner and primary heat

exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.4 Draining the domestic hot water system . . . . . 35

10 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

10.2 Logical fault finding procedure . . . . . . . . . . . . 36

10.2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.3 Status Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10.4 Diagnostic Modes . . . . . . . . . . . . . . . . . . . . . . . . 39

10.5 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10.6 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

11 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11.1 Functional Flow diagram:

aquaPLUS VUI 362-7 . . . . . . . . . . . . . . . . . . . . . 49

11.2 Wiring diagram: aquaPLUS . . . . . . . . . . . . . . . . 50

12 Short parts list

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List of Contents 1

Instructions for installation and servicing aquaPLUS VUI 362-7 3

1 List of Contents

1.1 Contents included with boiler

Ensure that all contents are included before commencing installation.

DO NOT remove the boiler from the polystrene base at this stage.

Fig. 1.1: Items supplied with unit

VRC-VC

Table 1.1: Items supplied with unit (aquaPLUS)

Item Quantity Description

1 1 Boiler 2 1 Flue restriction ring 3 1 Controls cover door 4 1 Lower cover plate (packed in bottom

packaging) 5 1 Cold water inlet valve 6 3 Flow and return service value, gas service

valve 7 5 Copper tails for gas and water pipework 8 1 Template 9 2 Guarantee Card and Benchmark log book 10 1 Installation and connection accessories and

PRV packages incl. DHW outlet union nut 11 3 Installation and Servicing, Users and Flue

Installation Instructions 12 1 Hanging bracket

1.2 Installation accessories

Cold water supply pressure

If the cold water inlet pressure exceeds 6.0 bar an approved pressure reducer must be installed in the cold water inlet to the boiler, the setting of the reducer should be 4.0 bar.

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2 Introduction

Instructions for installation and servicing aquaPLUS VUI 362-74

2 Introduction

2.1 General Information

aquaPLUS boiler

The aquaPLUS is a fully automatic, wall mounted, room sealed combination boiler for central heating and domestic hot water. The boiler has an integrated 15 litre stainless steel power store for enhanced domestic hot water delivery. Domestic hot water is supplied directly from the boiler, without requiring a copper cylinder, cold water tank, feed and expansion tank and associated pipework. Domestic hot water has priority over central heating. The aquaPLUS boiler has an output for domestic hot water of 36.9 kW. The appliance is available in natural gas only. aquaPLUS combination boilers incorporate a pre-heat facility that keeps the power store hot, providing an instantaneous delivery of domestic hot water. The temperature in the domestic power store is limited by the boiler control system and it is not necessary to install a scale reducer on the cold mains to the boiler. However, in exceptionally hard water areas to prevent scale formation in the property hot water system pipework, a scale reducer may be fitted. The heating system can be filled using the built-in filling loop contained within the boiler. No asbestos, mercury or CFC's are included in any part of the boiler.

2.2 General Notes

The boilers have been designed for use with a sealed central heating system, and come fully tested and assembled with a built in circulating pump, expansion vessel and diverter valve. The boilers are not suitable for use on open vented systems. The boilers are easily sited on any internal wall and can be installed with either a horizontal or vertical RSF (room sealed fan assisted) flue. Two types of flue systems are available, the standard concentric flue system (100 mm outside diameter) and a larger diameter concentric flue system (125 mm outside diameter) which allows longer flue lengths to be achieved. Flue extensions and additional bends and elbows are available for both flue systems to increase the siting flexibility. The boilers are not suitable for external installation. If desired, an inhibitor may be used in the system. Guidance on the use of inhibitors is contained in these

instructions. All boilers have a built in diagnostic system which indicates the operational status of the boiler.

This feature provides key information to aid commissioning and fault finding.

2.3 Showers

Only thermostatically controlled showers must be fitted with aquaPLUS boilers to guard against the flow of water at too high a temperature and to ensure constant shower outlet water temperatures.

The data badge is fitted on the rear of the control panel.

See text of General Requirements for installation requirements or notes.

Vaillant Ltd. support the Benchmark initiative.

Within the information pack, you will find a Benchmark Log Book. It is very important that this is completed correctly at the time of installation, commissioning and handover to the user.

2.4 EC designation

aquaPLUS boilers carry the "CE" Mark. This demonstrates that the boilers fulfil the essential requirements of the Gas Appliance Directive (90/396/EEC) and the Gas Appliance (Safety) Regulations 1992. The "CE" Mark also demonstrates that the boilers comply with the requirements of the Electromagnetic Compatibility Directive (89/336/EEC), the Low Voltage Directive (72/23/EEC), the Boiler Efficiency Directive (92/42/EEC) and the Boiler (Efficiency) Regulations

1993.

Note: This boiler must be installed and serviced by a competent person in accordance with the Gas Safety (Installation and Use) Regulations 1998. In the UK "CORGI" registered installers undertake the work to a safe and satisfactory standard.

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Boiler Specification 3

Instructions for installation and servicing aquaPLUS VUI 362-7 5

3 Boiler Specification

3.1 Technical data

aquaPLUS VUI 362-7 Units

Maximum CH heat input (net) 35.2 kW CH heat output range (80/60 °C) 10.5 - 32.0 kW Maximum DHW heat input (net) 40.5 kW DHW heat output 36.9 kW DHW flow rate ∆T = 35 °C rise (continously) 15.1 l/min DHW flow rate at factory set temperature rise (∆T = 42 °C) 13.7 l/min Mains water pressure required for max. flow rate 0.7 bar Minimum water flow rate > 0 l/min Mains water pressure required for min. flow rate 0.1 bar Maximum water inlet pressure 6 bar Inlet gas working pressure required (natural gas) 20 mbar Gas supply (G20) Gross CV (s.t.) 37.8 MJ/m

Gas burner pressure max. rate 11.0 mbar Gas burner pressure ignition rate 1.1 mbar Gas rate max. DHW 4.3 m3/h CH temperature flow range 35 - 82 °C Minimum CH water flow (for 20 °C rise) 1375 l/h Pump pressure available 250 mbar Expansion vessel pre-charge pressure 0.75 bar Maximum CH system pressure 3.0 bar Hot-water convenience complying with EN 13203 *** – Hot-water quantity complying with EN 13203 – Specific hot-water quantity in 10 min (∆T = 30 K) 201 l/10 min Perm. operating pressure on fresh-water side (PMW) 6 bar Specific flow rate complying with EN 625 (D-value) 20.1 l/min Weight empty/filled, approx. 56/76 kg Primary water content 2.0 l Electrical supply 240/50 V/Hz External fuse 3A Case height 800 mm Case width 440 mm Case depth 497 mm

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3.2 Boiler connections

Key: 1 Heating system return (22 mm tail) 2 Cold water connection with shut off valve (15 mm

tail) 3 Gas connection (22 mm tail) 4 Hot water connection (15 mm tail) 5 Heating system flow (22 mm tail) 6 Flue outlet (100 mm flue with turret) 7 Hanging bracket

Fig. 3.1: Connection diameters

543 21

122

780

100100

35 35

310

5 4321

130

180

3 Boiler Specification

Instructions for installation and servicing aquaPLUS VUI 362-76

3.3 Functional Diagram

Key: 1 Air duct 2Fan 3 Power store 4 Main heat exchanger 5 Temperature sensor (NTC I) 6 Temperature sensor (NTC III) 7 Diverter valve 8 DHW pressure relief valve 9 Temperature sensor (NTC IV) 10 DHW heat exchanger 11 DHW expansion vessel 12 DHW pump 13 Automatic bypass valve 14 CH flow service valve 15 Hot water outlet 16 Gas service valve 17 Cold water service valve 18 CH return service valve 19 Filling loop 20 Pressure relief valve 21 Aqua sensor (DHW flow switch) 22 Expansion vessel 23 Electronic box 24 Fully modulating automatic gas value 25 Circulating pump 26 Automatic air vent 27 Modulating burner 28 Temperature sensor (NTC II) 29 Air pressure switch 30 Flue gas duct

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Boiler Specification 3

Instructions for installation and servicing aquaPLUS VUI 362-7 7

1 2

Fig. 3.2: Functional Diagram aquaPLUS

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4 General Requirements

Instructions for installation and servicing aquaPLUS VUI 362-78

4 General Requirements

4.1 Preliminary remarks

This appliance should only be installed in conjunction with a Vaillant flue system.

Install the flue system as detailed in the separate flue installation instructions supplied with this boiler.

4.2 Related Documents

The installation of the boiler must be in accordance with the relevant requirements of Gas Safety (Installation and Use) Regulations 1998, Health and Safety Document No. 635 (The Electricity at Work Regulations 1989), BS7671 (IEE Wiring Regulations) and the Water Supply (Water Fittings) Regulations 1999, or the Water Bylaws 2000 (Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, Building Regulations (Scotland), Building Regulations (Northern Ireland) and the relevant recommendations of the following British Standards, including current amendments to Approved Documents Part L and J:

BS 5440: Flues and ventilation of gas fired boilers not exceeding 70 kW net:

- Part 1: Flues

- Part 2: Ventilation BS 5449: Specification for forced circulation hot water for domestic premises. BS 5546: Specification for gas hot water supplies for domestic premises. BS 6700: Services supplying water for domestic use within buildings and their curtilages. BS 6798: Specification for installation of gas fired boilers not exceeding 70 kW input. BS 6891: Specification for installation of low pressure gas pipework up to 28 mm (R1) in domestic premises (2

family gas). BS 7593: Treatment of water in domestic hot water central heating systems. Institute of Gas Engineers Publication IGE/UP/7/1998: Guide for Installation in Timber Framed Housing.

Benchmark Code of Practice, Building Regulations Approved Documents Part L 2002, Part J 2002.

4.3 Boiler location

The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location must also provide adequate space for servicing and air circulation around the boiler. The boiler may be installed in any room, although particular attention is drawn to the requirements of BS7671 (IEE Regulations) and, in Scotland, the electrical provisions of the Building Regulations (Scotland) and in IE the current edition of IS 813 and the current ETCI rules, in respect of the installation of a boiler in a room containing a bath or shower.

Where the installation of the boiler will be in an unusual location, special procedures may be necessary and BS 5546 and BS 6798 give detailed guidance on this aspect. The boiler must be mounted on a flat, vertical wall, which must be sufficiently robust to take the weight of the boiler. The boiler may be installed on a combustible wall, subject to the requirements of the Local Authorities and Building Regulations. A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. (An existing cupboard or compartment may be used provided that it is modified for the purpose). Details of essential features of cupboard/compartment design including airing cupboard installations are given in BS 6798. If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication IGE/UP/7/1998 "Guide for Gas Installation in Timber Framed Housing".

4.4 Gas Supply

• The gas supplier should ensure the availability of an adequate supply of gas.

• A gas meter may only be connected to the service pipe by the supplier of gas or their contractor.

• An existing meter should be checked to ensure that it is capable of passing the rate of gas supply required.

• Installation pipes should be fitted in accordance with BS 6891.

• Pipework from the meter to the boiler must be of an adequate size. Do not use pipes of a smaller size than the boiler gas connection (22 mm).

• The complete installation must be tested for soundness and purged as described in BS 6891.

Important: The appliance must be installed and serviced by a competent person as stated in the Gas Safety (Installation and Use) Regulations 1998. In IE, the installation must be in accordance with the current edition of IS 813 'Domestic Gas Installations', the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

Note: Where a room sealed boiler is installed in a room containing a bath or shower, any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

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General Requirements 4

Instructions for installation and servicing aquaPLUS VUI 362-7 9

4.5 Flue system

4.5.1 Top outlet flue system (100 mm outside diameter)

The top outlet horizontal flue system (Art. No. 303 807) is suitable for installations up to 720 mm measured from the centre of the boiler flue outlet to the outside face of the wall. Flue extensions are available to extend this length up to

3.2 m. Both 90° bends and 45° elbows are also available to increase siting flexibility. A vertical flue system is also available (Art. No. 303 800). Refer to flue system installation instructions for full details.

Fig. 4.1: Art.-No. 303 807

Fig. 4.2: Art.-No. 303 800

1285

603

4.5.2 Extended top outlet flue system (125 mm outside diameter)

A top outlet horizontal flue system of 125 mm outside diameter is also available (Art. No. 303 609) and can be used to achieve flue lengths of 10 m. Both 45° and 90° bends and elbows are also available to increase siting flexibility. A vertical 125 mm concentric flue system is also available (Art. No. 303 600). Refer to flue system installation instructions for full details.

Fig. 4.3: Art.-No. 303 609

1103

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750

4 General Requirements

Instructions for installation and servicing aquaPLUS VUI 362-710

4.5.3 Flue termination

The following details refer to both flue systems.

a.The terminal must be positioned such that the

products of combustion can disperse freely at all times.

b.In certain weather conditions a plume of water vapour

may be visible from the flue terminal. Positions where this could be a nuisance should be avoided.

c. If the terminal is fitted less than 2 m above a balcony,

above ground or above a flat roof to which people have access then a suitable terminal guard, Model K3, must be provided and fitted (made by Tower Flue Components, Tonbridge, TN9 1TB).

The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of the building.

1) In addition, the terminal should not be nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window.

* BS 5440-1 It is recommended that a fanned flue terminal should be

positioned as follows: a) at least 2 m from an opening in a building directly opposite, and b) so that the products of combustion are not directed to discharge across a boundary.

Note: Vertical flues must not terminate within 600 mm of an openable window, air vent or any other ventilation opening.

Fig. 4.4: Flue termination

BCD

A G

H, I

Terminal position for fan-assisted flue mm (minimum distance)

A1)Directly below an openable, above an opening or 300

horizontal to an opening i.e. air brick, opening

window or other , etc

B Below gutters, soil pipes or drain pipes 25

C Below eaves 25

D Below balconies (below car port roof) 25

E From vertical drain pipes and soil pipes 25

F From internal or external corners 25

G Above ground or balcony level 300

H From a surface or boundary facing a terminal 600*

I From a terminal facing a terminal 1200

J From an opening in a car port (e.g. door, window) 1200

into a dweling

K Vertically from a terminal on the same wall 1500

L Horizontally from a terminal on the same wall 300

M Distance from adjacent wall for vertical Flue 500

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General Requirements 4

Instructions for installation and servicing aquaPLUS VUI 362-7 11

4.6 Air supply

Detailed recommendations for air supply are given in BS 5440: Part 2. It is not necessary to have an air vent in the room or internal space in which the boiler is installed.

4.7 Cupboard or compartment ventilation

The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during operation is very low. For cupboard or compartment installations it is therefore not necessary to provide any high or low level permanent air vents for cooling purposes.

4.8 Electrical supply

A 230 V, ~ 50 Hz single phase electricity supply fused to 3 Amp. must be provided in accordance with the latest edition of BS7671 (IEE Wiring Regulations) and any other local regulations that may apply. In IE, reference should be made to the current edition of the ETCI rules. The method of connection to the mains electricity supply must provide a means of completely isolating the boiler and its ancillary controls. Isolation is preferably by the use of a fused three pin plug and unswitched shuttered socket outlet, both complying with the requirements of BS 1363. Alternatively, a 3 Amp. fused doublepole switch with a 3 mm contact separation on both poles may be used.

This appliance must be earthed.

4.9 Guide to system requirements

4.9.1 Water circulation system

Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449: Part 1 (for small bore and micro bore central heating systems).

Pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated underfloor spaces.

Draining taps must be located in accessible positions which permit the draining of the whole system including the boiler and the hot water system. Draining taps should be at least 1/2 in. BSP nominal size and be in accordance with BS 2879.

The boiler is suitable for use with minibore or microbore systems. Copper tubing to BS 2871: Part 1 should be used for water carrying pipework. All capillary joints in all DHW pipework must be made with lead free solder.

Particularly where a new boiler is to be fitted to an existing system, it is good practice that the system is thoroughly cleansed. This cleansing should take place prior to the fitting of the new boiler and be in accordance with BS 7593.

For advice on the application of system cleansers contact either Sentinel, Betz Dearborn Ltd. Widnes, Cheshire, WA8 8UD. Tel: 0151 495 1861 or: Fernox Alpha-Fry Technologies Tandem House Marlow Way, Beddington Farm Road Croydon CRO 4xS Tel. 0870 601 5000 Fernox technical help line 01799 550811

4.9.2 Filling and make up

The system can be filled using the built in filling loop. The connection must be removed when filling is completed. Where local Water Authority regulation does not allow temporary connection, a sealed system filler pump with break tank must be used. The heating system will not be filled automatically from the domestic hot water side. (Alternative methods of filling sealed systems are given in BS 5449).

4.9.3 Pressure relief valve (central heating)

A pressure relief valve is provided with the boiler. This safety device is required on all sealed C.H. systems and is preset at 3 bar and provided with a 15 mm compression connection for a discharge pipe, which must be of no less than 15 mm in diameter. The Pressure Relief Valve must not be used for draining purposes.

4.9.4 Pressure relief valve (hot water)

Due to the power store fitted an additional hot water pressure relief valve is also incorporated in the boiler. This is provided with a 15 mm compression connection for a discharge pipe, which must be of no less than 15 mm in diameter. The pressure relief valve must not be used for draining purposes.

4.9.5 Pressure gauge

This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing.

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4 General Requirements

4.9.6 Expansion vessel

The aquaPLUS incorporates a 10 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 100 litres. If the nominal capacity of the built in expansion vessel is not sufficient for the heating system (for instance in case of modernization of old open systems) an additional expansion vessel can be installed external to the boiler. It should be fitted in the return pipe as close as possible to the boiler in accordance with BS 5449: Part 1. Guidance on the sizing of an additional expansion vessel is given in Table 4.1.

4.9.7 Pump specifications

Fig. 4.5: Pump specifications

4.9.8 Circulating pump

The circulating pump is included in the boiler. The pump head available for the boiler is shown in Fig. 4.5.

4.9.9 System by-pass

An automatic system by-pass is included within the boiler. The boiler is suitable for use in systems with thermostatic radiator valves and no additional by-pass is required.

4.9.10 Venting

The boiler is fitted with an automatic air vent. Additional provision should be made to enable the heating system to be vented during filling and commissioning either by automatic air vents or manually.

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

100

150

200

250

300

350

400

450

500

550

600

650

700

Volume flow [l/min]

Lift [mbar]

Pump switch in position III (pre-delivery setting)

Pump switch in position II

1500 1600 1700

Instructions for installation and servicing aquaPLUS VUI 362-712

Vessel Volume [L] Initial system pressure (bar) 1.0 1.5 Pressure relief valve setting (bar) 3.0

Total water content of system

litres

25 2.7 3.9

50 5.4 7.8

100 10.9 15.6

125 13.6 19.5

150 16.3 23.4

175 19.1 27.3

200 21.8 31.2

225 24.5 35.1

250 27.2 39.0

275 30.0 42.9

300 32.7 46.8

325 35.7 50.7

350 38.1 54.6

375 40.9 58.5

400 43.6 62.4

425 46.3 66.3

450 49.0 70.2

475 51.8 74.1

500 54.5 78.0

For system volumes other than 0.109 0.156

those given above, multiply the

system volume by the factor across

Table 4.1: Sizing of additional expansion vessel

Supplied by HeatingSpares247.com

Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-7 13

5 Boiler Installation Sequence

5.1 General

5.1.1 Preparation of boiler location

Clearances required

Mount the boiler on a flat and vertical area of wall of sufficient area for the boiler plus the required clearances for installation and servicing. The clearances are as detailed below and are shown on the installation template supplied with the boiler:

- 150 mm below the boiler

- 5 mm on either side of the boiler

- 210 mm on top of the boiler

- 500 mm in front of the boiler*

* Clearance is only required to enable easier access to

the boiler for servicing and may be provided by an openable door, etc.

Fig. 5.1: Dimensions of boiler

440

800

497

Note: If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication IGE/UP/7/1998 "Guide for Gas Installations in Timber Framed Dwellings".

Fig. 5.2: Free space required for installation

5.1.2 Selecting position of boiler

Refer to "Boiler location" for information regarding siting the appliance. In general the boiler must be positioned such that:

• There is adequate space around the boiler for service and maintenance.

• The boiler can be correctly flued, i.e. the flue terminal position is sited in accordance with the flue termination section (see page 10) and the air/flue duct can be installed in accordance with the flue installation instructions supplied.

• All necessary pipework can be connected, including the pressure relief valves.

150

210

500

Supplied by HeatingSpares247.com

5 Boiler Installation Sequence

Instructions for installation and servicing aquaPLUS VUI 362-714

Fig. 5.3: Using Boiler template

124175 GB

60/100

08/2001

210

12,5

30,5

780

122

5.2 Using boiler template

Fix the paper template to the wall ensuring that the correct flue exit point has been identified, ensure that the template is vertical. The template shows

- The position of the fixing holes for the boiler mounting bracket.

- The position of the connections.

- The position of the flue exit hole.

- Upper hole (2) indicates top outlet flue with flue turret facing rearward.

• Mark the position of the hanging bracket fixing holes (1).

• Drill 2 holes Ø10 mm for the hanging bracket.

Top outlet rear exit

Mark the centre of the selected air/flue duct and its circumference, e.g. by drilling through the template.

Other flue options

Flue instructions for other flue systems such as vertical RSF flues, flues run to the side of the boiler and the use of additional bends etc. are detailed in the flue installation instructions provided with the boiler. Remove the template from the wall and plug the drilled holes using the wallplugs supplied.

Note: Use alternative fixing holes where necessary.

Supplied by HeatingSpares247.com

Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-7 15

5.3 Fitting the boiler hanging bracket

Fix the hanging bracket (2) to the wall using the fixings supplied. (it may be necessary to use additional or alternative fixings to ensure adequate support).

Fig. 5.4: Fitting the boiler

5.4 Install the flue system

Install the flue system (refer to separate air/flue duct installation instructions).

5.5 Fitting the boiler

• Lift the boiler (3) up to the wall so that it is slightly above the hanging bracket (1).

• Lower the boiler slowly onto the hanging bracket so that the slots at the rear of the boiler fully engage onto the hanging bracket (1).

Note: If the boiler is to be fitted in a timber framed building ensure that the bracket is secured to a substantial part of the timber frame capable of taking the weight of the boiler.

Note: Lift the boiler from either side at the centre of the bottom edge.

5.6 Removing boiler casing

• Turn both securing fasteners (1) anti-clockwise by 90° to release control panel (2).

• Pull the case (3) forward at the bottom to disengage from the securing clips.

• Lift the case slightly to clear the top locations and pull forward to remove.

Fig. 5.5: Remove of boiler casing

VRC-VC

I 0

90°90°

Supplied by HeatingSpares247.com

5 Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-716

5.7 Gas supply

• Connect the 15 mm compression gas service cock (1) and 22 mm copper outlet tail (3) as supplied with the appliance (2) and tighten.

• Connect a gas supply pipe of not less than 22 mm diameter to the copper tail.

• Tighten all connections. (Ensure the gas supply pipework is adequately sized such that a 20 mbar gas pressure is available at the boiler inlet at full flow rate).

Fig. 5.6: Fitting the gas connection aquaPLUS

I 0

5.8 Cold water mains inlet and hot water outlet

Flush all foreign matter from the mains supply before connecting to the boiler.

• Connect the cold water service valve (1) to the cold inlet water connection (3) of the appliance with the washer (2) provided and tighten.

• Connect the 15 mm cold water inlet pipe copper tail (4) to the cold water service valve (1) and tighten.

• Connect the 15 mm hot water outlet copper tail (6) to the hot water outlet connection of the appliance (8) with the washer provided (7) and tighten.

Note: The hot water outlet union nut is packed in with the PRV fitting pack.

• Connect the cold water service pipe and hot water outlet pipework to the copper tails.

Fig. 5.7: Fitting the hot and cold water connections aquaPLUS

I 0

Supplied by HeatingSpares247.com

Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-7 17

5.9 Central heating flow and return pipework

Before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris.

• Connect the central heating flow (6) and return (1) service valves to the appliance (8 and 3) with the washers provided (2 and 7) and tighten the nuts. Ensure that the valve spindles face downwards and the drain points face to either side of the boiler.

• Connect the 22 mm copper pipe tails to the service valves as shown in the illustration and tighten the nuts.

• Connect the central heating pipework to the flow (9) and return (4) tails.

Pressure Relief Valves (central heating and domestic hot water)

Connect discharge pipes not less than 15 mm diameter to the outlet of these valves. The discharge pipework should be as short as possible and installed with a continuous fall away from the boiler. The pipes should terminate in a position which ensures that any discharge of water or steam from the valves cannot create a hazard to persons in or about the premises, or cause damage to any electrical components or external wiring, and the point of discharge should be safe and clearly visible.

Fig. 5.8: Central heating flow and return pipework aquaPLUS

I 0

5.10 Connect the flue system to the boiler

• Refer to separate air/flue duct installation instructions included with the boiler.

Supplied by HeatingSpares247.com

5 Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-718

5.11 Electrical installation

General requirements

Important: All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations).

The boiler is supplied for connection to 230 V, ~ 50 Hz supply fused at 3 A rating.

Connection to the mains supply shall be made via a fused 3 pin plug to an unswitched shuttered socket, both complying to the requirements of BS1363.

(Alternatively, connection may be made via a 3 A fused double pole isolator having a contact separation of at least 3 mm in all poles and supplying the boiler and controls only).

The point of connection to the mains supply must allow complete electrical isolation of the boiler and its ancillary controls. It should be readily accessible and adjacent to the boiler. A 3 core flexible cord according to BS6500 tables 6, 8 or 16 (3 x 0.75 to 3 x 1.5 mm

)

should be used.

Warning: This appliance must be earthed.

Important: Ensure that all cords pass through the cable clamps in the rear of the control box and are securely fixed. Ensure that the power supply is connected such that the current carrying conductors become taut before the earth conductor should the supply cord slip from the cable clamp.

Note: DO NOT use boiler terminal connections 7-8-9.

Warning! Mains connection terminals L and N remain live even when the boiler on/off control is switched off.

5.12 Connection to the main supply

• Lower the control panel.

• Unclip the terminal box cover (1) from the control panel (2).

• Feed the power supply cord in to the appliance as shown (Fig 5.10).

• Use cable clamps.

• Connect the power supply cord as follows (Fig. 5.11, on page 20). Green/yellow (earth) wire boiler terminal Earth sign Blue (neutral) wire boiler terminal N Brown (live) wire boiler terminal L

• Refit the terminal box cover by pushing into place until it clips back into position.

• Raise the control panel and secure in place.

Note: DO NOT use boiler terminal connections 7-8-9.

Supplied by HeatingSpares247.com

Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-7 19

Fig. 5.9: Exposed rear view of switchgear cabinet

Fig. 5.10: Wiring system

NL987543

RT 24V 230V RT 230V

Supplied by HeatingSpares247.com

5 Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-720

NL987

543

24V

230V

Socket X2 for internal unit components

Socket X4 for diverter valve

Socket X7 for accessory box connection

Socket X8 for VRC-VC connection

Room thermostat, 230 V: connections 3, 4 and 5

Mains power supply: connections L, N and earth

Socket X12: pump connection

Socket X14: gas valve connection

Socket X13: fan unit connection

Do not use!

5.13 Electronic board layout

Fig. 5.11: Connection wiring

Socket X601: store charging pump connection

Supplied by HeatingSpares247.com

Boiler Installation Sequence 5

Instructions for installation and servicing aquaPLUS VUI 362-7 21

5.14 Controls

External electrical controls

The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. Terminals 3 and 4 are linked together when the boiler is supplied. If external controls are used, this link must be removed, and the controls connected across terminals 3 and 4. Terminal 5 is an additional neutral connection for external neutrals such as from the anticipator of a room thermostat.

Connection of external controls

Connection details for programmable room thermostats.

Fig. 5.12 shows the connection details where a programmable room thermostat (time switch with built in room thermostat) is used to control the boiler.

Important: The arrowed numbers indicate connection into the relevant terminal in the boiler terminal strip.

Fig. 5.12 Connection details for programmable thermostats

234

LN3

ACL Drayton Lyfestyle PT271, PT371

ACL Drayton Digistat 2, 3, 4

ACL Drayton Digistat RF - SCR Receiver

Danfoss Randall TP4, TP5, TP5E

Danfoss Randall TP5E RF with receiver RX1

Danfoss Randall TP75

Grässlin Towerchron RTC7

Honeywell CM61, CM67, CM31, CM37

Horstmann Centaurstat 1, 7

Landis & Staefa REV 11, REV 15, REV 22

Sunvic TLX 6501

Sunvic TLX RFP, TLX RFD

Vaillant VRT 220, 230

234

LN 3

2341

LL1

Smiths Timeguard ProgramaSTAT PRT11, PRT17

234

LN 3

Connection details for external time switches and boiler terminal strip.

Fig. 5.13 shows the connection details where a time switch is used without a room thermostat to control the boiler.

Important: The arrowed numbers indicate connection into the relevant terminal in the boiler terminal strip.

If a room thermostat is to be connected in addition to a time switch the wire between the time switch "ON" terminal and boiler terminal 4 should be broken by the contacts of the room thermostat (see schematic layout, Fig. 5.14).

Vaillant optional plug in timer accessories

Refer to the instructions supplied with the optional accessories for connection details.

Fig. 5.13 Connection details for time switch

Upon completion of all electrical connections refit the terminal box cover by pushing into place. The cover is secured by two locking clips.

234

LN3

ACL Drayton Tempus 1, Tempus 2 Lyfestyle LP111, LP711

ACL Drayton Switchmaster SM300

ACL Drayton Switchmaster 980

Danfoss Randall 103 Series

Danfoss Randall Set 1E, TS975

Danfoss Randall TS715

Grässlin Towerchron QE1, QM1

Honeywell ST610A, ST6100C

Horstmann Channel Plus H11, H17, 425 Coronet

Horstmann Centaur Plus C11, C17

234

LN4

Potterton Myson EP 4002, EP 5002

Smiths Timeguard SupplyMASTER FST11, FST17

Sunvic Select 107

AB C

65E

4L3

234

LN3

234

LN 3

234

LN3

234

LN 3

234

LN3

DLN

345E

4 3 2/L

1/N

mains supply

LNE

Landis & Staefa RWB7, RWB30

Supplied by HeatingSpares247.com

5.18 Anti-cycling ‘economiser’ control

The boiler incorporates a built in anti-cycling control to ensure that energy wasteful short cycling of the boiler cannot occur. This control prevents the boiler from reigniting for a preset period of 5 minutes after central heating operation (the hot water operation is unaffected by this control and hot water can be drawn at any time).

5.19 Automatic pump spin control (APS)

The boiler incorporates a built in control which will spin the built in circulating pump and operate the diverter valve once in a 24 hour period. This control helps to prevent seizure when the boiler is not operated for a period of time. This control is not active when the power supply to the appliance is turned off.

5.20 Anti legionella protection

If the temperature in the power store does not rise above a certain limit in a set time period, the boiler will operate and charge the store to protect against legionella.

5 Boiler Installation Sequence 5

Fig. 5.14

5.15 Thermostatic radiator valves

The boiler has a built-in automatic bypass valve making it ideal for use in systems with thermostatic radiator valves (no separate system bypass is required). For optimum fuel economy it is recommended that where TRV’s are used they are used in conjunction with a programmable room thermostat or separate timer and room thermostat to ensure complete boiler shut down when the heating demand is satisfied. (The radiator in the room containing the room thermostat should not be fitted with a TRV).

5.16 Frost protection

The boiler has an integral frost thermostat which is designed for protection of the boiler. To protect remote or exposed parts of the heating system or property additional frost protection measures must be taken such as the installation of an external frost thermostat. This frost thermostat should be connected across the boiler terminals 3 and 4, in parallel with any external heating controls.

Note: External frost protection cannot be used when plug in timers have been fitted.

5.17 Circulating pump

The boiler incorporates a built in circulating pump that is fully prewired (no additional wiring is necessary). The pump incorporates an automatic overrun period after the boiler switches off.

987

MAINS SUPPLY 230 V

50 Hz

20 VDC

DO NOT USE IN UK!

3 A FUSE

SWITCH CONTACTS

ROOM THERMOSTAT

CLOCK

Instructions for installation and servicing aquaPLUS VUI 362-722

Note: To temporarily override the anti-cycling control turn the main boiler on/off switch to the off position "0" and then back to the on position "I" after a few seconds.

Note: Very hot water will be discharged during tapping after this operation.

Supplied by HeatingSpares247.com

Commissioning Part I 6

Instructions for installation and servicing aquaPLUS VUI 362-7 23

Fig. 6.1: Filling aquaPLUS boiler

6.5 Initial system flush (“cold“)

The whole of the heating system must be flushed out at least twice: once cold, and once hot as instructed later.

• Open all radiator and heating valves and the boiler CH service valves and drain the heating system and boiler completely from the lowest points of the system via 1/2” BSP drain taps (opened full bore to remove any installation debris prior to lighting the boiler).

• Refill the heating system.

• Check the operation of the pressure relief valve by rotating the knob on the valve.

• Now check the water pressure in the unit again (and add more water if necessary).

• Close the filling valves (1) and disconnect the temporary connection.

90°

6 Commissioning Part I

6.1 Preliminary electrical checks

Check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity.

6.2 Gas supply

The complete gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with BS 6891. In IE the current edition of IS 813. The gas supply to the boiler can be purged by slackening the gas service valve beneath the boiler. Ensure that there is adequate ventilation, extinguish all naked flames and do not smoke whilst purging. After purging, the gas service valve connection must be retightened and tested for soundness. (The boiler itself does not require purging as this will be done by the automatic burner sequence control).

6.3 Cold water supply

Open all domestic hot water taps supplied by the boiler, turn on the mains water supply to the boiler and open the mains water isolating valve below the boiler. Water will now flow through the boiler to the hot taps. Starting with the lowest tap supplied, turn the hot taps off one at a time until the hot water pipework is purged of air. Check all hot and cold water pipework for leaks.

6.4 Filling the heating system

Proceed as follows to fill the system:

• Open all radiator valves on the system.

• Check flexible filling loop is connected.

• Locate the filling valve handle on the cold water inlet filling valve as shown (1).

• Open valve (1) fully.

• Remove filling valve handle and locate on return filling valve (2).

• Open the valve slowly and fill the unit with water until the required pressure has been achieved (3).

• Turn off valve (2).

• Remove valve handle and refit on cold water inlet filling valve (1).

• Fully close valve (1).

• Bleed the air from the radiators.

• The boiler is equipped with an automatic air release valve. To allow this to vent the boiler, the cap top must be slackened by 1 -2 turns. (This cap must be left slackened during operation to ensure any residual air or system gases are released).

Supplied by HeatingSpares247.com

7 Gas supply adjustments (Commissioning Part II)

Instructions for installation and servicing aquaPLUS VUI 362-724

7 Gas supply adjustments (Commissioning Part II)

7.1 Gas inlet working pressure

To check the gas inlet working pressure:

• Lower the front panel of the boiler.

• Lower the control panel.

• Slacken the sealing screw (1) located at measuring point "P.IN".

• Attach U-gauge to the inlet test point on the gas valve (2).

• Ensure that the gas service valve is open.

• Turn off the boiler at the main ON/OFF control.

• Press and hold the "+" button while pressing the button turn the main ON/OFF control to the "1" ON position.

• Continue holding "+" button until display alternates between "P1, P2, P3, P11, P12 and P13". Release "+" button.

• Press "+" button until "P1" (full gas rate) is shown in display.

• Press "i" button to operate boiler at full gas rate.

• Check that the U-gauge is reading in the range between 18 and 20 mbar. If the pressure is not within this range this should be investigated before continuing with the commissioning procedure. Lower pressures than this range are indicative of an incorrectly sized or partially blocked gas supply.

• Switch off the boiler at the main ON/OFF control.

• Remove U-gauge, tighten test point sealing screw (1).

• Test for soundness.

• Record appliance working gas inlet pressure (mbar) in the Benchmark Installation, Commissioning and Service Log Book.

Fig. 7.1: Checking the inlet pressure (gas-flow pressure)

Supplied by HeatingSpares247.com

Gas supply adjustments (Commissioning Part II) 7

Instructions for installation and servicing aquaPLUS VUI 362-7 25

7.2 Main burner pressure

The burner pressure on this appliance has been factory set and does not require adjustment. To check the main burner pressure connect the U-Gauge as follows.

• Remove front case and combustion chamber cover.

Note! All measurements and adjustments to the gas valve must be done with the combustion chamber cover removed.

• Slacken the sealing screw (1a) at test point on the burner inlet gas pipe and attach one arm of a U-gauge (2a) to the test point.

• Turn off the boiler at the main ON/OFF control.

• Press and hold the "+" button, while pressing the button turn the main ON/OFF control to the "1" ON position.

• Continue holding "+" button until display alternates between "P1, P2, P3, P11, P12 and P13". Release "+" button.

• Press "+" button until "P1" is shown in the display. "P1" indicates the maximum gas rate and "P2" indicates the ignition rate.

• Press "i" button to operate boiler at maximum gas rate.

Check that the burner pressure is correct as shown in table 7.7, page 30 for the appropriate boiler. To cancel selected "P1" or "P2" mode press the "i" and "+" buttons simultaneously. Measure the domestic hot water burner operating pressure (mbar), the heat input (kW), the inlet/outlet domestic hot water temperatures (°C) and flow rate (l/min) by fully opening a hot water tap and record details in the boiler logbook.

Fig. 7.2: Connecting the U-tube pressure gauge

Supplied by HeatingSpares247.com

7 Gas supply adjustments (Commissioning Part II)

Instructions for installation and servicing aquaPLUS VUI 362-726

Fig. 7.3: Setting the maximum heating load (nominal load)

7.3 Adjusting to the maximum heat load (nominal load)

• Remove the cap (1).

• Set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap.

• Turn off the boiler at the main ON/OFF control.

• Press and hold the "+" button, while pressing the button turn the main ON/OFF control to the "1" ON position.

• Continue holding "+" button until display alternates between "P1, P2, P3, P11, P12 and P13". Release "+" button.

• Press "+" button until "P1" (full gas rate) is shown in display.

• Press "i" button to operate boiler at full gas rate.

• Using a 10 mm spanner turn nut (2) to adjust the burner operating pressure.

- Turn the nut (2) clockwise to increase the nominal load

- Turn the nut (2) anticlockwise to decrease the nominal load.

• Adjust the burner pressure until it matches the maximum output as detailed in table 7.7, page 30.

• Now turn the 10 mm nut (2) anticlockwise until the burner pressure drops by approx. 0.3 - 0.4 mbar. Nominal load is now correctly adjusted.

• Refit the plastic cap (1).

Warning! The plastic cap (2)must be fitted for the gas valve assembly to function correctly.

• Turn off the hot water tap.

• To cancel selected "P1" or "P2" mode press the "i" and "+" buttons simultaneously.

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Gas supply adjustments (Commissioning Part II) 7

Instructions for installation and servicing aquaPLUS VUI 362-7 27

7.4 Adjusting the ignition rate

• Undo screw and remove the cap (1).

• Disconnect the modulating coil wires from the gas valve, set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap.

• Turn off the boiler at the main ON/OFF control.

• Press and hold the "+" button, while pressing the button turn the main ON/OFF control to the "1" ON position.

• Continue holding "+" button until display alternates between "P1, P2, P3, P11, P12 and P13". Release "+" button.

• Press "+" button until "P2" (ignition rate) is shown in display.

• Press "i" button to operate boiler at full gas rate.

• Use a suitably sized screwdriver to turn the inner screw (2).

-Turn the screw (2) clockwise to increase the ignation rate

- Turn the screw (2) anticlockwise to decrease the ignation rate

• Adjust the burner pressure until it matches the ignition rate in table 7.7, page 30.

• Turn off the hot water tap and reconnect the wires to the modulating regulator.

• To cancel selected "P1" or "P2" mode press the "i" and "+" buttons simultaneously.

Warning! The main burner pressure must be rechecked after adjusting the ignition rate.

Refit cap (1) and replace screw. Re-check ignition and main burner pressures. After completion of these tests tighten the sealing screw and check all joints and test points for soundness.

Fig. 7.4: Adjusting the ignition gas quantity

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7 Gas supply adjustments (Commissioning Part II)

Instructions for installation and servicing aquaPLUS VUI 362-728

7.5 Adjusting the central heating output (range rating)

The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the boiler, as follows:

• Connect the U-gauge to check burner pressure.

• Use Table on page 30 to determine the central heating output required.

• Identify required range rating setting and note main burner pressure in mbar for that output.

• Turn on the central heating.

• Ensure that any thermostatic radiator valves are open and set to high.

• Simultaneously press and release the "+" and "-" buttons to activate burner pressure mode.

• The boiler will light at the factory set nominal gas rate.

Warning! DO NOT open any hot water tap while carrying out this procedure.

• Check that the U-gauge reading corresponds to the maximum burner pressure as detailed on the table.

• Adjust central heating output range as shown on page

29.

Fig. 7.5: Using nozzle pressure to check and adjust the heating system partial load

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Gas supply adjustments (Commissioning Part II) 7

Instructions for installation and servicing aquaPLUS VUI 362-7 29

Note! Following adjustment of the central heating output, the new output can be checked using the gas rate table as detailed.

1 Simultaneously press the "i" and "+" buttons keys.

2 Keep the "+" button pressed until "d.0" is displayed.

(The display runs from "d.0" to "d.99" before restarting again at "d.0".)

3 Press the "i" button and a value between 1 and 15 will

be displayed.

4 Use the "+" or "-" buttons to increase or decrease the

value. Observe the U-gauge as the button is pushed and stop pushing when the required main burner pressure has been achieved.

5 After setting, press and hold the "i" button for five

seconds or until the display stops flashing. The new setting value is now memorised. The new main burner pressure can now be checked. If the new output is not correct repeat steps 3 to 5.

6 To return to normal mode, press the "i" and "+"

buttons simultaneously. The adjustment mode is also cancelled if no button is pushed for a period of four minutes.

• Record central heating burner pressure in the Benchmark Log Book along with the heat input (kW) and temperature difference between flow and return.

Supplied by HeatingSpares247.com

~ 5 s

7 Gas supply adjustments (Commissioning Part II) 7

Instructions for installation and servicing aquaPLUS VUI 362-730

7.6 Checking the gas valve mid setting point

To ensure the most efficient operation of the boiler a gas valve mid setting point is necessary. This mid setting point has been factory set and adjustment of this point is only required after exchanging either the electronic circuit board or gas valve or converting the boiler to another gas type.

To check the mid setting point proceed as follows.

• Turn off the boiler at the main ON/OFF control.

• Press and hold the ”+” button,,while pressing the button turn the main ON/OFF control to the ”I” ON position.

• Continue holding ”+” button until display starts to alternate between the P numbers (P1,P2,P3,P11,P12 and P13). Release ”+” button.

• Press ”+” button until ”P3 ” (mid setting point) is shown in display.

• Press ”i” button to operate boiler at mid setting point.

• The burner pressure should now read the mid setting

point pressure for the gas type used,as detailed in the table below.

If the mid setting point pressure is incorrect it can be adjusted as follows. Turn off the boiler at the main ON/OFF control.

• Press and hold the ”+” button,,while pressing the button turn the main ON/OFF control to the ”I” ON

position.

• Continue holding ”+” button until display starts to alternate between the P numbers (P1,P2,P3,P11,P12 and P13). Release ”+” button..

• Press ”+” button until ”P11 ” ((or natural gas)or "P 13" (for LPG) is shown in display.

• Press ”i” button to operate boiler at mid setting point.

• The mid setting point burner pressure is now adjusted by pushing the "+"button until the gauge equals the pressure as detailed in the table below.

Note! The "-" button has no function in this mode, if the required pressure is exceeded during set up, this operation should be recommenced from the beginning.

When the pressure is correct, to save the setting to memory, press and hold the "i"button until the display stops flashing. To cancel selected mode press the "i"and "+"buttons simultaneously. Re-check ignition and main burner pressures.After completion of these tests tighten the sealing screw and check all joints and test points for soundness.

Gas type Mid setting point pressure

Natural Gas (G20) 5.3 mbar LPG (G30/31) 15.3 mbar

Program No. Gas type Mid setting point

P.11 Natural Gas 5.3 mbar

(G20)

P.12 Not applicable -

for GB

P.13 LPG (G30/31) 15.3 mbar

7.7 Burner pressure and gas rate

15 °C, 1013 mbar, dry

The nozzles are stamped with the mark shown in this table. The

marking corresponds to the nozzle hole diameter multiplied by 100.

Gas Rate aquaPLUS Output [kW] Delivered Gas 10,5 12,0 16,0 18,0 20,0 24,0 28,0 30,0 33,0 36,9

Natural gas 2H Gas rate1)[m3/h] for G20 1.3 1.4 1.9 2.2 2.4 2.8 3.3 3.5 3.9 4.3

Main burner jet mark

7/120

Burner Pressure aquaPLUS Ignition Output [kW] Delivered Gas rate 10.5 12.0 16.0 18.0 20.0 24.0 28.0 30.0 33.0 36.9

Natural gas 2H Burner pressure

[mbar] for G20 1.1 1.1 1.4 2.4 2.9 3.6 5.0 6.7 7.5 9.0 11.0

Main burner jet mark

7/120

Setting-up program: P11 mid. setting point pressure: 5.3 mbar

L.P.G. 3+ Burner pressure1)[mbar] for G30 2.8 2.8 3.5 5.9 7.3 8.9 12.6 16.8 19.1 22.9 28.2

Main burner jet mark

7/ 0 7 2 Burner pressure

[mbar] for G31 3.5 3.5 4.4 7.3 9.1 11.1 15.6 20.8 23.7 28.3 34.9

Setting-up program: P13 mid. setting point pressure: 15.3 mbar

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Gas supply adjustments (Commissioning Part II) 7

Instructions for installation and servicing aquaPLUS VUI 362-7 31

7.8 Fit boiler casing

• Carefully push case (1) onto the boiler such that the locating points either side at the top of the boiler engage. Push the casing onto the securing clips at the bottom of the boiler.

• Close control panel (2).

• Secure control panel by turning both securing fasteners (3) clockwise by 90°.

• Close front door (4).

• Open the punch-out holes in the cover panel (6) for the pipework installation.

• Fit the bottom cover (6).

Fig. 7.6: Fit boiler casing

VRC-VC

90¡90¡

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8 Functional checks (Commissioning Part III)

Instructions for installation and servicing aquaPLUS VUI 362-732

8 Functional checks (Commissioning Part III)

8.1 Functional checks

Once the unit has been installed and the gas supply has been checked, operate the system to ensure that it is working correctly.

• Operate the system, following the operating instructions supplied with the boiler.

• Check the system for water leaks and escaping gas.

• Check that the flue has been correctly installed, according to the fitting instructions supplied with the flue assembly.

• Check the burner for correct ignition and flame picture.

• Check the hot water system for correct operation.

• Check the heating system for correct operation.

Fig. 8.1: Test for correct functioning

This appliance is fitted with a display unit that uses symbols to show the current operating status of the boiler. Additionally to this the status of the boiler can be checked using the Status Mode.

8.2 Hot-water supply

• Activate the system.

• Fully open one of the hot water taps in the system.

• Press the ”i“ key.

Status code “S.14” appears on the display to indicate that the hot-water supply is functioning correctly.

Fig. 8.2: Display indication while hot water is being supplied

8.3 Power store filling mode

Note: The power store is delivered turned off and must be turned on during commissioning.

• Activate the system.

• Ensure that the hot water thermostat is set to the required heat level.

• Press the ”i“ key.

Status code “S.24” appears on the display if the tank is being recharged.

Fig. 8.3: Display indication during power store filling mode

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Functional checks (Commissioning Part III) 8

Instructions for installation and servicing aquaPLUS VUI 362-7 33

8.4 Heating mode

• Activate the system and ensure the tank is fully charged.

• Ensure that the heating system is calling for heat.

• Press the ”i“ key.

Status code “S.4” appears on the display to indicate that heating is functioning correctly.

Fig. 8.4: Display indication during heating

8.5 Adjusting pump speed

The unit is fitted with a two-speed pump. The pump is delivered with the switch (1) set to position III.

Important note!

The boiler should only be operated at pump

setting III because the heating capacity for hot water is reduced when operated at pump setting II!

It is possible, however, to change the pump setting from Level III to Level II manually when there is noise coming from the heating system.

Fig. 8.5: Pump speed

8.6 Final system flush ("Hot")

Turn on the boiler for central heating and allow the boiler and system to reach operating temperature. Check that the heating system is watertight. Turn the boiler off and rapidly drain both boiler and system while still hot. Refill the system and release all air. Release water from the system until the system design pressure of 1.0 bar is attained. (The actual reading on the pressure gauge should ideally be 0.5 bar plus an additional pressure corresponding to the highest point of the system above the base of the boiler - 10 m head equals an additional 1 bar reading on the pressure gauge. The minimum pressure should not be less than 1 bar in any installation.) If the system is to be treated with an inhibitor it should be applied at this stage in accordance with the manufacturers instructions. Further information can be obtained from Sentinel, Betz Dearborn Ltd., Tel: 0151 4951861 or Fernox, Alpha-Fry Technologies, Tel: 0870 6015000.

Disconnect the temporary filling connection.

Refit the boiler casing.

Attach the bottom cover to the boiler by securing with the two screws provided. It may be necessary to apapt the bottom cover by removing the easy break sections.

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9 Servicing

9.1 Initial Inspection

To ensure the continued safe and efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate. It is the law that all servicing work is carried out by a competent person (Corgi registered).

Important: Before starting any maintenance work:

• Isolate the mains electricity supply by disconnecting the plug at the socket outlet (if there is only an isolating switch remove the fuse from the switch).

• Turn OFF the gas supply at the gas service valve fitted to the boiler.

• Always test for gas soundness and always carry out functional checks after any service work and after exchanging any gas carrying component.

• Always check earth continuity, polarity and resistance to earth with a multimeter after any service work and after exchanging any electrical component.

Before commencing any servicing or maintenance work, carry out an initial inspection of the system as follows:

• Inspect the flue, pipework and electrical connections for indications of damage or deterioration.

• Inspect the air supply and ventilation arrangements of the installation.

• Check the heating and water system, in particular the condition of radiator valves, evidence of leakage from the heating system and dripping hot water taps.

9.2 Functional check of boiler operation

• Carry out a functional check of the boiler operation as prevoiusly detailed.

• Remove the appliance casing as detailed on page 15 and operate the boiler by fully opening a hot water tap. Inspect the burner operation through the viewing window. Check that the flames are evenly covering the surface of the burner. Inspect for signs of excessive flame lift or sooting.

8 Functional checks (Commissioning Part III) Servicing 9

Instructions for installation and servicing aquaPLUS VUI 362-734

8.7 Handing over to the user

Set the maximum radiator temperature control to the desired setting.

Set the maximum hot water temperature control to the desired setting.

Instruct the user in the safe and efficient operation of the boiler, in particular the function of

• The boiler on/off control

• The maximum radiator temperature control

• The maximum hot water temperature control

• The pressure gauge

Show the user how to operate any external controls.

Explain to the user the importance of having the boiler regularly serviced by a competent servicing company. To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details.

Ensure the boiler log book is fully completed and leave with the end user. Failure to install and commission this appliance to the manufacturers instructions may invaludate the warranty (Note: This does not affect your statutory rights).

Leave the user instructions, the boiler log book and the installation and servicing instructions with the user.

8.8 Anti legionella protection

Advise the user that if the power store is turned off or if the domestic hot water thermostat is at a low setting the boiler will operate daily to charge the store and protect against legionella (the power store is turned off during production).

Note: Leave the Benchmark Log Book with the end user.

Note: The boiler is fitted with a combustion analysis

test point on the combustion chamber cover. A suitable combustion analyser can be connected to this point to establish the combustion performance of the boiler.

Note: Very hot water will be discharged during tapping after this operation.

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Servicing 9

Instructions for installation and servicing aquaPLUS VUI 362-7 35

9.3 Cleaning the burner and primary heat exchanger

• Turn off the boiler.

• Isolate the electrical supply to the boiler.

• Remove the boiler case as described on page 15.

• Turn off the gas service valve.

• Turn off the boiler CH service valves.

• Turn off the cold water inlet service valve.

• Release the three clamps (1), remove the combustion chamber cover (2) and then remove the flue gas connector (2a) on the fan.

• Remove the retaining spring (3).

• Remove both plugs (4) and two tubes (5) from the fan assembly.

• Remove the fan assembly (6).

• Remove the four screws (7) and detach the front cover panel from the combustion chamber (8).

• Check the burner (9) and heat exchanger fins (10) and remove any loose deposits with a soft brush.

• Reassemble in reverse order.

Check central heating expansion vessel.

• Release the system water pressure from the boiler.

• Remove valve cap from expansion vessel charge point.

• Check that the internal charge pressure of expansion vessel is between 0.7 - 0.9 bar. If pressure is lower than this the vessel should be re-pressurised using an air pump.

• Refit valve cap.

• Open central heating service valves and re-pressurise the boiler and heating system if necessary.

• Open the gas service valve.

• Turn on the mains power supply.

• Operate the boiler and carry out soundness, safety and function checks.

• Complete the service interval record section in the log book and leave with the user.

9.4 Draining the domestic hot water system (if

required)

• Turn off the cold water supply at the cold water service valve.

• Release the pressure in the boiler by opening the hot water taps.

• The power store can now be drained from the two drain points under the boiler (one on the cold water inlet pipe, the other on the outlet pipe of the domestic hot water heat exchanger).

Note: It is not necessary to carry out the following check every year – a check every three years should be sufficient.

Fig. 9.1: Cleaning the burner and primary heat exchanger

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10 Fault finding

10.1 Introduction

The aquaPLUS boilers have an inbuilt advanced multifunction diagnostic display to assist with fault finding in the unlikely event of a boiler malfunction. The display features the following four modes:

Normal Mode

Under normal conditions the boiler display will show the boiler flow temperature, this indicates that the boiler is operating correctly after an internal self check.

Status Mode

The status display is helpful in diagnosing faults where a fault code is not displayed.

Diagnostic Mode

In order to assist with the pinpointing of a particular fault it is possible to use the boiler display in a diagnostic mode to interrogate the boiler about the status of certain components.

Fault Mode

Should a fault develop in the boiler the display will show a fault code indicating what the problem may be.

Display key:

1 Fan speed malfunction 2 Heating demand 3 Hot-water demand 4 Power store on (Comfort mode) 5 Pump on 6 Gas valve on 7 Actual Heating-system flow temperature (e.g. 50 °C)

or Displaying of a status/error code

8 Correct burner operation (normal flame) or

lock out (crossed-out flame)

Instructions for installation and servicing aquaPLUS VUI 362-736

Fig. 10.1: Display indications

10.2 Logical fault finding procedure

These checks must be carried out before attempting to use the fault finding guide.

1. Carry out electrical safety checks (See Section ‘Preliminary Electrical Checks’).

2.Check that the external electricity supply to the boiler is on, and a supply of 230 V~ is present between boiler terminals ‘L’ and ‘N’.

3.Check that the gas supply to the boiler is on, that it has been correctly purged and that an inlet pressure of 20 mbar is available at the gas valve. (See Section ‘Gas Supply’).

4.Ensure the heating system is full of water and charged to between 1 and 1.5 bar. If not, refill and vent the system. (See Section ‘Filling the heating system’). Ensure boiler flow and return service valves are open.

5.Check that the main on/off control is set to the ‘on’ position.

6.Set the central heating temperature to maximum.

7. Set the domestic hot water temperature to maximum.

8.Check that all external controls are on and calling for heat (if, no external controls are fitted, boiler terminals 3 and 4 must be linked). Check that the boiler anti-cycling economiser is not engaged.

VRC-VC

1237654

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Fault finding 10

Instructions for installation and servicing aquaPLUS VUI 362-7 37

10.2.1 Procedure

Note: Always check the operation of the boiler for

central heating first before checking hot water operation. Do not open a hot water tap unless instructed to do so by the fault finding guide.

1. If a fault code is showing in the boiler display follow the fault finding charts referring also to the fault code and diagnostic mode tables.

2.If the boiler is not functioning correctly and a fault code is not showing in the boiler display follow the fault finding charts referring also to the status mode table.

3.Note: If the boiler display is completely blank initially check the two fuses (Isolate the electrical supply before checking the fuses, spare fuses are located on the inside of the control box rear cover).

To access the various modes press the buttons on the control panel as follows:

Please note: If no key is pressed for approx. 4 minutes the display will automatically change back to Normal mode.

Mode To display the required To return to Normal

mode mode

Status mode Press "i" button Press "i" button

Diagnostic mode Press the "i" and "+" Press the "i" and "+"

button simultaneously button simultaneously

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10 Fault finding

Instructions for installation and servicing aquaPLUS VUI 362-738

Display Indication

S.00 No heat demand (heating operation)

S.01 Fan running (heating operation)

S.02 Pump running (heating operation)

S.03 Ignition sequence (heating operation)

S.04 Burner ignited (heating operation)

S.05 Fan and water pump over run (heating operation)

S.06 Fan over run (heating operation)

S.07 Pump over run (heating operation)

S.08 Anti cycling mode (heating operation)

S.10 Hot water demand (hot water operation)

S.11 Fan running (hot water operation)

S.13 Ignition sequence (hot water operation)

S.14 Burner ignited (hot water operation)

S.15 Fan and water pump over run (hot water operation)

S.16 Fan over run (hot water operation)

S.17 Pump over run (hot water operation)

S.20 Store recharging

S.21 Fan running (store charging)

S.23 Ignition sequence (store charging)

S.24 Burner ignited (store charging)

S.25 Fan and water pump over run (store charging)

S.26 Fan over run (store charging)

S.27 Pump over run (store charging)

S.28 Anti cycling mode (store charging)

S.30 No heating demand from external controls

S.31 Summer mode (heating control knob in off position)

S.32 Main heat exchanger anti freeze protection due to fan speed deviation too great

S.33 Check air/flue system

S.34 Frost protection mode

S.36 No heating demand from external controls

S.39 Contact thermostat has been activated (under floor systems)

S.53 Delay mode due to lack of water in system (~2,5 mins.)

S.54 Delay mode due to flow temperature gradient too steep (approx 10 mins.)

Table 10.1: Status modes

10.3 Status Mode

The status mode provides information about the current operating status of the boiler. To display status mode proceed as follows:

• Press the "i" button below the display, and a status code will appear in the display indicating the current operational status of the boiler (see table below).

To cancel the status code mode proceed as follows:

• Press the "i" button below the display or

• Do not press any key for approximately four minutes. The display will now revert back to showing the current flow temperature.

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Fault finding 10

Instructions for installation and servicing aquaPLUS VUI 362-7 39

10.4 Diagnostic Modes

In order to assist with the pinpointing of a particular fault it is possible to use the boiler display in a diagnostic mode to interrogate the boiler about the status of certain components.

• Press the "i" and "+" buttons below the display simultaneously. The display will now show "d.00".

• Use "+" or "-" buttons to scroll up or down to the desired diagnosic number.

• Press "i" button to display the corresponding diagnosic information.

• If necessary, you can now alter the value by pressing "+" or "-" buttons. (When altering values display will flash). Press and hold the "i" button to save the value to memory, when the value is saved the display will stop flashing.

Diagnosic mode is cancelled as follows:

• Press the "i" and "+" buttons simultaneously or

• Do not press any key for approximately four minutes. The display will now revert back to showing the current flow temperature.

Table 10.2: Diagnostic modes 1 of 2

Display Indication Displayed values/adjustment values

d.00 Part load setting 0....30

d.01 Water pump over run 1, 2, 3, ....60 min (factory-adjusted to 5 min)

d.02 Maximum burner anti cycling period at 20 °C 8 - 60 min (factory-adjusted to 15 min)

flow temperature

d.03 Actual hot water temperature in °C

d.04 Actual tank temperature in °C

d.05 Flow temperature setting in °C

d.06 Target value for hot water temperature in °C

d.08 External controls heat demand 0 = open, no demand, 1 = closed, demand

d.10 Pump status 1 = on, 0 = off

d.11 External pump status 1 = on, 0 = off

d.12 DHW pump - status 100 = on, 0 = off

d.13 DHW circulation pump (external) 1 = on, 0 = off

d.21 Flame rectification 1 = on, 0 = off

d.22 Domestic hot water demand 1 = on, 0 = off

d.23 Summer/winter function (control knob) 1 = winter, 0 = summer

d.24 Air pressure switch 1 = on, 0 = off

d.25 Storage tank status 1 = on, 0 = off

d.30 Gas valve status 1 = on, 0 = off

d.33 Required value of the rotary speed of the fan r.p.m.

d.34 Actual value of the rotary speed of the fan r.p.m.

d.35 Diverter valve position 0 = heating, 1 = hot water

d.37 Modulator current in mA

d.40 Actual flow temperature in °C

d.41 Actual return temperature in °C

d.50 Maximum flow temperature in °C

d.60 Number over heat cut off operations

d.61 Number of lock outs

d.64 Average ignition time in s

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10 Fault finding

Instructions for installation and servicing aquaPLUS VUI 362-740

Table 10.3: Diagnostic Modes 2 of 2

Display Indication Displayed values/adjustment values

d.65 Maximum ignition time in s

d.67 Remaining burner anti-cycling period in min

d.68 Number of unsuccessful attempted 1st ignitions

d.69 Number of unsuccessful attempted 2nd ignitions

d.71 Maximum target value for heating system flow 0 = 82 ° C, 1 = 87 °C (factory-adjustment: 82 °C)

temperature

d.72 Pump over run time after filling hot water store 0, 1, 2, .....250 s (factory-adjustment: 80 s)

d.76 Gas type set H36 (nat gas) P36 (LPG) E36 (E+gas).

Factory setting H36

d.79 Anti- legionella protection mode activated 1 = no, 0 = yes

d.80 Number of heating system operating hours (total) in h

d.81 Number of hot water system operating hours (total) in h

d.82 Number of heating system cycles (total)

d.83 Number of hot water system cycles (total)

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Fault finding 10

Instructions for installation and servicing aquaPLUS VUI 362-7 41

10.5 Fault codes

Fault codes take priority over all other display functions in the event of a system fault occurring. If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each.

10.6 Fault memory

The fault memory stores detalis of the ten most recent faults.

• Press the "i" and "-" buttons simultaneously.

Table 10.4: Fault codes

• Use the "+" button to scroll back through the list of memorised errors.

To cancel fault error memory display mode, proceed as

follows:

• Press the "i" button below the display. or

• Do not touch any key for about four minutes. The display will now revert back to showing the current flow temperature.

Display Indication Cause

F.00 Flow-NTC: NTC broken; NTC cable broken; Flow-NTC cable defective/broken NTC faulty

Defective connection at NTC, Defective connection at electronics

F.01 Return NTC: NTC broken; NTC cable broken; Return-NTC cable defective/broken NTC faulty

Defective connection at NTC, Defective connection at electronics

F.02 DHW-NTC: NTC broken; NTC cable broken; Defective DHW- NTC cable defective/ broken NTC faulty

connection at NTC; Defective connection at electronics

F.03 Tank-NTC: NTC broken; NTC cable broken; Defective Tank- NTC cable defective/ broken NTC faulty

connection at NTC; Defective connection at

electronics F.10 Short circuit - flow-NTC (<130 °C) NTC-plug shorted to casing, NTC defective F.11 Short circuit - return-NTC (<130 °C) NTC-plug shorted to casing, NTC defective F.12 short circuit DHW- NTC NTC- plug shorted to casing, NTC defective F.13 short circuit tank- NTC NTC- plug shorted to casing, NTC defective F.20 Over heat cut off activated Maximun temperature exeeded F.22 Dry fire protection No water in appliance, pump cable defective, pump blocked or

defective, pump output too low

F.23 Dry fire protection (difference between flow and No water in appliance, pump cable defective, pump blocked

return NTC's too large) or defective, pump output too low F.24 Dry fire protection (temperature gradient of flow Air in boiler/system, pump blocked or defective,

NTC too steep) pump output too low F.27 No demand to gas valve Electronic board defective; Gas valve defective F.28 Boiler goes to lock out No gas; Insufficient gas; Incorrect gas valve adjustment;

Electrode defective; Ignition lead defect; Electronic igniter

defective F.29 Flame extinguished re-ignition unsuccesful Gas supply absent or insufficient F.32 Main heat exchanger anti freeze protection mode Check fan control cables/connections; Defective fan control cable;

due to fan speed deviation too great

F.33 Main heat exchanger anti freeze protection mode due Check air pressure switch, fan, fan supply or flue system

to no switching signal from the air pressure switch F.37 The rotary speed of the fan is too high or too low Air pressure switch defect; fan defect; electronics defect F.41 No setting for the type of gas is stored Set gas type in PCB (see page 30) F.42 Faulty cable loom Faulty or incorrect loom fitted F.43 Faulty cable loom Faulty or incorrect loom fitted F.60 Electronic fault Electronics defect F.61 Electronic fault Electronics defect F.62 Flame rectification present 4 secs. after gas valve Check gas valve, burner tubes and injectors or electronics defect

turns off F.63 EMC fault EMC or electronics defect F.64 Sensor or electronics fault Check NTC's/connections or electronics defect F.65 PCB processor temperature too high Check earth connection or electronics defect F.66 Display fault Display defect; fault in the connection to the display;

electronics defect

F.67 Electronic fault Electronics defect

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10 Fault finding

Instructions for installation and servicing aquaPLUS VUI 362-742

Ensure boiler main

ON/OFF control is set

to position "1"

Is there a display on

the LCD Panel?

Yes Go to sheet C

Check electrical supply, appliance fuses and on/off control

Is 230VAC present across

terminals L and N?

Yes

Is 230VAC present across

terminals 3 and 5?

Yes

Is voltage between

16-26 VDC present across

terminals 8 and 9?

Yes

Is 5 VDC present between

5V and GND test points

on electronic board?

Replace LCD display

Yes

NoRepair external fault

Is the continuity

across fuse F1?

Go to sheet B

Does ON/OFF knob

operate switch on

electronic board

Boiler ON/OFF control

defective,

change electronic

board

Replace switch

mechanism

Yes

Note 1:

For test purposes, disconnect

external controls from terminal

3 - 4 and replace with a bridge

between these terminals.

It appliance then operates, the

fault is with the external controls.

Sheet A

Is there continuity

across fuse F3?

Replace electronic

board

Check transformer

Replace if

necessary

Yes

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Fault finding 10

Instructions for installation and servicing aquaPLUS VUI 362-7 43

Sheet BCheck operation of pump and fan

Turn off the main ON/OFF control to the

"0" position

Disconnect the power supply to the boiler

Go to sheet A

Is there a display on the LCD panel?

Check transformer 230 VAC primary

(black/red) and approx. 17 VDC secondary

(blue/brown)

Check/replace pump

Replace fuse F1

If fan commences operation, exchange

gas valve

After approx. 20 secs.

Does fuse F1 blow?

Produce central heating demand.

Does fuse blow immediately?

Turn the main ON/OFF control to the "1"

position

Is t here a display on the LCD panel?

Yes

Check/replace fan Replace electronic board

Yes

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10 Fault finding

Instructions for installation and servicing aquaPLUS VUI 362-744

Check central heating and controls

Ensure that radiator temperature control knob

is set to vertical position and that any internal

timer (if fitted) is calling for heat

Check diagnostic code D.08 (see page

39). Is heating demand present?

Is 230 VAC present across terminals 4 and 5

External fault: Check all external controls are

calling for heat, replace or repair as necessary

(see also note 1 sheet A)

Yes

Does failure code show on LCD display?

Disconnect built in timer (if fitted)

No Go to sheet D

Does ignition

commence?

Yes

Replace defective

timer

Sheet C

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Fault finding 10

Instructions for installation and servicing aquaPLUS VUI 362-7 45

Does fan run after approx. 30 secs.?

Check flue and ignition system

Check diagnostic code D.24

(see page 39) equal 1?

Check pitot tube (in fan outlet) and air

hoses are not obstructed and correctly

aligned.

Check or replace air pressure switch.

837/637 Check 4 pin connector for

fan speed control.

Does the fan run now?

Is 230 VAC present across fan

terminals?

Replace electronic board

Yes

Yes Check/replace fan

Does the boiler

commence ignition

Check status code

(see page 38) is S.33?

Check air/flue gas system

is correctly fitted and not

obstructed

Yes

Replace electronic board

Yes

Are electrodes sparking at

the burner?

Yes Go to sheet E

Check electrodes and

electrode leads.

Replace as necessary.

Sheet D

Check flue restrictor

correspond to flue length

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10 Fault finding

Instructions for installation and servicing aquaPLUS VUI 362-746

Check gas valve and central heating system pressure

Does burner light 1st

attempt?

Does burner light within 3

ignition attempts?

Yes

Check gas supply

Does burner light?

Yes

Check burner pressure

settings are correct

Yes

No Reset boiler

Check/replace gas valve

as necessary

Does burner light?

Replace electronic board

Yes

Is burner indicator

illuminated?

Check flame

rectification lead and

electrode

Is burner indicator

illuminated

Yes

Does burner shut down after

approx. 15 secs.

No Go to sheet F

Yes

Does status code (see page 38)

show S. 53?

Check water pressure in

central heating system, refill

and vent. as necessary

Check pump is running?

Yes

Yes Replace pump

Is 230 VAC present at the

pump plug connection?

Replace electronic board

Sheet E

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Fault finding 10

Instructions for installation and servicing aquaPLUS VUI 362-7 47

Does flame indicator glow and

flames increase in size to full gas

rate after approx. 2 mins?

Yes

Does burner flame modulate/ go

out when radiator temperature

control is turned left to the

horizontal position at flow

temperature of approx. °50 C?

Yes

Does heating flow pipe

temperature rise?

Go to sheet GYes

Check operation of burner and modulation

Ensure flow and return service

valves are open

Replace electronic board

Check operation of boiler in DHW

mode, does flame increase in size

to full rate?

Yes

Check partial load

setting

Check diagnostic code D.22

(see page 39) equals 1

Go to sheet G

Yes

Check connections and

modulator, replace gas valve if

burner still fails to increase to full

rate

Turn main ON/OFF control to

the "0" position

Yes

Insert a small screwdriver

through the hole in the front of

the diverter valve and hold

blade lightly against spindle

Turn "ON" the main ON/OFF

control

Does spindle move?

Yes

Replace electronic board

Replace diverter valve

Sheet F

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10 Fault finding

Instructions for installation and servicing aquaPLUS VUI 362-748

Draw hot water at high rate

Does flow indicator (tap)

on display light up?

Yes

Check hot water flow rate and temperature.

Compare with technical data, if flow is not

sufficient, check incoming main and cold water

filter.

Check cold water inlet pressure is

sufficient and that cold water inlet

filter is clear

Check cold water inlet is fully open

and adjustment is at maximum

flow rate

Does green warmstart

indicator flash now?

Check/Clear impeller in

Aquasensor, replace if necessary

Check/replace hall sensor

Replace electronic board

Does hot water indicator

glow/flash now?

Does green warmstart

indicator flash now?

Yes

Sheet GCheck D.H.W operation

Go to sheet B/C/E or F

Check DHW pump operation, is

230 VAC present across terminal

X601;

check/clear non return valve

and impeller on the pump;

replace the pump, if necessary

Is the boiler running?

Yes

Is the boiler running continously?

Yes

Normal operation carry out electrical safety checks

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Diagrams 11

Instructions for installation and servicing aquaPLUS VUI 362-7 49

11 Diagrams

11.1 Functional Flow diagram: aquaPLUS VUI 362-7

POWER SUPPLY

F2A

MAIN SWITCH

MAIN

TRANSFORMER

230V 20V

AIR

PRESSURE

SWITCH

FAN

PUMP

NTC FLOW

TEMPERATURE

SENSOR

FLAME

SENSOR

GAS

VALVE

DHW Aqua

Sensor

F1,25A

NTC RETURN

TEMPERATURE

SENSOR

Burner lock out indicator

Hot water demand indicator

Ignition indicator

MAIN SWITCHBOARD

IGNITION

ELECTRODES

Legend

b blue br brown y/g yellow/green r red p pink or orange t transparent bl black gr grey w white

y/g

bbr

y/g

p p

CONTROL BOX

DIVERTER

VALVE

NTC

TANK

TEMPERATURE

SENSOR

plug in

connector

plus / minus buttons

reset button

info button

Hot water demand indicator

vi violet

NTC

DHW

TEMPERATURE

SENSOR

DHW

PUMP

b br y/g

Central heating demand indicator

r bl

b gr

Fig. 11.1: Functional Flow diagram VUI 362-7

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11 Diagrams

Instructions for installation and servicing aquaPLUS VUI 362-750

Switch gear cabinet

U100

T 2

T 1,25

= F3

24 23

11213

Aqua

sensor

NTC

air pressure

switch

NTC

tank

earth

ionisation

electrode

NTC

coding resistor

flow

NTC

return

lifting

magnet

24 23

11213

fan unit

ignition electrodes

gas valvediverter valveair pressure switch

NTC tank

ionisation

electrode

pump

Aqua sensor

NTC

flow

NTC

return

EV1

EV2

X8X4 (VUV)

X12

X14 X13

79L 48N35

X7 accessories

NTC DHW

X601

DHW pump

NTC DHW

X20

Fig. 11.2: Wiring diagram aquaPLUS

11.2 Wiring diagram: aquaPLUS VUI 362/7

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Short parts list 12

Instructions for installation and servicing aquaPLUS VUI 362-7 51

Table 12.1: Short parts list

* For these components, please observe the associated installation and removal instructions relating to spare parts.

12 Short parts list

Description Part No. Key No.

Burner Burner chamber group: 031 532 Fig. 10.1

Distributor tube: Natural gas: 126 795 LPG: 126 796

Ignition electrode 090 709 Fig. 10.2

Fan 190 215 Fig. 10.3

Gas valve Natural gas: 053 462 Fig. 10.5

LPG: 053 463

Flow-NTC/Return-NTC Storage tank-NTC 252 805 Fig. 10.6 Warmstart-NTC

Main heat exchanger 065 087 Fig. 10.7

Expansion vessel (10 l) 181 079 Fig. 10.8 (heating)

Switch and control board 130 821 Fig. 10.9

Main transformer 287 450 Fig. 10.10

Pump 160 928 Fig. 10.11

Air pressure switch 050 577 Fig. 10.12

Automatic bypass 150 246 Fig. 10.13

Diverter valve 252 457 Fig. 10.14

Pressure gauge 101 271 Fig. 10.15

Aqua sensor 194 819 Fig. 10.16

DHW heat exchanger 064 724 Fig. 10.17

Pressure relief valve 190 732 Fig. 10.18 (heating)

Pressure relief valve 190 745 Fig. 10.19 (DHW)

DHW pump* 255 031 (Motor incl. impeller) Fig. 10.20

092 001 (Impeller housing

incl. check valve)

DHW expansion vessel (1,0 l)* 181 081 Fig. 10.21

Hot water store 15 l content: 064 072 Fig. 10.22

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12 Short parts list

52 Instructions for installation and servicing aquaPLUS VUI 362-7

Fig. 10.1 Fig. 10.2 Fig. 10.3

Fig. 10.5 Fig. 10.6 Fig. 10.7

Fig. 10.8 Fig. 10.9 Fig. 10.10

Fig. 10.11 Fig. 10.12 Fig. 10.13

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Short parts list 12

53Instructions for installation and servicing aquaPLUS VUI 362-7

Fig. 10.14 Fig. 10.15 Fig. 10.16

Fig. 10.17 Fig. 10.18 Fig. 10.19

Fig. 10.20 Fig. 10.22

* *

* For these components, please observe the associated

installation and removal instructions relating to spare parts.

Fig. 10.21

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Instructions for installation and servicing aquaPLUS VUI 362-754

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Instructions for installation and servicing aquaPLUS VUI 362-7 55

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83 47 02_30_GB 04/2003 Mü Subject to alteration

Head Office: Vaillant Ltd.

Service Solutions 0870 6060 777

Vaillant House

Trident CloseMedway City Estate

Rochester

Kent ME2 4EZ

Technical Advice 01634 292392

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VUI 362-7

For the user

Instructions for use

aquaPLUS

Gas fired room sealed fan assisted combination boiler with integrated 15 litre power store

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page

Information to the documentation . . . . . . . . . . . . 2

Attachment and safe storage of the documentation 2

Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 General information . . . . . . . . . . . . . . . . . . . . . . 3

1.1 For your information . . . . . . . . . . . . . . . . . . . . . 3

1.2 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Specified use . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.4 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 Factory Guarantee . . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Setup and adjustments . . . . . . . . . . . . . . . . . . 4

2.1.2 If you smell gas . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.3 Modifications in and around the boiler . . . . . . 4

2.1.4 Explosive and flammable materials . . . . . . . . . 4

2.1.5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 General precautions . . . . . . . . . . . . . . . . . . . . . 4

2.2.1 Corrosion protection . . . . . . . . . . . . . . . . . . . . . 4

2.3 Showers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1.1 Operating controls . . . . . . . . . . . . . . . . . . . . . . . 5

3.1.2 Boiler display . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Initial checks before turning ON . . . . . . . . . . . 6

3.2.1 Open the service valves . . . . . . . . . . . . . . . . . . 6

3.2.2 Check the water contents . . . . . . . . . . . . . . . . . 6

3.3 Domestic hot water operation . . . . . . . . . . . . . 6

3.3.1 Power store operation . . . . . . . . . . . . . . . . . . . 7

3.3.2 Obtaining hot water . . . . . . . . . . . . . . . . . . . . . . 7

3.4 Heating operation . . . . . . . . . . . . . . . . . . . . . . . 8

3.4.1 Setting the maximum radiator

temperature control . . . . . . . . . . . . . . . . . . . . . 8

3.4.2 Setting the external controls . . . . . . . . . . . . . . 8

3.5 Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.6 Resetting the appliance . . . . . . . . . . . . . . . . . . . 9

3.6.1 Faults in the hot water system . . . . . . . . . . . . . 10

3.7 Turning the boiler OFF . . . . . . . . . . . . . . . . . . . 10

3.7.1 To turn OFF the central heating only

(Summer mode) . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.7.2 To turn OFF central heating and hot water

for short periods of time . . . . . . . . . . . . . . . . . . 11

3.8 Care and maintenance . . . . . . . . . . . . . . . . . . . 11

3.9 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table of contents Information to the documentation

Instructions for use aquaPLUS

Important note! This symbol is used to indicate a possibly dangerous situation for the product and the

environment!

Note! Useful information and guidelines.

• This symbol is used to indicate a required step.

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General information 1

3Instructions for use aquaPLUS

1 General information

1.1 For your information

Thank you for choosing a Vaillant boiler. The information given in this booklet will enable you to obtain the best performance from your boiler. aquaPLUS provides both central heating and domestic hot water, with the domestic hot water supplied directly from the boiler. The boiler will operate automatically to provide domestic hot water whenever a hot water tap is opened, and automatically adjusts to meet the demand for both central heating and domestic hot water in the most economical way. If, after reading these instructions, you have any questions on the operation of the boiler, please contact either your installer or Vaillant Technical Department.

1.2 Liability

Warning! We can accept no liability whatsoever for damage or injury resulting from failure to observe these instructions.

1.3 Specified use

Vaillant aquaPLUS boilers are made to fulfil the latest technical specifications and official safety regulations. These appliances are designed as boilers for use in central heating and hot water supply systems. If the appliances are used for purposes other than or in excess of these specifications, this shall be classed as incorrect operation, and neither the manufacturer nor supplier will accept any liability for resulting damage or injury. Use of this type is entirely at the owner’s risk. The term "specified use" also covers observance of the operating and installation instructions, along with adherence to the servicing schedules. The benchmark logbook should be completed by the installer and/or the commissioning engineer and handed to the user. All CORGI registered installers carry a CORGI ID card and have a registration number. Both should be recorded in your Benchmark Log Book. You can check your installer by calling CORGI direct on 01256 372300.

1.4 EC designation

The purpose of EC designation is to certify that the boiler complies with the requirements of the directives covering gas-fired appliances (Council directive 90/396/EEC) and electromagnetic compatibility (Council directive 89/336/EEC). These appliances also comply with the requirements of the directive on operating efficiency (Council directive 92/42/EEC).

1.5 Factory Guarantee

Our confidence in the quality of craftmenship and performance of our products is demonstrated by the Vaillant two year guarantee. During the first year from installation the guarantee covers your boiler against manufacturing defects for both parts and labour. In order to extend this guarantee to the second year from installation all you have to do is ensure that your boiler receives a service when it is a year old. (Please note that the cost of the service is not included in the guarantee).

Important To qualify for the your two year guarantee:

The boiler must be serviced either by Vaillant Ltd or another competent servicing company (CORGI registered) within one year of the installation date and the details recorded in the "Installation, Commissioning and Service Record Log Book" (this log book should have been completed by the installer and left with you). Please note that the cost of the service is not included in the guarantee.

Registering with us

Registaration is simple. Just complete the Guarantee Registration Card and return to Vaillant within 30 days of installation. Your details will then be automatically registered within the Vaillant scheme. Note: No receipt will be issued.

Immediate help

If your Vaillant boiler develops a fault your first action should be to contact your installer, as his professional assessment is needed under the terms of our Guarantee. If you are unable to contact your installer, phone Vaillant Service Solutions: 0870 6060 777.

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2 Safety

Instructions for use aquaPLUS 4

2.2 General precautions

2.2.1 Corrosion protection

DO NOT use aerosol sprays, solvents, chlorine-based cleaning products, paints, adhesives, etc. in the vicinity of the unit. The use of these items can, under certain circumstances, also result in corrosion damage to the flue outlet system.

2.3 Showers

Only thermostatically controlled showers must be used with aquaPLUS boilers to guard against the flow of water at too high a temperature and to ensure constant shower outlet water temperatures.

Warning! The appliance is equipped with an automatic

protection function against legionella. If the temperature in the power store falls below a set temperature for more than 23 hours the boiler will operate automatically to thermally disinfect the store.

Important note! After completion of the thermal disinfection process there is a possible risk of scalding when drawing off hot water. Hot water temperatures of up to 65 °C are possible immediately from the tap.

2 Safety

2.1 Safety instructions

2.1.1 Setup and adjustments

Installation and adjustment of the boiler as well as service maintenance and repair of the boiler may only be carried out by a competent person in accordance with the Gas Safety (Installation and Use) Regulations

1998. (In the U.K. "CORGI" Registered installers undertake the work to a safe and satisfactory standard). If the boiler is installed in a compartment do not obstruct any purpose provided ventilation openings, and do not use the compartment for storage purposes.

2.1.2 If you smell gas

If you smell gas or suspect a gas leak:

• Turn off the boiler

• Do not switch the light or any electrical switches in the hazardous area on or off, do not use the telephone in the hazardous area, avoid sparking, such as lighting the lighter or matches

• Do not smoke in the hazardous area

• Turn off the gas supply at the gas meter

• Ventilate the room

• Warn the other occupants and leave the house

• Consult your gas supplier, service agent or other competent person.

2.1.3 Modifications in and around the boiler

No modifications may be made to the following items:

• The boiler

• The gas, water and electrical supply

• The flue system

• The safety valve for the heating water

• Any structural changes around the appliance that could affect the operational safety of the boiler.

2.1.4 Explosive and flammable materials

Do not use or store any explosive or highly flammable materials (e.g. gasoline, paper or paint) near to the appliance.

2.1.5 Inspection

The boiler should be serviced annually. We recommend that you sign a service agreement with your service agent or Vaillant Ltd.

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Operation 3

Instructions for use aquaPLUS 5

3.1.2 Boiler display

aquaPLUS boilers have an advanced multifunction boiler display. When the main ON/OFF control is in the "ON" position the display will normally show the temperature of water in the boiler circuit (50° C in the example), which confirms that the boiler is functioning correctly. The display supplies the following information:

1 Fan speed malfunction 2 Heating demand 3 Hot-water demand 4 Power store on (Comfort mode) 5 Pump on 6 Gas valve on 7 Actual Heating-system flow temperature (e.g. 50 °C)

or Displaying of a status/error code

8 Correct burner operation (normal flame) or

lock out (crossed-out flame)

Fig. 3.2: Display indications

VRC-VC

1237654

3 Operation

3.1 Overview

3.1.1 Operating controls

For access to the controls pull the side edges of the lower front panel and drop it down. The following can be seen:

1 Maximum radiator temperature control 2 The "+" and "-" buttons for the display panel 3 Main ON/OFF control 4 Pressure gauge displaying the pressure in the heating

system

5 Built in control/timer module (if fitted) 6 The "i" information button 7 Boiler display 8 "Reset" button 9 Maximum hot water temperature control and

warmstart ON/OFF control

Fig. 3.1: Operating elements

32 4

VRC-VC

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3 Operation

Instructions for use aquaPLUS 6

Fig. 3.4: Checking the water level

3.3 Domestic hot water operation

Warning! The boiler should only be used when the heating system contains water. Use of the boiler without water may cause damage to the boiler or its components.

Setting the maximum domestic hot water temperature control

• Turn the main switch (2, Fig. 3.5) to the "l" position.

• The domestic hot water temperature can be adjusted using the hot water temperature control (3, Fig. 3.5).

• Turn the control clockwise to increase the temperature and anti-clockwise to decrease the temperature.

As a guide for normal circumstances set the knob to the one o´clock position.

Note! This control adjusts the maximum domestic hot water temperature. If adjusting the control upwards appears to have no effect on the temperature, then the boiler is already operating at full output for the selected flow rate.

Warning! If you live in a hard water area please do not set the control knob above the mid (12 o'clock) position to prevent excessive scale formation (fig. 3.5).

VRC-VC

3.2 Initial checks before turning ON

3.2.1 Open the service valves

• Ensure the cold water service valve is open. This can be checked by opening a hot water tap and ensuring water flows.

• Ensure that the service valves in the heating flow and return (2 and 1) and the gas service valve (3) are open.

Note! The flow, return and gas service valves are open when the line marking has the same direction as the pipe.

• The pressure relief valves (4) are provided for safety reasons and must not be interfered with.

Note! A bottom cover is fitted to the appliance. The service valves can be seen through the cover.

Fig. 3.3: Opening service valves

3.2.2 Check the water contents

• Check the water contents of the system on the pressure gauge (1).

The needle on the pressure gauge (1) should be within the green band (between 1 and 1.5 bar). If the needle displays a value below 0.75 bar when the appliance is cold, follow the instructions left by your installer to refill the system. Alternatively, your installer should be called to refill the system.

2 3 1 4

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Operation 3

Instructions for use aquaPLUS 7

Fig. 3.5: Domestic hot water supply

3.3.1 Power store operation

The integral 15 litre stainless steel power store provides instantaneous delivery of domestic hot water from the aquaPLUS boiler. When the power store is switched ON the boiler will automatically light periodically to maintain the internal temperature of the store. When the power store is switched OFF a short delay may be experienced in obtaining hot water at the tap.

Note! The power store is factory set off.

• The power store is activated by turning the hot water temperature control knob (1) all the way to the very right for a short time. Reset the hot water temperature control knob to the desired setting. The symbol "C" (comfort) appears in the display and shows that the power store is activated. The boiler will now provide instantaneous delivery of hot water directly when a hot water tap is turned on.

• The power store is switched off by momentarily turning the knob (1) to the left, as far as the stop. The "C" symbol no longer appears in the display. Reset the hot water temperature control knob to the desired setting.

Note! Irrespective of whether the power store facility is switched on or off, the boiler will automatically operate to provide hot water whenever a hot water tap is opened.

VRC-VC

Fig. 3.6: Switching the power store on and off

3.3.2 Obtaining hot water

When you open a hot water tap (1) at a draw-off point (wash basin, shower, bath etc.), the appliance supplies you with the hot water you require. When a certain volume of water has been drawn off, the appliance is brought into operation automatically and the power store is re-filled (in some circumstances, the appliance may operate only after the water has been drawn off).

Warning! The appliance is equipped with an automatic protection function against legionella. If the temperature in the power store falls below a set temperature for more than 23 hours the boiler will operate automatically to thermally disinfect the store.

Fig. 3.7: Drawing off hot water

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3 Operation

Instructions for use aquaPLUS 8

3.4.2 Setting the external controls

• Set the room thermostat (3, accessory) and/or the thermostatic radiator valves (4, accessory) according to the instructions supplied with the control(s).

Note! Vaillant offer room thermostat/ time control accessories which give accurate and economic room temperature control as well as improved comfort. Ask your installer!

The boiler will now operate automatically to provide central heating for the conditions selected on the external controls and also provide domestic hot water on demand). Whilst the boiler is operating, the boiler display (7, fig.

3.2) indicates the temperature of the water within the

boiler circuit. After the boiler stops operating the pump and fan will continue to operate for a short period to fully disperse the heat from the boiler.

Note! The boiler incorporates an anti-cycling economiser control to prevent energy wasteful ON and OFF operation of the boiler for short periods when in the central heating mode. When turning the room thermostat to a higher setting there may therefore be a short delay before the boiler operates.

Fig. 3.9: Setting the external controller

3.4 Heating operation

3.4.1 Setting the maximum radiator temperature ^ control

• Turn the main switch (1) to the "l" position.

• Set the maximum radiator temperature control to the

desired setting using the control knob (2). We recommend the following settings:

- Left setting during spring and autumn (turning the

control knob all the way to the very left switches OFF heating),

- Middle setting during mild winter,

- Right setting during cold winter.

Fig. 3.8: Setting the flow temperature

VRC-VC

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3.5 Status display

(For maintenance and service work performed by your installer or service agent)

The status displays are activated by pressing the "i" button (1). The current status code, e.g. "S.34" for the frost protection mode, is shown on the display (2, fig.

3.10).

Pressing the "i" button again will switch you back to the normal mode. The "+" and "-" buttons will only be used by your installer or service agent during service and maintenance work.

Fig. 3.10: Status displays

Table 3.1: Status displays (A complete overview of the status codes can be found in the installation instructions). * Heating operation, ** Hot water operation

VRC-VC

Operation 3

Instructions for use aquaPLUS 9

3.6 Resetting the appliance

When a hot water tap or the central heating system requires heat, the boiler automatically ignites and starts to operate. If the automatic ignition is not successful within 10 seconds, then the boiler does not go into operation and switches to "Lock out". This is indicated visually by the crossed out flame in the display and the displaying of fault code "F.28" or "F.29" (flame extinguished during operation). A new attempt to ignite the flame can then only be performed after pressing the "Reset" button.

• Press the "Reset" button (2, fig.3.11) and hold for approx. 1 second.

Warning! If the boiler still shuts off after a third attempt, then please consult your installer or Vaillant Service Solutions.

The boiler also switches to "Fault" when there is not enough water in the system. This fault is indicated by fault codes "F.22", "F.23" or "F.24". The boiler must only be placed back in operation after the heating system has been properly refilled with water. In the unlikely event of any other fault developing, which prevents the boiler from operating, the display will also show other fault codes. If a fault code is displayed please contact your installer or Vaillant Service Solutions.

Note! If contacting Vaillant Service Solutions please remember to quote the fault code, as this will help to pinpoint the fault.

Fig. 3.11: Reset

VRC-VC

Display Meaning

S.00* No heating demand S.02* Pump running S.03* Ignition sequence S.04* Burner ignited S.05* Fan and water pump over run S.07* Water pump over run S.08* Anti cycling mode (after heating operation) S.10** Hot water demand S.20** Power store cycle mode active S.28** Anti cycling mode (after power store filling) S.34* Frost protection mode active

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3 Operation

Instructions for use aquaPLUS 10

3.7 Turning the boiler OFF

3.7.1 To turn OFF the central heating only (Summer

mode)

• Turn the maximum radiator temperature control knob

used to control the heating supply temperature (1) all the way to the left.

Note! You can switch off the heating operation in summer, for example, but the boiler will continue to provide domestic hot water whenever a hot water tap is opened.

Fig. 3.13: Setting the summer operating mode

VRC-VC

Fig. 3.12: Reset

3.6.1 Faults in the hot water system

To protect the power store feed pump, the appliance is equipped with dry-running protection. This prevents operation of the feed pump if an insufficient quantity of water is available in the appliance. If dry-running protection is activated, reset the appliance as follows:

• Press the "Clear fault" button (see 2, illustration 3.12) and hold it down for approx. 1 sec. or, alternatively, switch the appliance main switch "OFF" and "ON" again.

If the boiler still shuts off after a third attempt, please consult your installer or Vaillant Service Solutions.

VRC-VC

STOP

max. 3 x

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Operation 3

Instructions for use aquaPLUS 11

3.7.2 To turn OFF central heating and hot water for short periods of time

• Turn the main ON/OFF control (2) to the "0" position.

Note! If you want to turn the aquaPLUS boiler OFF for a longer period of time (e.g. holidays), and there is no danger of frost, then you should also turn off the gas supply, the cold water service valve and the electrical supply. Please note the frost protection hints in this regard.

Fig. 3.14: Shutting down the unit completely

3.8 Care and maintenance

Clean the outer casing of your boiler with a damp cloth and a little soap. Do not use abrasive or solvent cleaning agents that may damage the case or the plastic fittings. The appliance should be serviced at least once per year. To ensure regular servicing, it is strongly recommended that arrangements are made with your service agent or Vaillant Ltd. For further details please contact Vaillant Service Solutions: (0870 6060777).

3.9 Frost protection

Your boiler is equipped with a frost protection function: If the heating water temperature drops below 5 °C when the main switch is ON, then the boiler goes into operation and heats the boiler circuit to approx. 30 °C.

Warning! It cannot be guaranteed that water will circulate throughout the entire heating system.

VRC-VC

If the boiler is not operated for several hours during very cold weather there is therefore the possibility of the system freezing. Please ensure that if you are absent during a period of frost the central heating remains in operation and all rooms are kept above freezing point. It must be remembered, however, that the boiler will be automatically switched off by the built in monitoring devices if certain faults occur, e.g. interruption in the gas or electricity supply or faults in the flue gas system. To overcome this possibility you can drain both the central heating system and boiler.

Warning! Frost protection and monitoring devices can only function when the main switch of the unit is set to the "I" position and the boiler is connected to the electrical supply.

3.10 Troubleshooting

In the unlikely event that a problem occurs with the operation of the aquaPLUS boiler, the following points should be checked:

Boiler fails to operate:

• Is the gas supply turned on?

• Is the water supply turned on?

• Is there enough water in the heating system?

• Is the electrical supply switched on?

• Is the main ON/OFF control in the "On" position? (switch position "I")

• Dry-running protection activated?

• Is the burner lock out indicator illuminated?

Hot water operates but no central heating

• Is the heating turned on?

• Are all external heating controls ON?

Warning! If your boiler still does not operate then please consult your installer or Vaillant Service Solutions (0870 6060 777).

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83 46 41_10_GB 04/2003 Mü Subject to alteration

Head Office: Vaillant Ltd.

Service Solutions 0870 6060 777

Vaillant House

Trident CloseMedway City Estate

Rochester

Kent ME2 4EZ

Technical Advice 01634 292392

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Vaillant aquaPlus, aquaPLUS VUI 362-7, AQUAPLUS SERIES Instructions For Installation And Servicing

Specifications and Main Features

Frequently Asked Questions

User Manual