Vaillant ecoMAX 635 Instructions For Installation And Servicing
For the installer
ecoMAX 635
GB
Instructions for installation and servicing
ecoMAX
Wall hung room sealed fan assisted condensing boilers
2
Table of contents
Instructions for installation and servicing ecoMAX2
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Boiler specification . . . . . . . . . . . . . . . . . . . 5
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Boiler connections . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Functional diagram . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Identification plate . . . . . . . . . . . . . . . . . . . . . . . 7
3 General requirements . . . . . . . . . . . . . . . . . 8
3.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . 8
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Contents included with boiler . . . . . . . . . . . . . . 8
3.4 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8.1 Cupboard or compartment ventilation . . . . . . 10
3.9 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Guide to system requirements . . . . . . . . . . . . . 10
3.10.1 Water circulation system . . . . . . . . . . . . . . . . . . 10
3.10.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . . 11
3.10.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 11
3.10.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 11
3.11 Pump specifications . . . . . . . . . . . . . . . . . . . . . 11
3.11.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 11
3.11.2 System by–pass . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.11.3 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.12 Condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Boiler installation sequence . . . . . . . . . . . . 12
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.1 Select position of boiler . . . . . . . . . . . . . . . . . . 12
4.1.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.3 Using boiler template . . . . . . . . . . . . . . . . . . . . 12
4.2 Rear flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Other flue options . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Fitting the boiler hanging bracket . . . . . . . . . . 13
4.5 Install the flue system . . . . . . . . . . . . . . . . . . . . 13
4.6 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7 Removing the front case . . . . . . . . . . . . . . . . . . 13
4.8 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.9 Central heating flow and return pipework . . . 14
4.10 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . 14
4.11 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . 15
4.12 Connection to a uniSTOR cylinder . . . . . . . . . 16
4.13 Connect the flue system to the boiler . . . . . . . 16
4.14 Electrical installation . . . . . . . . . . . . . . . . . . . . . 16
4.14.1 General requirements . . . . . . . . . . . . . . . . . . . . 16
4.14.2 Connection to the main supply . . . . . . . . . . . . 16
4.14.3 Electronic board layout . . . . . . . . . . . . . . . . . . . 17
4.14.4 Connection details for programmable
thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.15 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.15.1 External electrical controls . . . . . . . . . . . . . . . . 19
4.15.2 Connection of external electrical controls . . . 19
4.15.3 Connection details using an external
wiring centre . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.16 Thermostatic radiator valves . . . . . . . . . . . . . . 20
4.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 20
4.19 Anti–cycling ‘economiser’ control . . . . . . . . . . 20
4.20 Automatic pump spin control (APS) . . . . . . . . 20
5 Commissioning part I . . . . . . . . . . . . . . . . . 23
5.1 Preliminary electrical checks . . . . . . . . . . . . . . 23
5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Initial system flush (”Cold”) . . . . . . . . . . . . . . . 23
5.4 Filling the heating system . . . . . . . . . . . . . . . . . 23
5.5 Initial system flush (”Cold”) . . . . . . . . . . . . . . . 23
5.6 Filling condensate trap . . . . . . . . . . . . . . . . . . . 23
5.7 Adjusting pump speed . . . . . . . . . . . . . . . . . . . . 23
5.8 Checking the gas supply settings . . . . . . . . . . . 24
5.8.1 Factory–adjusted gas settings . . . . . . . . . . . . . 24
5.8.2 Gas inlet working pressure . . . . . . . . . . . . . . . . 24
5.8.3 Check gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.9 Refitting the case . . . . . . . . . . . . . . . . . . . . . . . . 25
5.10 Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Functional checks (commissioning part II) . 26
6.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.2 Heating system . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.3 Final system flush (”Hot”) . . . . . . . . . . . . . . . . . 27
6.1.4 Handing over to the user . . . . . . . . . . . . . . . . . 27
7 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Inspection and maintenance . . . . . . . . . . . . . . . 28
7.2 Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.1 Removing the compact thermal module . . . . . 28
7.2.2 Inspect main heat exchanger . . . . . . . . . . . . . . 29
7.2.3 Inspect burner . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.4 Refitting the compact thermal module . . . . . . 30
7.2.5 Cleaning the condensate trap . . . . . . . . . . . . . 30
7.2.6 Check expansion vessel . . . . . . . . . . . . . . . . . . . 30
7.3 Recommissioning the boiler . . . . . . . . . . . . . . . 30
7.4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Logical fault finding procedure . . . . . . . . . . . . 32
8.1.1 Status mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.2 Diagnosis mode . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 Parts replacement . . . . . . . . . . . . . . . . . . . 36
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . 36
9.1.1 Initial preparation . . . . . . . . . . . . . . . . . . . . . . . 36
9.1.2 Removal of burner assembly . . . . . . . . . . . . . . 36
9.2 Replacement of burner . . . . . . . . . . . . . . . . . . . 36
3
Table of contents
Instructions for installation and servicing ecoMAX 3
9.3 Replacement of fan . . . . . . . . . . . . . . . . . . . . . . 36
9.4 Replacement of gas valve . . . . . . . . . . . . . . . . . 36
9.5 Replacement of central heating
expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 37
9.6 Replacement of main heat exchanger . . . . . . . 38
9.7 Replacement of the electronic control board . 38
9.8 Check CO
2
content and adjust if necessary
(air–ratio adjustment) . . . . . . . . . . . . . . . . . . . . 38
10 Recycling and eventual scrapping . . . . . . . . 40
10.1 The appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Benchmark gas boiler commissioning checklist . . 41
4
1 Introduction
Instructions for installation and servicing ecoMAX4
1 Introduction
1.1 Introduction
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.
ecoMAX 635
The ecoMAX 635 is a fully automatic, wall mounted,
room sealed condensing (high efficiency) system boiler
for central heating and domestic hot water (where a
separate indirect hot water storage cylinder is also
incorporated in the system). The ecoMAX 635 boiler is
available in Natural Gas.
1.2 General Notes
The boiler has been designed for use with a sealed central heating system, and comes fully tested and assembled with a built in circulating pump and expansion vessel.
The boiler is easily sited on any internal wall and can be
installed with either a horizontal or vertical RSF (room
sealed fan assisted) flue.
The boiler uses a standard flue system (125 mm outside
diameter) which allows flue lengths up to 21 m. Flue
extensions and additional bends and elbows are available for the flue system to increase the siting flexibility. 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. The data badge is fitted to the underside of the
boiler. See text of General Requirements for installation
requirements or notes.
1.3 EC designation
ecoMAX 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!
Vaillant Ltd. support the Benchmark initiative.
In the installation manual you will find the
Benchmark gas boiler commissioning checklist.
It is very important that this is completed
correctly at the time of installation and commissioning.
5
Boiler Specification 2
Instructions for installation and servicing ecoMAX 5
2 Boiler specification
2.1 Technical data
ecoMAX 635 Units
Maximum CH heat input (G 20) (net) 34.9 kW
Maximum CH heat input (G 31) (net) 34.9 kW
CH heat output range
80 °C flow/60 °C return 10.5 - 34.9 kW
50 °C flow/30 °C return 11.0 - 36.7 kW
SEDBUK A Band
SAP Seasonal Efficiency 91.2 %
Inlet gas working pressure required
(natural gas) 20 mbar
Inlet gas working pressure required
(Propane) 37 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 MJ/m
3
Gas supply (G31) Gross CV (s.t.) 95.65 MJ/m
3
Gas rate (natural gas) max. 3.7 m3/h
Gas rate (Propane) max. 2.7 kg/h
CH temperature flow range 30 - 85 °C
Minimum CH water flow (for 20 °C rise) 1480 l/h
Pump pressure available 0.25 bar
10l expansion vessel pre–charge pressure 0.75 bar
Maximum CH system pressure 2.5 bar
Connections heating flow/return 22 mm
Gas inlet 15 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
Weight 41 kg
Primary water content 2,2 l
Volume of condensate (max.) 3,3 l/h
Maximum flue gas temperature 70 °C
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 4 A
Internal fuse (slow) low voltage 4 A
Power input 115 W
6
2 Boiler Specification
Instructions for installation and servicing ecoMAX6
2.2 Dimensions
Fig. 2.1
2 Hanging bracket
3 Heating–system return
5 Gas connection
7 Heating–system flow
2.3 Boiler connections
2.2 Boiler connections
2.4 Functional diagram
Fig. 2.3 Functional diagram ecoMAX 635
1 Air duct
2 Main heat exchanger
3 Burner
4 Condensate trap
5 Temperature sensor (NTC 1)
6 Temperature sensor (NTC 2)
7 Automatic air vent
8 Circulating pump
10 Automatic bypass valve
12 CH flow service valve
14 Gas service valve
16 CH return service valve
17 Pressure relief valve
20 Pressure gauge
21 Main ON/OFF control
22 Boiler display
23 Electronic box
24 Gas valve
25 Fan
26 Expansion vessel
27 Expansion vessel charging valve
28 Flue gas duct
28
27
26
2
4
5
6
7
8
10
12
3
1
25
24
22
23
21
20
17
16
14
Ø22
Ø22
25
33.5
100100
Ø 15
750
703
150
79
Ø15
113
190
480
800
2
100
450
7
Ø 20
100 100
Ø 20
5
3
7
Ø 20
20
R 1
/2
180
7
Boiler Specification 2
Instructions for installation and servicing ecoMAX 7
2.5 Design
Fig. 2.4 Functioning elements, ecoMAX 635 configuration
1 Expansion vessel
2 Air suction pipe
3 Burner assembly
4 Ignition electrode
8 Electronic box
9 Circulating pump
10 Gas valve assembly
11 Auto air vent
12 Main Heat exchanger
13 Air/flue gas duct
2.6 Identification plate
The identification plate of the Vaillant ecoMAX is supplied ready–attached to the bottom of the unit.
Fig. 2.5 Identification plate (example)
1
2
3
4
8
9
10
11
12
13
8
3 General requirements
Instructions for installation and servicing ecoMAX8
3 General requirements
3.1 Preliminary remarks for roomsealed appliances
This appliance should only be installed in conjunction
with either a Vaillant flue system or an alternative approved system (details of flue approval categories can be
found in the technical section of the installation manual).
Install the flue system as detailed in the separate flue installation instructions supplied with this boiler.
3.2 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
Fitting) Regulations 1999, or The Water Bylaws 2000
(Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Build-ing
Regulations, The Building Regulations (Scotland). The
Building Regulations (Northern Ireland) and the relevant
recommendations of the following British Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd 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 gas installations
in timber framed housing”
BS. 5482: Pt. 1 Domestic butane and propane gas burning installations.
IGE/UP1: Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2: Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP10: Installation of gas appliances in industrial
and commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.Part 1 Fundamental and
design considerations. Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using
an internal diaphragm, for sealed hot water heating
systems.
BS. 5440: Installation and maintenance of flues and
ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases). Part 1
Specification for installation of flues.Part 2 Specification
for installation and main-tenance of ventilation for gas
appliances.
Attention!
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 I.S.813 ‘Domestic Gas
Instal–lations’, the current Building Regulations
and reference should be made to the current
ETCI rules for electrical installation.
Attention!
When tightening or loosening screwed connec-
tions always use suitable open–ended spanners
(not pipe wrench, or extensions, etc.).
Incorrect use and/or unsuitable tools can lead to
damage being caused (e.g. gas or water leakage)!
3.3 Contents included with boiler
Ensure that all contents are included before commencing installation.
Fig. 3.1 Items supplied with unit
Do not remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Boiler
2 1 Hanging bracket
3 3 Installation and Servicing, Users and
Flue Installation Instructions
4 1 Installation and connection accessories
5 1 Guarantee Card
6 1 Template
7 4 Copper tails for gas and water pipework
8 3 Flow and return service valve, gas service
valve
9 1 Pressure relief valve
Table 3.1 Items supplied with unit
4
5
2
6
7
3 1
8
9
9
General requirements 3
Instructions for installation and servicing ecoMAX 9
3.4 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), the electrical
provisions of the Building Standards (Scotland)
Regula–tions, and in IE the current edition of IS813 and
the current ETCI rules, in respect of the installation of a
boiler in a room containing a bath or shower.
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.
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”.
3.5 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. In IE the current edition of IS 813. 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 (15 mm). The complete installation must
be tested for soundness and purged as described in
BS 6891.
3.6 Flue system
3.6.1 Optional 125 mm flue system
A concentric flue system of 125 mm outside diameter is
available and can be used to achieve flue lengths up to
21 m. A vertical flue system is also available. Refer to
flue system installation instructions for full details.
Fig. 3.2 Art.–No. 303 209
Fig. 3.3 Art.–No. 303 200
3.7 Flue termination
The following details refer to both flue systems.
a.The terminal must be positioned such that the produc-
ts of combustion can disperse freely at all times.
b.A plume of water vapour will sometimes 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 must be
provided and fitted (contact Tower Flue Components,
Tonbridge, TN9 1TB).
Fig. 3.4 Flue termination
Note!
Vertical flues must not terminate within 600 mm
of an openable window, air vent or any other
ventilation opening.
A
BCD
A
G
H, I
F
J
B
F
M
L
L
K
K
G
G
F
F
E
A
A
1530
880
70
70
1103
70
15
10
3 General requirements
Instructions for installation and servicing ecoMAX10
The flue assembly shall be so placed or sheilded as to
prevent ignition or damage to any pary of the building.
Terminal position mm
A Directly below an opening, above an opening or
horizontal to an opening, air brick, opening window, etc. 300
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent for vertical Flue 500
Table 3.2 Terminal position for a fan assisted concentric flue
Note!
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 the fanned flue terminal should be positioned as follows:
a) at least 2m from an opening in the building directly
opposite, and
b) so that the products of combustion are not directly
directed to discharge across a boundary.
1) Dimensions B, C and D:
These clearances may be reduced to 25 mm without
affecting the performance of the boiler. In order to
ensure that the condensate plume does not affect
adjacent surfaces the terminal should be extended as
shown in fig. 3.8.
2) Dimension F:
This clearance may be reduced to 25 mm without
affecting the performance of the boiler. However, in
order to ensure that the condensate plume does not
affect adjacent surfaces a clearance of 300 mm is pre
ferred. For IE, recommendations are given in the current edition of IS 813.
Fig. 3.5
3.8 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.
3.8.1 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. Compartment ventilation is required if the flue used in not concentric and air is supplied
from the room or compartment the boiler is installed in.
3.9 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.
3.10 Guide to system requirements
3.10.1 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.
Attention!
To prevent the formation of deposits and pre-
vent serious damage to the appliance and
system , cleansers must be used carefully and
must be completely removed by thoroughly
flushing the system. Cleansers should only be
left in systems for a maximum of 24 hours.
balcony/eaves
flue extended to
clear any overhang
flue adequately
supported
gutter
11
General requirements 3
Instructions for installation and servicing ecoMAX 11
This cleansing must 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 Sentinel,
Betz Dearborn Ltd. Widnes, Cheshire, WA8 8UD. Tel:
0151 495 1861, or Fernox, Alpha Fry Technologies, Tandem
House, Marlow Way, Croydon, CR0 4XS. Tel 0870 6015000
3.10.2 Filling and make up
The system can be filled via a separate filling point fitted at a convinient position on the heating circuit. 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).
3.10.3 Pressure relief valve
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.
3.10.4 Pressure gauge
This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing.
3.10.5 Expansion vessel
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
those given above, multiply the
system volume by the factor across 0.109 0.156
Table 3.3 Sizing of additional expansion vessel
ecoMAX 635 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 3.3.
3.11 Pump specifications
3.11.1 Circulating pump
The ecoMAX 635 is fitted with a modulating circulating
pump. The pump head available for the heating system
is shown in figure 3.6.
Fig. 3.6 Pump specifications
3.11.2 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.
3.11.3 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.
3.12 Condensate trap
The boiler is fitted with a condensate trap incorporating
a water trap of 75 mm.
400
300
200
100
0
0 200 400 600 800 1000 1200 1600
Lift
[
mbar
]
1800
Volumeflow [l/h
]
1900
1400
100 %
53 %
60 %
70 %
85 %
12
4 Boiler installation sequence
Instructions for installation and servicing ecoMAX12
4 Boiler installation sequence
4.1 General
Fig. 4.1
The boiler should be mounted on a flat and vertical area
of wall of sufficient area for the boiler plus the required
clearances for installation and servicing (fig. 3.8). These
are shown on the installation template supplied with the
boiler and are:
– 5 mm either side of the boiler
– 145 mm below the boiler
– 205 mm* above the boiler when utilising the 100 mm
outside diameter flue
– 220 mm* above the boiler when utilising the 125 mm
outside diameter flue
– 500 mm in front of the boiler**
Note!
If the boiler is to be fitted in a timber framed
building, it should be fitted in accordance with
British Gas publication DM2 ‘Guide for gas
installations in timber framed housing’.
4.1.1 Select position of boiler
Refer to section ‘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 these instructions
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 valve and condensate drain.
** This clearance is only required to enable easier access to the boiler for
servicing and may be provided by an openable door, etc.
4.1.2 Unpack the boiler
To unpack the boiler, cut both plastic carton straps, open
box and lift out the polystyrene top packing. Lift the
cardbox box upwards.
Note!
Care should be taken not to scratch the white
surface of the boiler casing.
Packed in the boiler carton are the following:
• Boiler
• Flow and return central heating service valves
• Gas service valve
• Pressure relief valve
• Pre–formed copper pipework (for central heating flow
and return, gas and pressure relief valve connections)
• Boiler installation template
• Boiler hanging bracket
• Fixing screws, wall plugs and washers
• Installation and user instructions
• Flue installation instructions
• Guarantee card and envelope
4.1.3 Using boiler template
Fix the paper template to the wall ensure that the
template is vertical.
The template shows:
– The position of the fixing holes for the boiler
mounting bracket (1).
– The position of the connections.
– The position of the flue exit hole.
Mark the position of the hanging bracket fixing holes (1).
Drill 2 holes Ø 8 mm for the hanging bracket.
Note!
Use alternative fixing holes where necessary.
4.2 Rear flue exit
Mark the position of the air/flue duct and its circumference.
4.3 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.
min
min 5
min 5
min 500**
min 145
205/220*
Fig. 4.2 Using Boiler template
4.4 Fitting the boiler hanging bracket
Fix the hanging bracket (2) to the wall using the screws
supplied. (it may be necessary to use additional or
alternative fixings to ensure adequate support).
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.
Fig. 4.3 Fitting the boiler
4.5 Install the flue system
Install the flue system (refer to separate air/flue duct
installation instructions)
4.6 Fitting the boiler
• Lift the boiler (3) up to the wall so that it is slightly
above the hanging bracket (1).
Note!
Lift the boiler from either side at the bottom
edge.
• Lower the boiler slowly onto the hanging bracket so
that the cross member at the rear of the boiler fully
engages onto the hanging bracket.
4.7 Removing the front case
To remove the front section of the case,
proceed as follows:
• Loosen the screw (1) on the bottom of the unit.
• Push in the two retaining clips (2) on the bottom of
the appliance until the case is released.
• Grasp the front case (3) by its bottom edge, pull it
towards the front and remove it by lifting it off the
unit.
85
50
240
75
75
23
50
3
1
2
Boiler casing
Minimum
Clearances
Reqd.
Flow
Gas in Return
Condensate
discharge
Minimum Clearances
Reqd.
Fixing holes and
Position for
optional
pre-instalation
connection
Flue hole
(80/125 mm
flue system)
Please use
the new
Boiler hanging
bracket
ecoMAX 635
13
Boiler installation sequence 4
Instructions for installation and servicing ecoMAX 13
14
3 General requirements
Instructions for installation and servicing ecoMAX14
Fig. 4.4 Removing/Refitting the case
4.8 Gas supply
Fig. 4.5 Fitting the gas connection
• Connect the compression gas service cock and 15 mm
copper outlet tail as supplied with the appliance and
tighten.
• Connect a gas supply pipe of not less than 15 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).
4.9 Central heating flow and return pipework
Fig. 4.6 Central heating flow and return pipework
Before connecting the heating circuit to the boiler, all
pipework and radiators must be thoroughly flushed to
remove any installation debris.
• Connect the central heating flow and return service
valves to the appliance.
• 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 and
return tails.
Two additional tubes are supplied with the appliance for
top connection of the flow and return pipework within
the casing.
4.10 Pressure Relief Valve
A pressure relief valve is provided within the boiler cardboard box and should be assembled as shown below.
Connect a discharge pipe not less than 15 mm diameter
to the outlet of this valve.
The discharge pipework should be as short as possible
and installed with a continuous fall away from the boiler.
The pipe should terminate in a position which ensures
that any discharge of water or steam from the valve 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 clearly
visible.
1
2
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