Vaillant ecoMAX 635 Instructions For Installation And Servicing

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Page 1

For the installer

ecoMAX 635

Instructions for installation and servicing

ecoMAX

Wall hung room sealed fan assisted condensing boilers

Page 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

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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

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

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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.

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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

Gas supply (G31) Gross CV (s.t.) 95.65 MJ/m

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

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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

5 6

16 14

Ø22

33.5

100100

Ø 15

750

703

150

Ø15

113

190

480

800

100

450

Ø 20

100 100

Ø 20

R 1

180

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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)

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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

3 1

Page 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.

BCD

A G

H, I

1530

880

1103

Page 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

Page 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

0 200 400 600 800 1000 1200 1600

Lift

[

mbar

]

1800

Volumeflow [l/h

]

1900

1400

100 %

53 %

60 %

70 %

85 %

Page 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 500**

min 145

205/220*

Page 13

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.

240

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

Boiler installation sequence 4

Instructions for installation and servicing ecoMAX 13

Page 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.

Page 15

General requirements 3

Instructions for installation and servicing ecoMAX 15

Fig. 4.7 Fitting the pressure relief valve

4.11 Condensate drain (fig. 4.8)

Fig. 4.8

Connect the boiler condensate drain (1) to the condensate discharge pipe (2) the condensate discharge pipe should be minimum of 19mm internal diameter (22mm external diameter for any pipework installed external to the property) and be made of an acid resistant material (e.g. plastic overflow pipe). The discharge pipe from the boiler condensate drain must have a continuous fall (45mm per metre) and preferably be installed and terminated within the building to prevent freezing. The condensate discharge pipe must terminate in a suitable position, e.g.: a)preferably the discharge pipe should be run and termi-

nate internally to the house soil and vent stack (at

least 450mm above the invert of the stack). A trap giving a water seal of at least 75mm (3) should be incorporated into the pipe run, and there must be an air break (4) in the discharge pipe upstream of the trap. This should be designed so that the condensate cannot be discharged into the house if the condensate pipe becomes blocked.

b)connecting into the internal discharge branch (e.g. sink

waste or washing machine) with an external termination, the condensate discharge pipe should have a minimum diameter of 22mm with no length restriction and should incorporate a trap with a 75mm (3) seal The connection should preferably be made down stream of the sink waste trap. If the connection is only possible upstream, then a air break is needed between the two traps. This is normally provided by the sink waste. c) terminating in a gully (5) below grid level (6) and above the water level. The external pipe length should be kept a short as possible to minimize the risk of freezing and should not be more than 3m.

d)At a condensate absorption point (soakaway) (7). The

external pipe length should not be more than 3m

Fig. 4.9

Note! If it is necessary to install any condensate discharge pipework externally, then it should be kept as short as possible to a maximum length of 3m, be insulated with waterproof insulation and have a continuous fall of a least 2.50 (i.e. 45mm for every metre length).

An optional siphon condensate discharge accessory is available (Art. No. 2370104) and is for use where external discharge pipework is very exposed and at risk of freezing. This accessory is for installation within the condensate discharge pipework immediately below the boiler. Refer to ‘BS 6798 Specification for installation of gas– fired boilers of rated input not exceeding 70 kW net for further information. Before operating the boiler the condensate trap (1, fig.4.9) must be filled with water as described in relevant section.

Internal stack

pip

Internal discharge system

Gulley Soakaway

ab c d

Page 16

4 Boiler installation sequence

Instructions for installation and servicing ecoMAX16

4.12 Connection to a uniSTOR cylinder

• For connecting a Vaillant uniSTOR cylinder please refer to the uniSTOR installation instructions provided with the cylinder.

4.13 Connect the flue system to the boiler

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

4.14 Electrical installation

4.14.1 General requirements

All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations). In IE, reference should be made to the current edition of the ETCI rules. 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.

Attention! This appliance must be earthed.

Note! Do not use boiler terminal connections 7–8–9.

Attention! 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.

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

4.14.2 Connection to the main supply

• Remove the front case and lower the control panel.

• Unclip the bottom of the terminal box cover and hinge back to reveal the connection plugs.

• Pull out the power L, N and earth plug.

• Feed the power supply flex into the appliance and the control panel through the cable clamps provided and tighten.

• Connect the flex to the L,N and earth plug, reconnect plug to terminal block.

Green/yellow (earth) wire – boiler terminal Earth sign Blue (neutral) wire – boiler terminal N

Brown (live) wire – boiler terminal L

Note! Do not use boiler terminal connections 7–8–9.

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

• Raise the control panel.

Fig. 4.10 Wiring system

Fig. 4.11 Exposed rear view of electronic box

230V

Page 17

Boiler installation sequence 4

Instructions for installation and servicing ecoMAX 17

4.14.3 Electronic board layout

Fig. 4.12: Connection wiring

987

543

Pump 2. Pump

Contact

therm

L N

24V I

230V

RT 24V

230V

RT 230V

X 4

X 10

X 7

X 8

X 2

X 6

1 1

Coding resistance

Diagnostic connection

Diverter valve

Connection for multi–function module 306 253

Room thermostat 24 V: Connections 7, 8 and 9

Caution: Do not connect directly to mains supply: danger of irreparable damage to electronic system

Room thermostat 230 V/50 Hz (remove bridge for connection)

Heating pump connection

Mains power supply: 230 V/50 Hz

Under–floor heating overload thermostat, 20 V (remove bridge for connection)

Edge connector for Vaillant weather compensator

External CH pump (adjustment via diagnostic system, diagnostic setting d.16)

Page 18

4 Boiler installation sequence

Instructions for installation and servicing ecoMAX18

4.14.3 Electronic board layout

Fig. 4.13: Connection wiring ecoMAX 635

Fan unit

Ignition electrode

Pump

NTC flow

Gas valve assembly

NTC backflow

X 2/4 red

X 2/10 white

X 2/15 blue

Plug-in coupling

Electronic control box

987

543

Pump 2. Pump

Contact therm

L N

24V I 230V

RT 24V

230V

RT 230V

X 4

X 10 X 7

X 8

X 6

X 2

Coding resistance

1 1

X 2/9 red (22 VDC)

X 2/24 blue (earth)

X 2/12 blue (earth)

X 2/7 grey (PWM)

X 2/3 black (Hall signal)

X 2/17 red (22 VDC)

Water Switch

Page 19

Boiler installation sequence 4

Instructions for installation and servicing ecoMAX 19

4.14.4 Connection details for programmable thermostats

Fig. 4.14

234

LN 3

ACL Drayton Lyfestyle PT271, PT371

ACL Drayton Digistat 2, 3, 4

ACL Drayton Digistat RF - SCR Receiver

Danfoss Randall TP4, TP5

Danfoss Randall TP7000-RF with receiver RX1

Danfoss Randall TP7000

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 230, 220

234

LN 3

LL1

Smiths Timeguard ProgramaSTAT PRT11, PRT17

234

LN 3

4.15 Controls

4.15.1 External electrical controls

The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a programmer, room thermostat, etc. 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 controls.

4.15.2 Connection of external electrical controls

4.15.3 Connection details using an external wiring centre

The boiler should be connected to the system controls using an external wiring centre. Fig. 4.15 shows connection details for a system utilising a 3 port mid position motorised valve, figure 4.16, 4.17 shows the connection details for a system utilising two 2 port motorised valves (Important: the arrowed numbers indicate connection into the relevant terminal of the external wiring centre).

Page 20

4 Boiler installation sequence

Instructions for installation and servicing ecoMAX20

4.16 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 where TRV’s are used they must be used in conjunction with a boiler control interlock. A programmable room thermostat or separate timer and room thermostat will 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).

4.17 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 are utilised.

4.18 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.

4.19 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 re–igniting for a preset period after central heating operation (the hot water operation is unaffected by this control and hot water can be drawn at any time).

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.

4.20 Automatic pump spin control (APS)

The boiler incorporates a built in control which will spin the built in circulating pump and operate the external diverter valve once in a 23 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.

Fig. 4.15

Connection details for control systems utilising 3 port motorised valve via external wiring centre/junction box

Diagram only applies to the specific controls mentioned

345

EN L

CENTRAL HEATING ON

HOT WATER ON

HOT WATER OFF

3 amp fused main supply

ecoMAX terminal strip

Programmer for programmer connections see fig. 16.b

345

E5367 8

External wiring centre/junction box*

345678910

NNL

*Do not use pre-wired printed circuit board type

not used

EARTH BLUE

BROWN OR WHITE

GREY ORANGE

3 Port mid position motorised valve

4E5 89

ECA

4 N 4

2 4

3 3 3

2 2

1 L 2

1 L

1 3

E E E

Vaillant VRT 9090

ACL Drayton Digistat 2, 3, 4

ACL Drayton RTS 1, 2

Danfoss Randall RX-1

Danfoss Randall RMT 230

Danfoss Randall RET 230

Tower SS

Honeywell T6360

Horstmann HRT 2

Siemens-Landys & Staefa RAD 1

Sunvic TLX 2000 series

5 9 6 L N E

Room thermostat

21 C

3 3 2

RED

C 1 1 3

ACL Drayton HTS3

Danfoss Randall ATC

Tower STTCSW

Honeywell L641

Horstmann HTC2

Siemens-Landis & Staefa RAM 1

Sunvic SA 2452

8 4 7 E

Cylinder thermostat

Vaillant VRT 30

543

43 1

Sunvic TLX 9000

Page 21

Boiler installation sequence 4

Instructions for installation and servicing ecoMAX 21

Fig. 4.16

Fig. 4.17

Connection details for control systems utilising 2 x 2 port motorised valves via external wiring centre/junction box

Diagram only applies to the specific controls mentioned

345

N L

CENTRAL HEATING ON

HOT WATER ON

HOT WATER OFF

3 amp fused main supply

ecoMAX terminal strip

Programmer for programmer connections see fig. 16.d

345

5367 8

External wiring centre/junction box*

345678910

NNL

*Do not use pre-wired printed circuit board type

not used

EARTH BLUE BROWN GREY ORANGE

Hot water 2 port motorised valve

4E5 310

21 C

3 3 2

RED

C 1 1 3

ACL Drayton HTS3

Danfoss Randall ATC

Tower STTCSW

Honeywell L641

Horstmann HTC2

Siemens-Landis & Staefa RAM 1

Sunvic SA 2452

10 7 E

Cylinder thermostat

EARTH BLUE BROWN GREY ORANGE

Central heating 2 port motorised valve

4E5 39

ECA

4 N 4

2 4

3 3 3

2 2

1 L 2 1 L 1

1 1

1 3

E E E

Vaillant VRT 9090

ACL Drayton Digistat 2, 3, 4

ACL Drayton RTS 1, 2

Danfoss Randall RX-1

Danfoss Randall RMT 230

Danfoss Randall RET 230

Tower SS

Honeywell T6360

Horstmann HRT 2

Siemens-Landys & Staefa RAD 1

Sunvic TLX 2000 series

5 9 6 L N E

Room thermostat

Vaillant VRT 30

543

43 1

Sunvic TLX 9000

234

53 8

not used

Lifestyle LP241, LP 522, LP 722

Tempus 6, Tempus 7

Danfoss Randall CP 715, FP715

Note: *Earth not required

Danfoss Randall Set 2E, Set 3E Note: *Earth not required,

Link L - 2 - 5

Grässlin Towerchron QE2

Honeywell ST699B, ST799A

Note: Link L - 5 - 8

Honeywell ST6200, ST6300, ST6400

Horstmann Channel Plus H21, H27 Note: *Earth not required,

Link L - 2 - 5

Siemens-Landis & Staefa RWB 29

Potterton Myson EP 2002, EP 3002, EP 6002

Note: Link L - 5

Sunvic Select 207

234

53 8

234

53 8

234

53 7

234

53 8

567

234

53 8

234

53 7

234

53 8

234

53 8

234

53 8

not used

Page 22

4 Boiler installation sequence

Instructions for installation and servicing ecoMAX22

Fig. 4.18

234

not used

Lifestyle LP241, LP 522, LP 722

Tempus 6, Tempus 7

Danfoss Randall CP 715, FP715

Note: *Earth not required

Danfoss Randall Set 2E, Set 3E Note: *Earth not required,

Link L - 2 - 5

Grässlin Towerchron QE2

Honeywell ST699B, ST799A

Note: Link L - 5 - 8

Honeywell ST6200, ST6300, ST6400

Horstmann Channel Plus H21, H27 Note: *Earth not required,

Link L - 2 - 5

Siemens-Landis & Staefa RWB29

Potterton Myson EP 2002, EP 3002, EP 6002

Note: Link L - 5

Sunvic Select 207

234

not used

234

not used

234

not used

234

not used

234

53 7

not used

234

not used

567

56not used

not used

234

not used

234

53 7

not used

234

not used

Page 23

Commissioning Part I 5

Instructions for installation and servicing ecoMAX 23

5 Commissioning Part I

5.1 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.

5.2 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).

5.3 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 on page 27. Open all radiator or 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 both filling valves and disconnect the temporary connection.

5.4 Filling the heating system

The boiler and the heating system should be filled using a filling method as described on page 11.

• Ensure that the boiler CH service valves are open.

• Partially open the filling valve and allow water to enter the system. Starting with the lowest radiator, open the radiator air release until water (clear of bubbles) is emitted.

• Repeat this at all radiators until the complete system is full, all air locks have been cleared and the boiler pressure gauge reads 1.5 bar. Release any air from the pump by slackening the centre screw.

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

• Check the heating system and boiler connections are sound.

5.5 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 on page 27.

• Open all radiator or 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.

5.6 Filling condensate trap

Remove the lower part of the condensate trap (by unscrewing and fill with water to about 10 mm from the top. Refit to boiler.

5.7 Adjusting pump speed

The ecoMAX 635 is fitted with an automatic modulating pump which regulates according to the resistance of the heating circuit. Within the diagnostic system (see next page) it is possible to preset the pump to five resistance persentage steps up to the maximum available output in 53, 60, 70, 85 and 100 %. Therefore when using this selection option the automatic modulation is switched off.

Note! Where a mixing valve is fitted in the heating circuit (underfloor heating circuit) the pump setting in the diagnostic mode (d.14) should be set to 100%.

Fig. 5.1 Pump specifications

Modulating pump settings

In order to set the pump from modulating to a number of fixed persentage output values, please follow the instruction below.

• Open the appliance to obtain access to the diagnostic display.

• Turn the appliance ”on/off”–contol to the ”I”–position (”on”).

400

300

200

100

0 200 400 600 800 1000 1200 1600

Lift

[

mbar

]

1800

Volumeflow [l/h

]

1900

1400

100 %

53 %

60 %

70 %

85 %

Page 24

5 Commissioning Part I

Instructions for installation and servicing ecoMAX24

1 Press the ”i” and ”+” buttons below the display simul-

taneously. The display will now show ”d.0”. Use the ”+” button to scroll up to ”d.14”.

2 Press the ”i”–button to display the diagnostic informa-

tion (e. g. factory setting ”auto” = pump modulation on).

3 Press the ”+” or ”–” button to select the pump resi-

stance value (0 = auto, 1 = 53%, 2 = 60%, 3 = 70%, 4 = 85%, 5 = 100% these figures represent the percentages of the maximum pump output).

When altering values the display will flash.

4 Press and hold the ”i”–button to save the required

value to memory. When the value is saved, the display will stop flashing.

5 Diagnostic 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 return to its normal state (current heating–system flow temperature, e.g. 45°C).

Tab. 5.1 Maximum gas rates.

5.8 Checking the gas supply settings

5.8.1 Factory–adjusted gas settings

Attention! Before operating the boiler check the data badge and ensure that the correct gas type

appliance has been installed.

The boiler is supplied ready adjusted and no further gas adjustments are necessary, however both the gas inlet working pressures and maximum gas rates should be checked as detailed below.

5.8.2 Gas inlet working pressure

Check the inlet pressure as described below:

• Remove the front case from the boiler.

• Close the gas shutoff valve fitted to the boiler.

• Loosen the sealing screw marked ”in” (1) on the gas valve assembly (Fig. 5.2).

• Connect a digital or a U gauge (2).

• Open the gas shutoff valve fitted to the boiler.

• Put the boiler into service (refer to the Instructions for Use supplied with the boiler).

• Check the U gauge reading and ensure the inlet gas pressure is between the pressures detailed below.

Natural gas: Do not proceed with adjustment or attempt to put the unit into service if the inlet working

pressure lies outside the 17–25 mbar range.

LPG: Do not proceed with adjustment or attempt to put the unit into service if the inlet working

pressure is lower than 37 mbar.

≈ 5 sec

Appliance ecoMAX 635

Maximum net heat input in kW 34.9 Maximum gas rate Natural gas in m3/h 3.70 Maximum gas rate Propane in kg/h 2.70

Page 25

Commissioning Part I 5

Instructions for installation and servicing ecoMAX 25

• Turn off the appliance, remove U gauge.

• Tighten the test point screw and test for soundness.

• Record appliance working gas inlet pressure (mbar) in the Benchmark gas boiler commissioning checklist.

5.8.3 Check gas rate

The boiler is fitted with a fully modulating automatic gas valve which ensures that the precise air/gas ratio is provided under all operating conditions. The gas rate has been set during production and does not require adjustment. The gas rate of the boiler should be checked with the front case fitted as follows:

• Activate full gas rate mode by simultaneously pressing the ”+” and ”–” buttons on the display system

• Wait at least 5 minutes, or until the boiler has reached its operating temperature

• With all other gas appliances turned off measure the gas rate at the gas meter. Check that the gas rate is as stated in Table 5.1.

Fig. 5.2 Measuring the inlet working pressure

5.9 Refitting the case

Fig. 5.3 Removing/Refitting the case

Note! Ensure that the front panel retaining cords are positioned such that they will not become trapped in the casing.

• Hook the top of the front casing (4) over the lip on the top of the boiler chassis and push the bottom of the front casing (3) into place.

• Ensure the spring retaining clips (2) engage correctly.

• Tighten case securing screw (1).

5.10 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: 1 Press the ”i” and ”+” buttons simultaneously.

Fig. 5.4 ff Adjusting the central heating output

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

display runs from ”d.0” to ”d.99” before restarting at ”d.0”.

3 Press the ”i” button. The ”=” symbol is displayed. The

part–load setting is now displayed in kW.

Page 26

5 Commissioning Part I 6 Functional checks (Commissioning Part II)

Instructions for installation and servicing ecoMAX26

4 Use the ”+” and ”–” buttons to increase or decrease

the value in steps of 1 kW. The displayed value will flash while the adjustment procedure is being carried out. The available ranges of settings are given in Tab.

5.2 on page 39.

5 Finally, keep the ”i” button pressed for about five

seconds, or until the display stops flashing. The value is now saved to memory. The display will now return to its normal state (current heating–system flow temperature, e.g. 45 °C).

Fig. 5.5 Adjusting the central heating output

6 Press the ”i” and ”+” buttons simultaneously to cancel

adjustment mode. Adjustment mode is also cancelled if no button is operated for a period of 4 minutes.

Fig. 5.6 Adjustment of heating system part–load

Appliance Heating Output in kW

ecoMAX 635 10 to 35

Tab. 5.2 Heating system part–load adjustment ranges

6 Functional checks (Commissioning Part II)

6.1 Functional checks

6.1.1 Procedure

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 heating system for correct operation.

Fig. 6.1 Test for correct functioning

6.1.2 Heating system

• Switch the unit on.

• Ensure that there is a heating demand.

• Press the ”i” button.

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

Fig. 6.2 Heating mode display messages

≈ 5 sec

Page 27

Functional checks (Commissioning Part II) 4

Instructions for installation and servicing ecoMAX 27

6.1.3 Final system flush (”Hot”)

• Turn on the boiler for central heating and allow the boiler and system to reach 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 manufacturer’s 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 sliding the front edge of the cover into the lip at the bottom front edge of the appliance chassis.

• Carefully push the rear of the bottom cover upwards until the spring retaining clips engage at the side of the appliance. It may be necessary to apapt the bottom cover by removing the easy break sections.

6.1.4 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 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.

• Record central heating operating pressure in the Benchmark gas boiler commissioning checklist along with the heat input (kW) and temperature difference between flow and return. 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 users instructions and installation instructions with the user.

Attention! The device may only be used

• for initial operation

• for testing

• for continuous operation with the chamber cover closed and with the flue system fully mounted and sealed.

Note! When you have finished the installation, attach the sticker supplied (835593) to the appliance in the user’s language.

Danger! Note that if the boiler is run with an empty condensate trap there is a danger that fumes might escape. Into the room and cause poisoning. For this reason, it is important to ensure that the trap is topped up each time the unit is cleaned.

Page 28

7 Servicing

Instructions for installation and servicing ecoMAX28

7 Servicing

7.1 Inspection and servicing

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 the boiler should be inspected once per year and serviced every second year. We therefore recommend that a service contract be taken out for the boiler. It is law that all servicing work is carried out by a competent person (CORGI registered). For safety reasons only genuine Vaillant spare parts should be used when servicing the boiler.

Attention! Failure to carry out work in accordance with these instructions could result in personal injury or damage to the property

7.2 Initial inspection

Every year the boiler should be inspected to check its general condition. This inspection should include the boiler, flue, pipework and electrical connections for any indications of damage or deterioration. A gas rate check of the boiler and a visual inspection of the combustion should also be carried out. Every second year the compact thermal module should be removed and the burner and heat exchanger cleaned. All inspection and servicing work should be performed in the order as per Table 7.1

No Description Inspection Service

1 Carry out functional check of boiler X X 2 Remove the compact thermal module X 3 Clean primary heat exchanger X 4 Clean burner X 5 Refit compact thermal module,

replace burner seals (Spare part number 98 1046) X

6 Check general condition of

boiler and clean as necessary X X 7 Check electrical plugs and connections X X 8 Check/re-pressurise expansion

vessel as necessary X 9 Check and clean condensate

trap and connection pipes X X 10 Check ignition and burner flame picture X X 11 Check boiler for any leaks X X 12 Check air/gas flue system X X 13 Complete benchmark logbook X X

Table 7.1

Note! The boiler is fitted with a combustion analysis test point. A suitable combustion analyser can be connected to this point to establish the combustion performance of the boiler. It is not necessary to check the CO

content or adjust the air ratio of the boiler during inspection or annual service. This value requires checking and adjusting only in the following instances: replacement of gas valve, conversion to or from Natural Gas/ LPG or if incorrect combustion is suspected.

Attention!

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.

• When removing any water carrying components ensure that water is kept away from all electrical components.

• Always use new seals and O–rings when replacing parts.

• 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.

7.2.1 Removing the compact thermal module

Turn off the boiler

• Isolate the electrical supply to the boiler.

• Remove boiler bottom cover by releasing the two spring retaining lugs and lowering the rear of the bottom cover.

• Gently pull the bottom cover backwards to remove from the appliance. Turn off the gas service valve.

• Turn off the boiler CH service valves.

• Loosen case retaining screw and release the front case spring retaining clips located beneath the front edge of the appliance.

• Remove the front casing by easing forward the bottom edge and gently lifting.

• Lower electronic control box.

Page 29

Servicing 7

Instructions for installation and servicing ecoMAX 29

Fig. 7.1 Removing the compact thermal module

Remove burner assembly

• Remove screw (1) and disconnect air inlet pipe (2).

• Disconnect gas supply from gas valve by undoing union (4).

Fig. 7.2 Disconnecting gas supply from the gas valve assembly

• Disconnect HT lead and earth lead (3) from spark electrode.

• Remove five nuts (7) from burner manifold.

• Pull forward complete burner, gas valve and fan assembly.

• Disconnect two electrical connections (5 and 6) from fan and gas valve.

• Remove burner, gas valve and fan assembly (8) from boiler (9).

Note! The compact thermal module may be very hot and care should be taken when removing the module. The compact thermal module must not be suspended from the corrugated gas tube.

Attention!

Under no circumstances should the venturi tube

be removed and dismantled from the gas valve as this part is sealed and gas checked during production.

Fig. 7.3 Renewing the seals (1) and checking the burner flange

insulation (2)

7.2.2 Inspect main heat exchanger

With the burner and fan assembly removed it is now possible to inspect the main heat exchanger. Remove any loose deposits from the heat exchanger using a soft brush and jet of water (ensure that water is kept away from all electrical components. Any water used to clean the main heat exchanger will drain through the condensate trap).

Fig. 7.4 Inspecting the main heat exchanger

7.2.3 Inspect burner

• Visually inspect burner for signs of damage or deterioration.

• Ensure a gap of 4 mm exists between the spark electrode and earth probe.

• Check that the burner manifold sealing gasket is in good condition.

• The burner is maintenance–free and does not require cleaning. The burner must be replaced if its outer surface shows any signs of damage (fig. 7.5).

Fig. 7.5 Inspecting the burner

Page 30

7.2.4 Refitting the compact thermal module

• Renew the silicone gaskets (1) (see Fig 7.3)

• Loosely position the burner, fan and gas valve assembly in place and reconnect the two electrical connections to the fan.

• Refit the burner, fan and gas valve assembly. Ensure that the burner manifold gasket is correctly fitted and that a good seal is obtained.

• Reconnect the gas supply to the gas valve, ensuring that a new sealing washer is used and correctly located.

• Turn on the gas supply and test for soundness.

• Reconnect the HT lead and earth lead to the spark electrode.

• Refit the air inlet pipe.

Danger! The two silicone seals (1 - fig. 7.3) on the compact thermal module ((SP no. 98-1046) must be replaced each time the module is removed (for example during maintenance). The burner flange insulation (2 - fig. 7.3) on the compact thermal module (SP no. 21-0734) may not show any signs of damage; otherwise it must also be replaced.

7.2.5 Cleaning the condensate trap

Fig. 7.6 Cleaning the condensate trap

• Unscrew the bottom section (1) of the condensate trap (see fig. 7.6).

• Clean the bottom section of the trap by rinsing it out with water.

• Refill with water to about 10 mm from the top.

• Screw the bottom section back onto the condensate trap.

Danger! Note that if the boiler is run with an empty condensate trap there is a danger that fumes might escape into the room and cause poisoning. For this reason, it is important to ensure that the trap is topped up each time the unit is cleaned.

7.2.6 Check expansion vessel

Fig. 7.7 Checking expansion vessel admission pressure

Note!

It is not necessary to perform this check every year – a check every three years is sufficient.

• Ensure the boiler CH service valves are closed.

• Release the pressure from the boiler.

• Remove valve cap from expansion vessel charge point.

• Check that the internal charge pressure of the expansion vessel is between 0.75 and 0.9 bar. If the pressure is lower than this the vessel should be repressurised using an air pump.

• Refit the valve cap.

• Repressurise boiler and heating system.

7.3 Recommissioning the boiler

• Carry out electrical safety checks.

• Turn on the electrical supply.

• Open the boiler CH service valves.

• Carry out function checks of boiler operation as previously detailed.

• Check gas rate as previously detailed.

• Check water soundness.

• Refit case, ensuring that a good seal is obtained.

7 Servicing

Instructions for installation and servicing ecoMAX30

Page 31

31Instructions for installation and servicing ecoMAX 31

7.4 Tes t

Carry out the following checks once the maintenance tasks have been completed:

• Start the unit up according to the instructions supplied with the appliance.

• Check the unit for any signs of escaping gas or water leaks.

• Check the air/flue duct system for leaks and correct attachment.

• Check for excess ignition and ensure that the flame burns regularly and smoothly.

• Check the heating system and hot–water supply for correct functioning.

• Complete the Benchmark gas boiler commissioning checklist.

Fig. 7.8 Test for correct functioning

Servicing 7

Page 32

8 Troubleshooting

Instructions for installation and servicing ecoMAX32

8 Troubleshooting

8.1 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. 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.

Fig. 8.1 Displaying of status codes

8.1.1 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 8.1).

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.

Key to status codes

Code Meaning ecoMAX 635

S.0 No heat demand

(heating operation) X

S.1 Pump running

(heating operation) X

S.2 Pump running – pre ignition

(heating operation) X

S.3 Ignition sequence

(heating operation) X

S.4 Burner ignited

(heating operation) X S.5 – S.6 Heating system fan over run X S.7 Pump over run

(heating operation) X S.8 Anti cycling mode

(heating operation) X S.30 No heating demand from

external controls X S.32 Fan unit waiting period X S.34 Frost protection mode X S.36 No heating demand from

low voltage controls X S.37 Fan unit waiting period X S.39 Contact thermostat has been

activated (under floor systems) X S.53 Delay mode due to lack

of water in system (~20 mins.) X S.54 Low water–level waiting period X

Table 8.1 Status codes

8.1.2 Diagnosis 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 (Table 8.2).

• Press the ”i” and ”+” buttons below the display simultaneously. The display will now show ”d.0”.

• 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.

Page 33

Troubleshooting 8

Instructions for installation and servicing ecoMAX 33

Key to diagnosis codes

Code Meaning Displayed/Adjustable values

d.0 Part load setting Adjustable values in kW d.1 Water pump over run 1 – 60 min (factory–adjusted to 5 min) d.2 Maximum burner anti cycling period at 20 °C

flow temperature 2 – 60 min (factory–adjusted to 20 min) d.5 Flow temperature setting Target value in °C d.8 External controls heat demand 0 = room thermostat open (no demand)

1 = room thermostat closed (demand)

d.10 Pump status 1 = ON

0 = OFF

d.11 External pump status 1 = ON

0 = OFF

d.13 External circulation pump 1 = ON

when fitted 0 = OFF d.14 Pump speed Set value for built–in pump.

Factory setting: ”auto”; possible adjustments: 0 = auto, 1 = 53%, 2 = 60%, 3 = 70%, 4 = 85%, 5 = 100%

d.16 2ndpump 1 = DHW circulating pump

2 = external CH pump 3 = vantage loading pump 4 = solar pump

d.22 Domestic hot water demand 1 = ON

0 = OFF

d.23 Summer/Winter function (control knob) 1 = Winter

0 = Summer d.24 Not applicable in GB – d.25 Hot–water activation 1 = yes

via warm–start clock 0 = no d.34 Current fan speed value Current value in rpm/10 d.35 Diverter valve position 0 = heating system

1 = hot water

2 = mid position d.40 Actual flow temperature Current value in °C d.41 Actual return temperature Current value in °C d.44 Actual ionisation–current value Current value /100 in μA d.46 Outside–temperature correction Correction value in K

(only when VRC 410s is fitted)

d.47 Actual outside temperature Current value in °C

(only when VRC 410s is fitted) d.60 Number over heat cut off operations Number d.61 Number of lock outs Number of unsuccessful ignition operations at

last attempt d.67 Remaining anti cycling period in min d.68 No first start Number of unsuccessful attempted 1stignitions d.69 No second start Number of unsuccessful attempted 2ndignitions d.71 Maximum target value for heating system Max. target value for heating–system flow temp. flow temperature

(factory–adjusted to 75 °C) adjustable value 40–85 °C

d.72 Pump over run (for loading warmstart) Pump over run period, in seconds, after filling

factory–adjusted to 80 s of an electronically–controlled hot–water tank (incl.

d.73 Offset warmstart temperature value Range: –15 K to +15 K

For solar applications: Switching difference Factory–adjusted to –5 K (ecoMAX 800).

for the solar pump Recommended setting for solar applications: +7 °C d.80 Number of heating system operating hours in h d.81 Number of hot water system operating hours in h d.82 Number of heating system cycles (Total) d.83 Number of hot water system cycles (Total)

Table 8.2 Diagnosis codes

Page 34

8 Troubleshooting

Instructions for installation and servicing ecoMAX34

Key to Fault codes

Code Meaning Cause

F.0 Flow–NTC:

– NTC broken

– NTC cable broken Flow–NTC cable defective/broken NTC faulty

– Defective connection at NTC

– Defective connection at electronics

F.1 Return–NTC:

– NTC broken

– NTC cable broken Return–NTC cable defective/broken NTC faulty

– Defective 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.13 Short circuit in tank sensor NTC defective, earth leak/short circuit in cable loom,

damp plug connection

F.20 Over heat cut off activated Maximum temperature exceeded

No water in system

F.22 Low water or no water in appliance Pump defective

Pump lead defective

F.23 Water level low Pump obstructed, pump running at lower capacity,

Temperature range too wide Air in appliance, system pressure too low,

flow and backflow NTC reversed

F.24 Water level low Pump obstructed, pump running at lower capacity,

Temperature rises too fast ir in appliance, system pressure too low,

flow and backflow NTC reversed

F.25 Water Switch Water Switch - plug disconnected

System pressure too low Waterswitch activated

F.27 No demand to gas valve Electronic board defective

Gas valve defective No gas Insufficient gas Incorrect gas valve adjustment

F.28 Boiler goes to lock out Electrode defective

Ignition lead defect Electronic igniter defective Check air inlet duct

F.29 Flame extinguished re–ignition unsuccessful Gas supply absent or insufficient

Check flue duct

F.32 Fan turning–speed malfunction Fan unit obstructed, plug–in fan connector not

(too fast at start–up) correctly inserted, Hall sensor defective, fault in cable

loom, defective electronic control system

F.60 Gas–valve control + defective Short circuit/earth (ground) leak in cable loom to gas

valves, gas valve assembly defective (earth/ground leak from coils), electronic control system defective Short circuit/earth (ground) leak in cable loom to gas

F.61 Gas–valve control – defective valves, gas valve assembly defective (earth/ground

leak from coils), electronic control system defective F.62 Defective gas–valve closure mechanism Leak in gas valve assembly, electronic fault F.63 EEPROM error Electronic fault F.64 Electronic system/sensor fault Short circuit in flow or backflow NTC,

electronic fault F.65 Electronic system temperature too high Electronic system affected by external heat source,

electronic fault F.67 Electronic fault in flame system Electronic fault

(non–plausible flame signal)

Table 8.3

Page 35

Troubleshooting 8

Instructions for installation and servicing ecoMAX 35

8.1.3 Fault codes

Fault codes take priority over all other display functions in the event of a system fault occurring (Table 8.3). If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each.

8.1.4 Fault memory

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

• Press the ”i” and ”–” buttons simultaneously.

• 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.

8.2 Test programs

The use of different test programs permits the activation of a range of special unit functions. Please refer to Table 8.4 (below) for detailed information.

• Test programs P.1 to P.6 are activated by operating the Power ON switch and pressing the ”+” button at the same time (and keeping it pressed for five seconds). ”P.1” will now appear on the display

• Press the ”+” button to increase the test number

• Now press the ”i” button to start up the unit and activate the test program

• Test programs can be aborted by pressing the ”i” and ”+” buttons at the same time. Test programs are also cancelled if no button is operated for 15 minutes.

Display Meaning

P.1 Test program used when the unit runs at

full load after successful ignition

P.2 Test program used when the unit runs with

minimum gas consumption after successful

ignition P.3 not applicable P.4 not applicable P.5 Program for STB (safety temperature

limiter) testing; the device heats up,

bypassing the regulator shutdown

procedure, until it reaches the STB

shutdown temperature of 97 °C P.6 not applicable

Table 8.4 Test programs

Page 36

9 Parts replacement

Instructions for installation and servicing ecoMAX36

9 Parts replacement

Ensure that all regulations are observed.

9.1 Safety instructions

The following safety instructions are to be followed when installing replacement parts!

Note! 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.

• When removing any water carrying components ensure that water is kept away from all electrical components.

• Always use new seals and O–rings when replacing parts.

• 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.

9.1.1 Initial preparation

• Turn off the boiler.

• Isolate the electrical supply to the boiler.

• Remove boiler bottom cover.

• Turn off the gas service valve.

• Turn off the boiler CH service valves.

• Turn off the cold water inlet service valve (ecoMAX 800).

• Remove front case

• Lower electronic control box.

• Release central heating water pressure by draining the boiler from the drain points provided. (This needs only to be carried out when detailed in these instructions).

• After installing replacement parts, recommission and check boiler function as described in commissioning section.

Note! The boiler is fitted with a combustion analysis test point. A suitable combustion analyser can be connected at this point to establish the combustion performance of the boiler.

9.1.2 Removal of burner assembly

• Remove screw and disconnect air inlet pipe.

• Disconnect gas supply from gas valve by undoing union.

• Disconnect HT lead and earth lead from spark electrode.

• Remove five nuts from burner manifold.

• Disconnect two electrical connections from fan and gas valve.

• Pull forward complete burner, gas valve and fan assembly.

• Remove burner, gas valve and fan assembly from boiler.

9.2 Replacement of burner

Fig. 9.1 Replacing the burner

• Turn off boiler.

• Remove front casing.

• Lower control box.

• Remove burner, gas valve and fan assembly as previously detailed.

• Remove 4 screws (1) securing burner to burner manifold.

• Fit new burner to manifold using the new sealing gasket supplied, ensuring that the notch in the burner aligns with the burner viewing window.

• Reassemble in reverse order.

• Recommission boiler as detailed.

9.3 Replacement of fan

• Turn off boiler.

• Remove front casing.

• Lower control box.

• Remove burner, gas valve and fan assembly as previously detailed.

• Remove 4 screws (1).

• Separate gas valve and fan assembly from burner manifold (2).

• Remove 2 screws (3) securing gas valve to fan.

• Fit gas valve to new fan using the new sealing gasket supplied.

• Refit gas valve and fan assembly to burner manifold using the new sealing gasket supplied. Equally tighten the four screws (1) to ensure a good seal is made.

• Reassemble burner, gas valve and fan assembly in reverse order.

• Recommission boiler as previously detailed.

9.4 Replacement of gas valve

• Turn off boiler.

• Remove front casing.

• Lower control box.

• Remove burner, gas valve and fan assembly as previously detailed.

• Remove 4 screws (1).

• Separate gas valve and fan assembly from burner manifold (2).

Page 37

Parts replacement 9

Instructions for installation and servicing ecoMAX 37

• Remove 2 screws (3) securing gas valve to fan.

• Disconnect gas inlet supply connection from gas valve by removing four screws. Refit the gas inlet supply connection to the new gas valve using the new sealing gasket supplied.

• Fit new gas valve to fan using the new sealing gasket supplied.

• Refit gas valve and fan assembly to burner manifold using the new sealing gasket supplied. Equally tighten the four screws (1) to ensure a good seal is made.

• Reassemble burner, gas valve and fan assembly in reverse order.

• Recommission boiler as previously detailed. Ensure combustion analysis is carried out after part replacement as detailed in section 9.8.

Fig. 9.2 Replacing the gas valve

Fig. 9.3 Gas valve

9.5 Replacement of central heating expansion vessel

• Turn off boiler.

• Remove front casing.

• Lower control box.

• Drain boiler as previously described.

• Disconnect union (1) from expansion vessel (4).

• Remove two screws (2) and remove retaining bracket (3).

• Slide the expansion vessel forward to remove from the boiler.

• Reassemble in reverse order.

• Recommission boiler as previously detailed.

Fig. 9.4 Replacing the expansion tank

Page 38

9 Parts replacement

Instructions for installation and servicing ecoMAX

9.6 Replacement of main heat exchanger

• Turn off boiler.

• Remove front casing.

• Lower control box.

• Drain boiler as previously described.

• Remove burner, gas valve and fan assembly as previously detailed.

• Disconnect condensate drain by removing spring clip (4) and pulling condensate drain (5) downwards.

• Disconnect primary flow connection (7) from main heat exchanger. (A flexible connection has been provided in the flow pipe to allow easier access to the return connection. The flow pipe can be carefully eased out of the way by bending at the flexible connection).

• Disconnect primary return connection (6) from main heat exchanger.

• Loosen nylon nut at bottom of heat exchanger.

• Slacken the two top securing bolts (8) and rotate clamps away from heat exchanger.

• Fully remove bottom screw and securing clamp (8).

• Pull heat exchanger forwards to remove from the boiler.

• Drain any residual water from the heat exchanger.

• Reassemble in reverse order.

• Recommission boiler as previously detailed.

Fig. 9.5 Replacing the main heat exchanger

9.7 Replacement of the electronic control board

Danger!

Ensure you observe the safety precautions when replacing this component.

• Turn off boiler.

• Remove front casing.

• Lower control box.

• Unclip the back cover from the electronics box and open the cover.

• Unclip the front cover from the electronics box and remove the cover.

• Disconnect all wires from the circuit board.

• Unclip the circuit board and remove.

• Remove the display unit and (if fitted) the built–in timer from the electronics box.

• Clip the new circuit board into position in the electronics box, reconnect all plug–in wires and refit back cover of the switch box by clipping the cover back into position.

• Raise the electronics box and reinstall the display unit and (if fitted) the built–in timer. The display unit and built–in timer are connected using the contact pins on the circuit board.

• Recommission boiler as previously detailed.

The new circuit board must be adapted to the heating unit and its system. To do so, carry out the adjustments to the display system of the heating unit as shown in Tab. 9.1.

Note! The values in Tab. 9.1 that appear in bold script must be adjusted. All other values can be adjusted as required, or the circuit board default values can be retained

9.8 Check CO2content and adjust if necessary

(air–ratio adjustment)

Note!

Checking/adjustment of this value is required in the following instances: replacement of gas valve, conversion to or from Natural Gas/ LPG or if incorrect combustion is suspected!

• Remove the case from the unit.

• Activate full gas rate mode by simultaneously pressing the ”+” and ”–” buttons on the display system

• Wait at least five minutes, or until the unit has reached its operating temperature.

• Measure the level of CO

content at the exhaust–fume test outlet (3) (Fig. 9.6). Check the reading against the corresponding value in tab. 9.2.

• If the exhaust–fume setting requires adjustment, remove the screw (4) and swivel the air suction pipe (5) forwards through 90° (Fig. 9.6). DO NOT remove the air suction pipe.

• Adjust the corresponding setting as required (see tab. 5.2, p. 26) by turning the screw (6) (fig. 9.7).

4 5

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Parts replacement 9

Instructions for installation and servicing ecoMAX

Fig. 9.6 Carrying out measurement of CO2 levels, preparing for

air–ratio adjustment

Natural gas: Adjust in steps of no more than 1/8 of a turn, and wait for each new value to stabilise (about one minute).

LPG: Adjust in small steps of no more than 1/16 of a turn, and wait for each new value to stabilise (about one minute).

• Turn anti–clockwise to increase level of CO

content.

• Turn clockwise to reduce level of CO

content.

• Once the adjustment procedure is complete, swivel the air suction pipe upwards and back into position.

• Re–check the level of CO

content.

• The adjustment procedure may have to be repeated.

• Press the ”+” and ”–” buttons simultaneously to deacti–vate full gas rate mode. Measurement mode is also cancelled if no control button is operated for 15 minutes.

• Reposition air suction pipe and tighten screw (4).

• Raise control panel.

Adjustment Natural gas (H) Propane Unit settings Tolerance Tolerance

CO2after 5 min. 9,0 ± 1,0 10,0 ± 0,5 Vol.–% operation at full load Adjusted for 15 22,5 kWh/m

Wobbe index Wo

Tab. 9.2 Factory–adjusted gas settings

Fig. 9.7 Carrying out air–ratio adjustment (gas supply settings)

Tab. 9.1 Values to be programmed in after installation of a new circuit board

Code Meaning Displayed/Adjustable values Circuit board Setting for

setting (default) ecoMAX 635

d.0 Heating system part load Adjustable values in kW 45 kW system-dep. d.1 Heating system pump over run 1 - 60 min. 5 min. system-dep. d.2 Heating system max. off-period 1 - 60 min. 20 min. system-dep. d.14 Pump speed Set value for built-in pump

0 (= auto), 53, 60, 70, 85, 100 % 0 = (auto) system-dep. d.16 External CH pump 1, 2, 3, or 4 1 d.71 Max. target value for heating-system

flow temperature 40 - 85 °C. 82 °C. system-dep.

d.72 Hot-water pump over run 0 - 250 s 80 s system-dep.

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10 Recycling and eventual scrapping

Instructions for installation and servicing ecoMAX

10 Recycling and eventual scrapping

The design of all Vaillant products takes into account the subsequent recycling and/or eventual safe scrapping of each component used. Vaillant’s in–house rules set strict standards in this respect. The selection process used for choosing raw materials includes full consideration of their recycling characteristics, and of the breakdown and separation properties of subassemblies. We also take fully into account the environmental and health hazards involved in recycling and in the disposal of non–reusable waste items.

10.1 The appliance

The Vaillant ecoMAX consists largely (92 %) of metal components designed for eventual recycling by incorporation into the smelting process of a steelworks. This gives these parts virtually unlimited scope for subsequent re–use. All plastic materials are duly identified to facilitate sorting and separation when the time comes to recycle the unit.

10.2 Packing

Vaillant endeavours to keep the amount of transport packaging used for its equipment to the bare minimum necessary. Subsequent re–use is taken into account when selecting packaging materials. High–quality cardboard has long been a valuable secondary raw material for the card and paper industry. The sections of EPS (Styropor®) are required in order to protect equipment in transit. EPS is 100 % recyclable and CFC–free. The foil–wrapping and securing straps are likewise made of recyclable plastic.

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0020014605_00GB 03 2006 Subject to alteration