To be left with the user
Instructions for Use, Installation and Servicing
ecoMAX pro
Wall hung condensing
boilers for traditional open vented systems
GB
18 E
28 E
Table of Contents
Instructions for Installation and Servicing ecoMAX pro2
Page
1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 4
Contents included with ecoMAX pro boiler . . . 4
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 General Information . . . . . . . . . . . . . . . . . . . . . 5
2.2 Gas Category . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Gas Safety (Installation and Use) Regulations 5
2.4 Gas Testing and Certification . . . . . . . . . . . . . . 5
2.5 CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Control of Substances Hazardous to Health . . 5
2.7 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.8 Manual Handling Guidance . . . . . . . . . . . . . . . . 5
2.9 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.10 Protection Against Freezing . . . . . . . . . . . . . . . 6
2.11 Boilers Installed in a Compartment or Cupboard 6
2.12 Boiler Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.13 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . 6
2.14 Pluming from flue terminal . . . . . . . . . . . . . . . . 6
2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.16 Maintenance and Servicing . . . . . . . . . . . . . . . . 6
2.17 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Operating the Boiler . . . . . . . . . . . . . . . . . . . . . 7
3.1Sealed Central Heating Systems only. . . . . . . . 7
3.2 All Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3User Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4To Turn the Boiler Off . . . . . . . . . . . . . . . . . . . . 8
4 General Information . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Sheet Metal Parts . . . . . . . . . . . . . . . . . . . . . . . 8
4.2Statutory Requirements . . . . . . . . . . . . . . . . . . 8
4.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . 9
4.7Heating System Controls . . . . . . . . . . . . . . . . . . 9
5 Water system . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1Draining Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.5 Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.6 Open (Vented) Water System . . . . . . . . . . . . . . 10
5.7 Domestic Hot Water Cylinder . . . . . . . . . . . . . . 10
5.8 Domestic Hot Water System - unvented . . . . . 10
5.9Sealed water Systems . . . . . . . . . . . . . . . . . . . . 11
5.9.1 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.9.2Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . 11
5.9.3Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.9.4 Domestic Hot Water Cylinder . . . . . . . . . . . . . . 11
5.9.5 Water Makeup . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.9.6 Filling a Sealed Water System . . . . . . . . . . . . . 11
5.10 Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . 11
Page
6 Boiler Location and Ventilation . . . . . . . . . . . . . 12
6.1 Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3 Timber Frame Buildings . . . . . . . . . . . . . . . . . . 12
6.4 Room Ventilation . . . . . . . . . . . . . . . . . . . . . . . . 12
6.5 Compartment Ventilation . . . . . . . . . . . . . . . . . 12
7 Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. 1 Flue Position and Length . . . . . . . . . . . . . . . . . 13
7. 2 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . 13
7. 3Internal Flue Installation . . . . . . . . . . . . . . . . . . 14
7. 4 Flue Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Installation Preparation . . . . . . . . . . . . . . . . 14
8.1 Unpacking of Boiler . . . . . . . . . . . . . . . . . . . . . . 14
8.2 Using boiler template . . . . . . . . . . . . . . . . . . . . 14
8.3 Rear flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.4 Other flue options . . . . . . . . . . . . . . . . . . . . . . . 15
8.5 Flue Hole Cutting . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9.1 Fitting the boiler hanging bracket . . . . . . . . . . 15
9.2Boiler Fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 Gas, Water and Condensate Connections . . . . . 16
10.1 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . 16
10.2 Water Connections . . . . . . . . . . . . . . . . . . . . . . 16
10.3 Condensate Drain Connection . . . . . . . . . . . . . 16
11 Flue Preparation and Installation . . . . . . . . . . . 17
11.1 Flue Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.2 Extension pipes . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.3 Flue Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11.4 Flue Attachment To Boiler . . . . . . . . . . . . . . . . 18
12 Electrical Connections . . . . . . . . . . . . . . . . . . . 19
12.1 Mains, external controls and pump connections
(mains voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . 19
12.2 Electrical connections – testing . . . . . . . . . . . . 19
13 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 20
13.1 Preliminaries - All Systems . . . . . . . . . . . . . . . . 20
13.2 Sealed Systems . . . . . . . . . . . . . . . . . . . . . . . . . 20
13.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13.4 Initial Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13.5 Testing - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
13.6 Testing - Heating System . . . . . . . . . . . . . . . . . 21
13.7 User Controls and Options . . . . . . . . . . . . . . . . 21
13.8 Temperature Display . . . . . . . . . . . . . . . . . . . . . 21
13.9 Pump Exercise Programme . . . . . . . . . . . . . . . . 21
13.10 Handover to user . . . . . . . . . . . . . . . . . . . . . . . . 21
Table of Contents
Instructions for Installation and Servicing ecoMAX pro 3
Page
14 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14.2 Spark Electrode . . . . . . . . . . . . . . . . . . . . . . . . . 22
14.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14.4 Combustion Chamber and Heat Exchanger. . . 23
14.5 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . 23
14.6 Inner Casing Panel Seal Check. . . . . . . . . . . . . 23
15 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
16 Short Spare Parts . . . . . . . . . . . . . . . . . . . . . . 27
17 Boiler Specification . . . . . . . . . . . . . . . . . . . . . 28
1 List of contents
Instructions for Installation and Servicing ecoMAX pro4
1 List of contents
1.1 Contents included with ecoMAX pro boiler
Ensure that all contents are included before commencing installation.
Fig. 1.1: Items supplied with unit (ecoMAX pro)
1
2
3
4
5
6
7
8
Item Quantity Description
11 Boiler
21 Hanging bracket
31 Flue connection adaptor
41 Instruction booklet
52 Guarantee card and envelope and log book
61 Template
71 Screws/wallplugs
81 Gas service valve and compression couplers
Vaillant Ltd. support the Benchmark initiative.
Within the information pack you will find a
Benchmark Log Book. It is very important that this
is completed correctly at the time of installation,
commissioning and handover to the user.
Important information 2
Instructions for Installation and Servicing ecoMAX pro 5
2 Introduction
2.1 General Information
Thank you for choosing a Vaillant boiler. The information
given in this booklet will enable you to obtain the best
performance from your boiler.
The Benchmark logbook should be completed by the
installer and/or commissioning engineer and handed to
the user.
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.
This boiler is designed to provide central heating from a
fully pumped open-vented or sealed water system with a
fully indirect cylinder.
The central heating water temperature can be adjusted
on the boiler.
Once the controls are set the boiler operates automatically.
A frost protection programme is also included.
Please read these instructions and follow them carefully
for the correct and economical use of your boiler.
2.2 Gas Category
This boiler is for use only on Natural gas (G20).
2.3 Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law
that ALL gas appliances are installed by a competent
person in accordance with the current issue of the
above regulations.
2.4 Gas Testing and Certification
The boiler is tested and certificated for safety and performance. It is, therefore, important that no alteration is
made to the boiler.
2.5 CE Mark
This boiler meets the requirements of Statutory
Instrument, No. 3083 The Boiler (Efficiency)
Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or
gaseous fuels.
Type test for purposes of Regulation 5 certified by:
Notified body 0086.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the
laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonisation of the Laws
of the Member States relating to electrical equipment
designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the
Laws of the Member States relating to electromagnetic
compatibility.
2.6 Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act
1974, we are required to provide information on
substances hazardous to health.
The adhesives and sealants used in this appliance are
cured and give no known hazard in this state.
2.6.1 Insulation Pads
These can cause irritation to skin, eyes and the
respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if
the material is broken.
Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before
eating, drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation
to the skin seek medical attention.
2.7 Spare Parts
Only original Vaillant spare parts may be used.
2.8 Manual Handling Guidance
During the appliance installation and the replacement of
the heat exchanger it will be necessary to employ
caution and assistance whilst lifting as the appliance or
component exceeds the recommended weight for a one
man lift.
In certain situations it may be required to use a
mechanical handling aid.
Ta ke care to avoid trip hazards, slippery or wet surfaces.
2.9 Warnings
Gas Leak or Fault
If a gas leak or fault exists or is suspected, turn the
boiler mains electrical supply off and turn off the gas
supply at the meter. Consult your local gas company or
your local installation/servicing company.
Clearances
If fixtures are positioned close to the boiler, space must
be left as shown in Fig. 6.1. Enough space must also be
left in front of the boiler to allow for servicing.
2 Important information
2.12 Boiler Casing
Do not remove or adjust the casing in any way, as
incorrect fitting may result in incorrect operation or
failure to operate at all.
2.13 Condensate Drain
The condensate drain, see section 10.3, must not be
modified or blocked.
2.14 Pluming from flue terminal
All condensing boilers produce a plume of water vapour
from the flue terminal. This is due to the high efficiency
and hence low flue gas temperature. This may increase
in wet, damp weather but this is completely normal and
indicates that the boiler is operating correctly.
2.15 Cleaning
This appliance contains metal parts and care should be
taken when handling and cleaning with particular regard
to edges.
The boiler casing can be cleaned using a mild liquid
detergent with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as
you may damage the paintwork.
2.16 Maintenance and Servicing
For the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced
at regular intervals. The frequency of servicing will
depend upon the installation conditions and usage, but
in general, once a year should be enough.
If this appliance is installed in a rented property there is
a duty of care imposed on the owner of the property by
the current issue of the Gas Safety (Installation and Use)
Regulations, Section 35.
Servicing/maintenance should be carried out by a
competent person in accordance with the rules in force
in the countries of destination.
To obtain service, please call your installer or Vaillant
Service Solutions (0870 6060 777).
Please be advised that the installation engineer on completion of commissioning and servicing should complete
the ‘Benchmark’ logbook.
All CORGI Registered Installers carry a CORGI ID card,
and have a registration number. Both should be recorded in your boiler Logbook. You can check your installer
is CORGI registered by calling CORGI direct on: - 01256
372300.
Instructions for Installation and Servicing ecoMAX pro6
Sheet Metal Parts
This boiler contains metal parts (components) and care
should be taken when handling and cleaning, with
particular regard to edges.
Sealed Components
Under no circumstances must the User interfere with
any sealed component as this could result in a
potentially dangerous situation arising.
Electrical Supply Failure
This boiler must be earthed.
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the
electrical supply is restored.
Reset any external controls to resume normal operation
of the central heating.
If the boiler does not resume normal operation turn the
mains reset switch off and on. If the boiler does not
resume normal operation after this the overheat
thermostat may have operated. The overheat
thermostat would only operate under abnormal
conditions and, under these circumstances; it would be
advisable to consult your installation / servicing
company.
2.10 Protection Against Freezing
The boiler has a built in frost protection programme as
long as the electricity and gas are left switched on.
This device operates the burner and system pump when
the temperature inside the boiler falls to 3 °C.
Any other exposed areas of the system should be
protected by a separate frost thermostat.
If the mains electricity and gas are to be turned off for
any long periods during severe weather, it is
recommended that the whole system, including the
boiler, should be drained to avoid the risk of freezing.
Make sure that, if fitted, the immersion heater in the
cylinder is switched off.
If you have a sealed water system contact your
installation/ servicing company as draining, refilling and
pressurising MUST be carried out by a competent
person.
As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the
condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe. The
boiler should then restart. Contact your installation/
servicing company if the fault persists.
2.11 Boilers Installed in a Compartment or Cupboard
If the boiler is fitted into a compartment or cupboard it
does not require ventilation openings.
Do not use the compartment or cupboard for storage.
2 Important information Operating the boiler 3
Instructions for Installation and Servicing ecoMAX pro 7
3.2 All Systems
Check that the electrical supply to the boiler is ON at
the external isolator.
Set any remote heating system controls as required.
3.3 User Controls
Slide the On / Off control down to the I position to turn
on the boiler. The operating indicator will illuminate
(green) to show that the boiler is on.
The temperature of the central heating water can be
adjusted by pushing the mode button ( ) until the
radiator symbol is displayed. Pushing the + or - buttons
will then set the water temperature as desired. (Typical
setting temperatures for a normal radiator heating
sytem will be in the range of 60 °C to 80 °C. Note that
set temperatures below 60 °C will not sufficiently heat
any hot water cylinder). To return to the normal mode
push the mode button ( ) until the display shows the
current temperature of water in the boiler.
When the boiler is operating the flame symbol will be
shown in the display. The bar symbol is also shown and
this indicates the modulating output of the boiler. The
boiler will automatically modulate to the output needed
by the heating system - the more bars that are displayed, the higher the output.
The ecoMAX pro is a fan flue appliance and the operation of the fan may be heard when the boiler is running
and for a short period after the boiler has stopped.
Should a fault condition occur the operating indicator
will flash red and will be accompanied by an "F" symbol
in the display. To reset the boiler slide the On / Off control to the Off (O) position and after 5 seconds back to
the On (I) position. The boiler should now operate.
If the fault persists contact your installer / service provider.
The ecoMAX pro has a Holiday / frost mode. If you are
going on holiday and do not want the boiler to be operated by the external heating controls press the mode button ( ) until the MODE indicator flashes in the left
hand edge of the display. Then press the + or - button
until the arrow indicator points to the holiday symbol.
The boiler will now only operate if necessary for frost
protection of the boiler itself as well as running a daily
pump exercise programme to prevent sticking. It will
not be turned on and off by the external heating controls. If a system frost protection thermostat has been
fitted this will remain active.
2.17 Guarantee
Our confidence in the quality of craftmanship and
performance of our products is demonstrated by the
Vaillant two year guarantee.
During the first year from installation the guarantee
covers your boiler against manufacturing defects for
both parts and labour. In order to extend this guarantee
to the second year from installation all you have to do is
ensure that your boiler receives a service when it is a
year old. (Please note that the cost of the service is not
included in the guarantee).
Should your boiler develop a fault please contact your
original installer or alternatively contact Vaillant Service
Solutions on 0870 6060 777.
IMPORTANT...
to qualify for your two year guarantee:
Please complete the registration details on the
guarantee card and return in the pre-paid envelope to:
Vaillant Registration Department
Freepost CV 2560
BEDWORTH
Warwickshire
CV12 8BR
The registration card must be returned within 30 days of
the boiler being installed.
The boiler must be serviced either by Vaillant Ltd. or
another competent servicing company (CORGI
registered) within one year of the installation date and
the details recorded in the "Installation, Commissioning
and Service Record Log Book" (this log book should
have been completed and left with you by your installer).
Please note that the cost of the service is not included
in the guarantee.
Vaillant is a member of the Benchmark initiative and
fully supports the aims of the programme. Benchmark
has been introduced to improve the standards of installation and commissioning of central heating systems in
the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
3 Operating the Boiler
3.1 Sealed Central Heating Systems only.
CAUTION. A sealed water system must be filled and
pressurised by a competent person.
Only light the boiler when you are sure that the system
and boiler have been filled and pressurised.
The pressure should read at least 0.7 bar, when the
system is cold. If the needle displays a value below this,
follow the instructions left by your installer to refill the
system.
Alternatively your installer should be called to refill the
system.
4 General Information
Instructions for Installation and Servicing ecoMAX pro8
3.4 To Turn the Boiler Off
Normally the boiler will be turned off by the heating
system controls. The mains On / Off control may be
used to switch off the boiler, however it is preferable to
leave the electrical supply on whenever possible to permit operation of the built-in frost protection and daily
pump exercise programme.
Fig. 3.1
4 General Information
Important notice
The boiler is supplied in one pack and the flue is
supplied separately.
This boiler is for use only on G20 natural gas.
Where no British Standards exists, materials and
equipment should be fit for their purpose and of suitable
quality and workmanship.
Refer to Manual Handling Operations, 1992 regulations.
The installation of this boiler must be carried out by a
competent person in accordance the rules in force in the
countries of destination.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
4.1 Sheet Metal Parts
Warning!
When installing the appliance, care should be
taken to avoid any possibility of personal injury
when handling sheet metal parts.
4.2 Statutory Requirements
The installation of the boiler MUST be carried out by a
competent person in accordance with the relevant
requirements of the current issue of:
Manufacturer's instructions supplied.
The Gas Safety (Installation and Use) Regulations, The
Building Regulations, The Building Standard (Scotland)
Regulations, Water Supply (Water Fittings) Regulations,
Water Bylaws, The Health and Safety at Work, Act,
Control of Substances Hazardous to Health, The
Electricity at Work Regulations and any applicable local
regulations.
Detailed recommendations are contained in the current
issue of the following British Standards and Codes of
Practice, BS4814, BS5440 Part 1 and 2, BS5449,
BS5546, BS6700, BS6798, BS6891 and BS7074 Part 1
and 2, BS7478, BS7593, BS7671.
4.3 Gas Supply
The gas installation must be in accordance with the
current issue of BS6891.
The supply from the governed meter must be of
adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.
On completion, test the gas installation for soundness
using the pressure drop method and suitable leak
detection fluid, purge in accordance with the above
standard.
4.4 Technical Data
All dimensions are given in millimetres (except as
noted). See Fig. 4.1.
The data label is positioned on the combustion chamber
cover see fig. 4.2.
Fig. 4.1
Fig. 4.2
4 General Information Water system 5
Instructions for Installation and Servicing ecoMAX pro 9
4.5 Electrical Supply
The boiler must be earthed.
All system components shall be of an approved type and
all wiring to current I.E.E. wiring regulations.
The boiler must be connected to a permanent 230 V ac,
50 Hz supply.
Connection of the whole electrical system of the boiler,
including any heating controls, to the electrical supply
must be through one common isolator and must be
fused 3 Amp maximum. Isolation should be by a double
pole switched fused spur box, with a minimum gap of
3mm for both poles. The fused spur box
should be readily accessible and preferably adjacent to
the appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both
to the current issue of BS 1363 may be used, provided
they are not used in a room containing a bath or shower.
The colours of three core flexible cable are,
blue - neutral, brown - live, green and yellow - earth.
4.6 Condensate Drain
A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the
internal household draining system. If this is not
practical, discharge can be made externally into the household drainage system or a purpose designed soak
away, see Section 10.3 for more details.
4.7 Heating System Controls
It is recommended that a programmer and room thermostat control the boiler.
Thermostatic radiator valves may be installed, however
they must not be fitted in a room where the room thermostat is located.
Note!
All systems must have at least one radiator not fitted with a thermostatic valve.
Note!
For further information, see the current issue of
the Building Regulations, approved document L1,
and the references:
1) GIL 59, 2000: Central heating system specification
(CheSS)
and
2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
5 Water system
5.1 Draining Tap
A draining tap must be provided at the lowest point of
the system, which will allow the entire system and hot
water system to be drained.
Draining taps shall be to the current issue of BS 2879.
5.2 Safety Valve
A safety valve need not be fitted to an open-vented
system.
Fig. 5.1
Fig. 5.2
28 E Pressure Loss Graph
Flow Rate (litres/hour)
1289 l/hr = 20 diff @ 30kW
Water Pressure Loss (metres head of water)
0.00
0.50
1.00
1.50
2.00
2.50
3.00
200 400 600 800 1000 1200 1400
2.55 m
0
0.5
1
1.5
2
2.5
0100200 300 400 500 600 700 800 900 1000
18 E Pressure Loss Graph
Flow Rate (litres/hour)
773.86 l/hr = 20 diff @ 18 kW
Water Pressure Loss (metres head of water)
1.38m
Water system 5
Instructions for Installation and Servicing ecoMAX pro10
5.5 Inhibitor
Attention is drawn to the current issue of BS 5449 and
BS 7593 on the use of inhibitors in central heating
systems.
If an existing system is to be reused take special care to
drain the entire system, including the radiators, then
thoroughly cleaning out before fitting the boiler whether
or not adding an inhibitor.
For advice please refer to 5.10, Water Treatment.
5.6 Open (Vented) Water System
The boiler must be supplied from an unrestricted water
supply taken from a feed and expansion cistern situated
at a maximum height of 27 metres (90ft) above the
boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump,
cold feed and open vent are as shown in Fig. 5.3.
5.7 Domestic Hot Water Cylinder
Warning!
Single feed indirect cylinders are not suitable.
The domestic hot water cylinder must be of the double
feed fully indirect coil type.
5.8 Domestic Hot Water System - unvented
Where a storage system will not have a vent to
atmosphere the installation must comply with the building regulations and local Water Company bylaws, see
also the current issue of BS5546 and BS6700.
If fitting to an existing system the local authority should
be informed.
Note!
ecoMAX pro boilers are not suitable for use with
Vaillant VANTAGE unvented cylinders and MUST
not be used in connection with these cylinders.
Fig. 5.3
Table 5.1 Flow rate
5.3 Pump
The pump should be fitted on the flow pipe from the
boiler and have isolating valves each side.
A variable duty pump should be set to give a
temperature difference of no greater than 20 °C
between the flow and return, with the thermostat set at
“MAX”, which is about 80 °C, to give a flow rate as
shown in table 5.1.
See chart for pressure loss of the boiler, Fig. 5.1 or 5.2.
High resistance microbore systems may require a higher
duty pump.
5.4 Bypass
A bypass is not required on the central heating system
unless all radiators are fitted with thermostatic radiator
valves or the system controls could allow the boiler and
pump to operate when there is no flow.
Where a bypass has to be fitted, the bypass must be placed at least 1.5 metres away from the boiler.
Open (vented) system.
Recommended
relationship between
pump, cold feed and vent.
22mm (MIN.) VENT
FEED AND
EXPANSION CISTERN
15mm (MIN) COLD FEED
15mm (MIN.) BY-PASS
(if required)
RETURN
FLOW
HEATING
CYLINDER
PUMP
BOILER
150mm MAX.
1000mm
MIN.
450mm
MIN.
HEIGHT
Model Minimum flow rate
ecoMAX pro 18 E 773.8 litres/hr
ecoMAX pro 28 E 1289 litres/hr
This is equal to 20 °C differential at maximum heat input.
Water system 5
Instructions for Installation and Servicing ecoMAX pro 11
5.9.3 Pressure Gauge
A pressure gauge with a set pointer and covering at
least 0 to 4 bar (0 to 60 lb/in2) shall be fitted permanently to the system in a position where it can be seen
when filling the system.
5.9.4 Domestic Hot Water Cylinder
The domestic hot water cylinder must be of the double
feed fully indirect coil type. It must be suitable for
working at a gauge pressure of 0.35 bar above the
safety valve setting.
5.9.5 Water Makeup
Provision should be made for replacing water loss from
the system using a make up bottle mounted in a position
higher than the top point of the system, connected
through a non-return valve to the return side of either
the heating circuit or the hot water cylinder.
Alternatively, provision for make up water should be
made using a proprietary filling loop.
5.9.6 Filling a Sealed Water System
Provision for filling the system at low level must be
made. This can be achieved by the use of a proprietary
filling loop.
5.10 Water Treatment
For optimum performance after installation, the boiler
and its associated central heating system should be
flushed in accordance with BS7593: 1992 using a
cleanser.
For advice on the application of system cleansers and
inhibitors contact either;
Fernox, Alpha-Fry Technologies
Tandem House
Marlow Way
Beddington Farm Road
Croydon CR0 4XS
Tel: 0870 601 5000
Fernox technical help line
01799 550811
or:
Sentinel, GE Betz
Widnes
Cheshire, WA8 8UD
Tel: 0151 420 9595
5.9 Sealed water Systems
The installation must comply with the appropriate
requirements of the current issue of BS4814, BS5449,
BS6759, BS6798 and BS7074 Part 1 and 2.
See Fig. 5.4 for a suggested layout.
Fig. 5.4
5.9.1 Safety Valve
A safety valve must be fitted to a sealed system.
It shall be preset, non-adjustable with a lift pressure of
3bar, incorporating seating of a resilient material, a test
device and a connection for drain.
The safety valve discharge pipe must be routed to
outside the building, must not discharge above an
entrance or window or any type of public access area, be
clear of any electrical fittings and positioned so that any
discharge can be seen.
5.9.2 Expansion Vessel
A diaphragm type expansion vessel, conforming to the
current issue of BS4814 (see also BS7074 Part 1 and 2)
must be connected at a point close to the inlet side of
the circulating pump, see the diagrammatic layout, Fig.
5.4. unless laid down differently by the manufacturer.
The expansion vessel volume depends on the total water
system volume and the initial system design pressure.
For any system an accurate calculation of vessel size is
given in the current issue of BS5449 and BS7074 Part 1.
Example: For an initial design pressure of 0.7 bar, the
minimum total vessel volume required is 0.063 x Total
System Volume.
Note!
A higher initial design pressure requires a larger
volume expansion vessel.
The charge pressure must not be less than the
static head of the system, that is, the height of the
highest point of the system above the expansion vessel.
3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
FLOW
DRAIN
COCK
BOILER
SAFETY
VALVE
(Make-up
alternatives)
EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING
CIRCUIT
BY-PASS 'B'
IF REQUIRED
FLOW
CONTROL
VALVE 'A'
FLOW
CONTROL
VALVE 'A'
6 Boiler Location and Ventilation
Instructions for Installation and Servicing ecoMAX pro12
Fig. 6.1
*
*
*
*
Increase to 25mm clearance from
comb ustible material.
†
MINIMUM CLEARANCE FROM
PERMANENT SURFACES
† A removable compartment door can be
placed at least 5mm in front of the appliance.
5
5
600
200**
20
20
200
** 220mm above the boiler when utilising the
125mm flue system
6 Boiler Location and Ventilation
6.1 Boiler Location
The boiler may be installed in any room although
particular attention is drawn to the requirements of the
current issue of BS7671 with respect to the installation
of a boiler in a room containing a bath or a shower. Any
electrical switch or boiler control using mains electricity
should be so situated that a person using the bath or
shower cannot touch it. The electrical provisions of the
Building Standards (Scotland) Regulations are applicable
to such installations in Scotland.
The boiler must be mounted on a flat wall, which is
sufficiently robust to take its total weight.
The boiler is not suitable for fitting outdoors.
Any electrical switch or boiler control using mains
electricity must be positioned so that a person using a
bath or shower cannot touch it.
6.2 Clearances
The boiler should be positioned so that at least the
minimum operational and servicing clearances are
provided, see Fig. 6.1.
Additional clearances may be beneficial around the
boiler for installation and servicing.
For flue installations where external access is not
practicable, consideration should be given for the space
required to insert the flue internally, which may
necessitate clearance larger than those specified in
Fig. 6.1.
6.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building
it should be fitted in accordance with the Institute of Gas
Engineers document IGE/UP/7/1998.
6.4 Room Ventilation
The boiler is room sealed, so when it is installed in a
room or space, a permanent air vent is not required.
6.5 Compartment Ventilation
If the boiler is installed in a compartment, a permanent
air vent is not required.
Leave existing air vents.
Flue 7
Instructions for Installation and Servicing ecoMAX pro 13
7.2 Flue termination
The following details refer to both flue systems.
a. The terminal must be positioned such that the pro-
ducts of combustion can disperse freely at all times.
b. In certain weather conditions a plume of water
vapour may be visible from the flue terminal.
Positions where this could be a nuisance should be
avoided.
c. If the terminal is fitted less than 2 m above a bal-
cony, above ground or above a flat roof to which people have access then a suitable terminal guard must
be provided and fitted (A suitable guard is manufactured by: Tower Flue Components, Morley Road,
Tonbridge, Kent, TN9 1RA. Size: 280mm x 280mm x
270mm).
Note!
Vertical flues must not terminate within
600 mm of an openable window, air vent or any
other ventilation opening.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
Fig. 7.3
A
BCD
A
G
H, I
F
J
B
F
M
L
L
K
K
G
G
F
F
E
A
A
7 Flue
7. 1 Flue Position and Length
The standard horizontal flue is fitted onto the top of the
boiler.
See Fig. 7.1 and 7.2 to determine whether a standard flue
can be used.
Fig. 7.1
Fig. 7.2
Flue system
The standard 100mm flue system (Art. No. 303 930) is
suitable for installations up to 730 mm measured from
the centre of the boiler flue outlet to the outside face of
the wall.
Flue extensions are available to extend this length up to
10.8m (see section 11.2). Both 90° bends and 45° elbows
are also available to increase siting flexibility.
A concentric flue system of 125 mm outside diameter is
available and can be used to achieve flue lengths up to
20 m.
A vertical flue system is also available.
Refer to flue system installation instructions for full
details.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at
least 3° to allow condensate to run out via the drain.
SIDE FLUE - STANDARD
DISTANCE 'Y' = 345 TO 730mm - Left
DISTANCE 'Y' = 250 TO 730mm - Right
"Y"
WALL THICKNESS 'X' = 75 TO 550 mm
REAR FLUE - STANDARD
"X"
7 Flue Installation Preparation 8
Instructions for Installation and Servicing ecoMAX pro14
1) In addition, the terminal should not be nearer than 150mm to an
opening in the building fabric formed for the purpose of
accommodating a built-in element such as a window.
2) Dimension 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 7.4.
3) 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 preferred.
4) BS 5440-1 It is recommended that a fanned flue terminal should
be positioned as follows:
a) at least 2m from an opening in a building directly opposite, and
b) so that the products of combustion are not directly directed to
discharge across a boundary.
Fig. 7.4
7. 3 Internal Flue Installation
The flue can be installed from inside the building when
access to the outside wall face is not practicable.
7. 4 Flue Options
There are various flue systems to choose from, as
follows:
balcony/eaves
flue extended to
clear any overhang
flue adequately
supported
gutter
•Vertical air/flue duct and terminal 303 900
• Air/flue duct extension (470 mm) 303 902
• Air/flue duct extension (970 mm) 303 903
• Air/flue duct extension (1970 mm) 303 905
•Telescopic air/flue duct extension
(440 mm - 690 mm) 303 906
•87° elbow 303 910
•Two 45° bends 303 911
•Standard horizontal air/flue duct
with elbow and terminal (800 mm) 303 930
Additional accessories are available.
8 Installation Preparation
8.1 Unpacking of Boiler
Stand the boiler carton upright.
Cut and remove the securing straps and lift off the carton sleeve. Place aside the flue adaptor and connections
pack until required.
Carefully lay the boiler on its back, remove the two front
casing panel securing screws and lift off the panel from
two retaining lugs, see diagram 8.1.
Remove the two inner casing panel securing screws at
the bottom front of the panel, then lift off the two retaining lugs, see diagram 8.2.
8.2 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 top hanging bracket fixing
holes.
Drill 2 holes to accept the wallplugs/screws supplied for
the hanging bracket.
Note!
Use alternative fixing holes where necessary.
Fig. 8.1
SECURING
SCREW (2 OFF)
FRONT
CASING
PANEL
RETAINING
LUG (2 OFF)
Terminal position
mm
A1)Directly below an opening, above an opening
or horizontal to an opening i.e. air brick, opening
window or other, etc 300
BBelow gutters, soil pipes or drain pipes 75
2)
CBelow eaves 200
2)
DBelow balconies 200
2)
EFrom vertical drain pipes and soil pipes 25
FFrom internal or external corners 300
3)
G Above ground, roof or balcony 300
HFrom a surface facing a terminal 600
4)
IFrom a terminal facing a terminal 1200
KVertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent wall for vertical Flue 500
8 Installation Preparation Boiler fixing 9
Instructions for Installation and Servicing ecoMAX pro 15
Fig. 8.3
To allow for the flue passing through the wall at this
angle a 127 mm hole should be drilled irrespective of
internal or external installation.
If necessary remove the template whilst drilling the flue
hole.
9 Boiler fixing
9.1 Fitting the boiler hanging bracket
Fix the hanging bracket 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.
9.2 Boiler Fixing
Having previously secured the hanging bracket to the
wall, lift the boiler into position in the following manner:
Lean the top of the boiler slightly to the wall and
position just above the hanging bracket. Allow the boiler
to slowly move downwards until engaged in the hanging
bracket.
Fig. 9.1
WALL PLUG
(4 OFF)
SCREW No12 x 50mm
(4 OFF)
WALL
TEMPLATE
HANGING
BRACKET
WALL
TEMPLATE
Ø 127
90
0
176
Fig. 8.2
8.3 Rear flue exit
Mark the position of the air/flue duct and its
circumference.
8.4 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.
Remove the template from the wall and plug the drilled
holes using the wallplugs supplied.
8.5 Flue Hole Cutting
The standard horizontal flue is designed with an internal
fall of 50 mm (
± 20 mm) /metre towards the boiler for
disposal of condensate.
If the standard flue length alone is being used then the
flue hole can be cut in the position marked on the wall
template.
For installations with external access, a 107 mm diameter core drill can be used.
For installations with internal access only, a 127 mm diameter core drill should be used.
For extended side flues, the flue hole centre should be
determined by extending the dashed incline line on the
template to the side wall. This dashed line is drawn at a
50 mm/metre (3°) rise from the boiler. Where this line
reaches the side wall, a horizontal line should be marked. The vertical centre line of the flue should then be
marked at 176 mm from the back wall, see Fig. 8.3.
INNER
CASING
PANEL
RETAINING
LUGS
10 Gas, Water and Condensate Connections
Instructions for Installation and Servicing ecoMAX pro16
10 Gas, Water and Condensate
Connections
10.1 Gas Connection
Before connection check the supply of local gas.
The gas supply can be connected from below, or through
the wall at the rear of the boiler.
Ensure the supply pipe is fully engaged in the compression fitting on the gas service valve inlet. See Fig. 10.1.
and refer to section 4.3.
Fig. 10.1
10.2 Water Connections
Provision is made for the water connections to be made
from above the boiler, see Fig. 10.2 (using the two 22mm
compression couplers supplied). The position is shown
on the wall template.
Flush out the domestic hot water and the heating
systems before connecting to the boiler.
Fig. 10.2
FLOW
RETURN
PLASTIC
OVERFLOW
PIPE
GAS
SERVICE
COCK
GAS
SUPPLY
PIPE IN
GAS SERVICE
COCK SHOWN IN
OPEN POSITION
UNION CONNECTOR
CAP
GAS SERVICE
COCK LINER
SPIGOT
CONDENSATE DRAIN
CONNECTION
10.3 Condensate Drain Connection
The condensate drain connection is at the rear of the
boiler, see Fig. 10.1. A 21.5 mm plastic overflow pipe
should be connected to the spigot on the condense trap
(using the coupler). The drain pipe should have a fall of
a least 2.5° away from the boiler. Condensate should, if
possible be discharged into the household internal drainage system. If this is not practicable, discharge can be
allowed into the external household drains or a purpose
designed soak away.
It is recommended that any external condensate drain
pipe is insulated and also preferably of 32mm diameter,
to prevent freezing in adverse weather conditions.
The condensate is discharged periodically in ‘slugs’ by
siphonic action.
It is not necessary to provide air breaks or extra traps in
the discharge pipe, as there is already a trap inside the
boiler. Refer to BS 6798 for advice on the disposal of
the boiler condensate.
Flue Preparation and Installation 11
Instructions for Installation and Servicing ecoMAX pro 17
11.2 Extension pipes
Refer to Figs. 11.3 and 11.4.
Note maximum permitted flue lengths.
When extension pipes are required please note the
length of the extensions, which should be taken into
account when calculating the length that requires cutting.
For example:
Distance from outside wall to butt joint on the flue
elbow ‘Y’ = 1500 mm.
Standard flue length = 633 mm.
Extension pipe length = 970 mm.
Length of extension pipe air duct
= 1500 - 633 = 867mm.
In this example the extension pipe would be cut to
867 mm, this would be measured from the end of the air
duct where the flue duct contains the ‘o-ring’ seal.
When cutting, the flue duct should be cut to protrude
13 mm from the end of the air duct at the opposite end
to where the flue duct contains the ‘o-ring’ seal.
The maximum permitted straight flue length is
10 metres plus the standard horizontal flue. For each
90° elbow or pair of 45° bends fitted, the maximum
length must be reduced by 1 metre.
Note!
When using elbows/bends any horizontal extension pipe should be inclined by 3° ± 1° fall
towards the boiler to facilitate condense removal.
Fig. 11.3 Side flue extension
DRILL
AND
SCREW
Side of boiler
107
127
11 Flue Preparation and Installation
11.1 Flue Length
All dimensions are in mm.
To determine flue length, temporarily fit flue elbow to
top of boiler.
For rear or side flue, measure the distance from the
outside wall to the butt joint of the flue elbow fitted on
top of the boiler. A standard flue system will be suitable
if the length measured ‘Y’ is less than 633 mm, see
Figs. 11.1 and 11.2.
If the measurement ‘Y’ exceeds 633 mm then one or
more extension pipes are required.
When cutting, the flue duct should protrude 13 mm from
the end of the air duct.
Fig. 11.1 Rear flue
Fig. 11.2 Standard side flue
OUTER
RUBBER
COLLAR
Internal
square
trim ring
Y
70
OUTSIDE
WALL
FACE
DRILL AND
SCREW
BOILER
MOUNTING
WALL
145
11 Flue Preparation and Installation
Instructions for Installation and Servicing ecoMAX pro18
11.4 Flue Attachment To Boiler
Lubricate the internal rubber seal of the flue outlet on
the boiler with a suitable lubricant. Secure the flue
adapter in position on top of the boiler with the four screws supplied, making sure the nib fits into the locating
slot in the boiler casing to ensure correct orientation.
Fit the flue elbow with the securing collar (length
40 mm) on to the flue adapter.
Secure the flue elbow by tightening the two screws on
the securing collar.
Draw flue assembly from wall, fit securing collar (length
70 mm), slide flue duct into flue elbow.
Note!
If the air and flue ducts have been correctly cut
to the instructions given in sections 11.1-11.2 the
rubber sealing collar should fit flush with the
outside wall.
Position securing collar centrally over joint, tighten
securing screws. Drill and insert four self-tapping
screws, supplied, in the holes provided in the securing
collar.
Secure internal trim ring in position with a small amount
of sealant.
Fig. 11.4 Elevated horizontal flue
11.3 Flue Assembly
The flue assembly is a push fit design with securing
collars.
Remove all burrs from cut pipes.
Fig. 11.5 shows the components supplied in the standard
kit and the flue adapter.
Having cut the air and flue ducts as described in
sections 11.1- 11.2 assemble the flue as follows, the flue
can be fitted externally or internally.
Fit the rubber sealing collar behind the locating lugs on
the flue terminal, see diagram 11.5. Push the flue
assembly into the wall, externally or internally, initially
until the end of the assembly protrudes a short way
from the inside face of the wall. This will enable the
internal square trim ring to be positioned and allow the
flue duct to be drawn into the flue elbow after the flue
adapter has been fitted.
Fig. 11.5
FLUE
ELBOW
FLUE
ADAPTER
SECURING
COLLAR
(40mm)
SECURING
COLLAR (70mm)
INTERNAL TRIM
AIR
DUCT
FLUE
DUCT
SEALING
COLLAR
FLUE
TERMINAL
RING (SQUARE)
EXTENDED HORIZONTAL FLUE
X + Y must not exceed
10 metres plus standard
horizontal flue kit.
Reduce flue length by
1 metre for every
additional 90° or pair of 45°
bends.
X
Y
Total flue length must not exceed 10
metres plus standard horizontal flue kit
Reduce flue length by 1 metre for every
additional 90° or pair of 45° bends.
Electrical Connections 12
Instructions for Installation and Servicing ecoMAX pro 19
Disconnect and remove the test cable from the terminal
strip and discard.
Connect both the mains supply and switched live from
the external controls (room thermostat and, if applicable, frost thermostat) into the marked terminals as
shown in Figs. 12.2 and 15.1.
Fig 12.2
Connect the pump supply into the marked pump terminals as shown in Figs.12.2 and 15.1.
(Note: the boiler incorporates a pump overun thermostat. Only feed the pump from the marked terminals in the
terminal box on the boiler, not from a separate supply).
Observe all terminal markings and colour codes shown
in Fig. 15.1.
Ensure that all flexible cords are routed through the
strain relief cable glands on the inlet of the terminal box.
Refit the terminal box to the underside of the boiler
using the two retaining screws.
12.2 Electrical connections – testing
Carry out preliminary electrical system checks as below;
1. Test insulation resistance to earth of mains cable.
2. Test the earth continuity and short circuit of cables.
3. Te st the polarity of the mains.
12 Electrical Connections
Warning!
This boiler must be earthed.
All system components must be of an approved type.
Electrical components have been tested to meet the
equivalent requirement of the BEAB.
Connection of the whole electrical supply must be
through a common isolator.
Isolation should preferably be by a double pole switched
fused spur box having a minimum contact separation of
3mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It
should be identified as to its use. A fused three pin plug
and shuttered socket outlet may be used instead of a
fused spur box provided that:
a) They are not used in a room containing a fixed bath
or shower.
b) Both the plug and socket comply with the current
issue of BS1363.
Do not interrupt the mains supply with a time switch or
programmer.
Warning!
This appliance must be wired in accordance with
these instructions. Any fault arising from
incorrect wiring cannot be put right under the
terms of the Vaillant guarantee.
12.1 Mains, external controls and pump connections
(mains voltage)
ecoMAX pro boilers are fitted with a terminal box located at the base of the boiler into which all connections
are made.
To gain access to the terminal box remove the two retaining screws indicated in Fig. 12.1 and carefully lower to
reveal the terminal strip inside.
Fig. 12.1
13 Commissioning
Instructions for Installation and Servicing ecoMAX pro20
13 Commissioning
13.1 Preliminaries - All Systems
A competent person in accordance with the current
issue of BS 6798 should carry out commissioning.
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.
Make sure that the system has been thoroughly flushed
out with cold water.
Refill the system with water, making sure that all the air
is properly vented from the system and pump, Fig. 13.1
shows vent point.
Before operating the boiler check that all external controls are calling for heat.
Fig. 13.1
13.2 Sealed Systems
Fill the system until the pressure gauge registers the
recommended pressure. Clear any air locks and check
for leaks.
Check the operation of the safety valve, preferably by
allowing the water pressure to rise until the valve lifts.
This should be within ± 0.14 bar, of the preset pressure.
Where this is not possible a manual check should be
carried out.
Release the cold water to the initial design pressure.
VENT POINT
FLOW
PIPE
OVERHEAT
THERMOSTAT
FLOW
THERMISTOR
RETURN
THERMISTOR
13.3 Gas supply
Isolate the boiler from the mains electrical supply.
The complete gas installation including the gas meter
must be inspected, tested for soundness and purged in
accordance with BS 6891.
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).
13.4 Initial Lighting
The lighting procedure of the boiler is fully automated.
To prepare the boiler for initial lighting first ensure that
all external controls are not calling for heat.
With the front casing panel and inner casing panel
removed turn on the mains electrical supply. Slide the
On / Off control down to the I position to turn on the
boiler. The operating indicator will illuminate (green) to
show that the boiler is on.
Now adjust the boiler thermostat to its lowest setting by
pushing the mode button (see Fig. 3.1.) until the radiator
symbol is displayed. Push the - button until the lowest
temperature possible is selected. Now return to the normal mode by pushing the mode button, the display will
now show the current temperature of water in the boiler.
Now turn on external heat demand to boiler.
The fan should start and after a few seconds the ignition
will commence.
Note!
Allow the boiler to run on minimum until commissioning is complete.
If the burner fails to light the fan will stop. Initially this
may be due to air in the gas supply line.
The boiler will have three attempts at ignition.
To reset the boiler slide the On / Off control to the Off
(O) position and after 5 seconds back to the On (I) position. The boiler should now restart.
Once the boiler has lit, allow the system to warm at the
minimum temperature setting to purge any air from the
system.
Once the system has been purged of air, the temperature of the central heating water can be adjusted to the
desired setting by pushing the mode button (see Fig.3.1.)
until the radiator symbol is displayed. Pushing the + or buttons will then set the water temperature as desired.
(Typical setting temperatures for a normal radiator heating sytem will be in the range of 60 °C to 80 °C. Note
that set temperatures below 60 °C will not sufficiently
heat any hot water cylinder). To return to the normal
mode push the mode button ( ) until the display
shows the current temperature of water in the boiler.
Commissioning 13
Instructions for Installation and Servicing ecoMAX pro 21
The boiler will then continue to fire until the user controls are satisfied.
Note: After the first power up the firing sequence changes. After one minute stabilisation time the boiler will
ramp slowly to full rate rather than going immediately to
full rate, this feature is designed to cope with small
system requirements.
13.5 Testing - Gas
The boiler is supplied ready adjusted and no further gas
adjustments are necessary, however both the gas inlet
working pressure and the maximum gas rate should be
checked at least 10 minutes after the burner has lit.
The gas inlet working pressure can be checked at the
pressure test point on the gas valve (Fig 13.2.). The gas
inlet working pressure should be 20 mbars when the
boiler is firing at full rate.
After testing the inlet pressure remove the U gauge,
tighten the sealing screw and test for tightness.
The approximate gas rates are:
18 E : 1.81 m
3
/h
28 E : 2.7 m
3
/h
Note: The burner pressure cannot be measured at the
gas valve due to the fan/burner design.
Replace the inner and front casing panels.
Record appliance working gas inlet pressure (mbar) in
Benchmark Installation, Commissioning and Service log
book.
13.6 Testing - Heating System
Check that all remote controls are calling for heat. The
boiler will fire automatically. Fully open all radiator
valves, flow control valve ‘A’ and bypass valve ‘B’ if
fitted, see Fig. 5.4.
Balance the radiators as required and if fitted adjust
valve ‘A’ to give the required system differential. Turn off
all radiators that can be shut off by the user and check
to see if less than the maximum differential allowed of
20 °C can be achieved across flow and return.
Allow the system to reach maximum temperature then
switch off the boiler by isolating from the electrical
supply.
Fig. 13.2
PRESSURE TEST
POINT
ELECTRICAL
PLUG
GAS CONTROL
VALVE
THROTTLE
OFFSET
ADJUSTMENT
Drain the entire system rapidly whilst hot, using the
drain tap at the lowest part of the system. Fill and vent
the system as described previously.
Lock or remove the handles from controls valve ‘A’ and
bypass valve ‘B’ to prevent unauthorised adjustment.
13.7 User Controls and Options
The mains/reset switch is used to restart the boiler after
a fault condition has occurred, i.e. ignition failure.
The user display (see section 3.3) allows the user to set
the desired central heating temperature.
13.8 Temperature Display
The boiler shows the operating temperature of the unit.
13.9 Pump Exercise Programme
After a power cut or every 24 hour in frost setting/
summer mode the pump will run for one minute to
prevent it from sticking. This will also occur during
normal operating if there is no demand for more than
24 hours.
13.10 Handover to user
Instruct and demonstrate the lighting procedure and
advise the user on the safe and efficient operation of
the boiler. Instruct on and demonstrate the operation of
any heating system controls.
Advise that to ensure the continued efficient and safe
operation of the boiler it is recommended that it is
checked and serviced at regular intervals. The frequency
of servicing will depend upon the installation conditions
and usage, but in general, once a year should be
adequate.
Draw attention, if applicable, to the current issue of the
Gas Safety (Installation and Use) Regulations, Section
35, which imposes a duty of care on all persons who let
out any property containing a gas appliance.
It is the Law that any servicing is carried out by a
competent person.
Advise the user that, like all condensing boilers this
appliance will produce a plume of condensation from the
flue terminal in cool weather. This is due to the high
efficiency and hence low flue gas temperature of the
boiler.
Advise the user of the precautions necessary to prevent
damage to the system, boiler and the building, in the
event of the heating system being out of use during
frost or freezing conditions.
Advise the user that the permanent mains electrical
supply SHOULD NOT be switched off, as the built in
frost protection and pump saver program would not be
operable.
RReemmiinnddeerr,,
leave these instructions and the ‘Benchmark’
logbook with the user.
14 Servicing
Instructions for Installation and Servicing ecoMAX pro22
14 Servicing
14.1 General
Measurement of the products of combustion can be
achieved by connection of a probe to the combustion
analyser test point on the flue adaptor, see Fig. 14.4.
Refer to section 14.7 and data table.
Before commencing with a service or replacement of
parts the boiler should be isolated from the electrical
supply and the gas supply should be turned off at the
gas isolation valve, see Fig. 14.2.
All routine servicing requirements can be achieved by
the removal of the front panel, inner panel and chassis
front only.
Remove the two screws on the underside of the front
panel and lift off. Undo the two screws on the front of
inner panel and lift off, see Fig. 14.7.
To remove chassis front, refer to section 14.3.
Unless stated otherwise any part removed during
servicing should be replaced in the reverse order to
removal.
Servicing should always include the removal of any
debris from the condensate pipe and siphon.
After completing any servicing of gas carrying
components, ALWAYS test for gas soundness and carry
out a functional test of the controls.
14.2 Spark Electrode
Disconnect the ignition lead and earth lead from the
ignitor unit and two securing screws at the spark
electrode. Withdraw the spark electrode carefully from
the combustion chamber, see Fig. 14.1.
Inspect the tips for damage.
Clean away any debris and check the spark gap is 3.5 -
4.5 mm.
Check the electrode gasket for signs of damage and
replace if necessary.
Fig. 14.1
SECURING
SCREW
2 OFF
SPARK GAP
HEAT
EXCHANGER
GASKET
SPARK
ELECTRODE
3.5 to 4.5mm
EARTH
LEAD
14.3 Burner
Refer to Figs. 14.2, 14.3, 14.4 and 14.5.
Isolate the gas supply at the gas service cock.
Disconnect the gas supply at the gas service cock.
Note!
Do not disconnect at the gas valve.
Remove the two gas pipe bracket securing screws from
underside of inner case, see Fig. 14.2.
Drop down the control panel into the service position.
Remove the four screws from the chassis front, see Fig.
14.3.
Remove the chassis front by pulling it out at the top
from its retaining slots.
Note!
When replacing chassis front panel ensure the
bottom fits behind lip.
Disconnect the gas control valve plug at the gas control
valve, see Fig. 14.4.
Disconnect the electrical leads from the fan.
Remove the five combustion chamber front securing
nuts, see Fig. 14.5.
Fig. 14.2
Fig. 14.3
CONTROL
PANEL
SERVICE
POSITION
SECURING
SCREW
(4 OFF)
CHASSIS
FRONT
CONDENSE
TRAP
GAS SERVICE
COCK
GAS
SUPPLY PIPE IN
GAS PIPE BRACKET
SECURING SCREW
SEALING
GROMMET
UNION NUT
Servicing 14
Instructions for Installation and Servicing ecoMAX pro 23
Fig. 14.4
Fig. 14.5
Gently remove the fan, gas control valve and burner
assembly from the combustion chamber complete with
the gas pipe bracket and seal.
Clean the burner with a soft brush taking great care not
to damage the front insulation. DO NOT use wire or
sharp instruments to clean the holes of the burner.
Inspect the burner for any signs of damage.
Removal of the burner is not necessary during a normal
service.
BURNER
COMBUSTION
CHAMBER
FAN
GAS
CONTROL
VALVE
GAS PIPE
BRACKET
& SEAL
SECURING
NUTS (5
OFF)
GAS CONTROL
VALVE
FAN
COMBUSTION
CHAMBER FRONT
SECURING NUTS
(5 OFF)
HEAT EXCHANGER
IGNITION
LEAD
COMBUSTION
ANALYSER TEST
POINT
FLUE
ADAPTER
ELECTRODEŁ
CONNECTOR
Note!
If the burner has to be removed it will require a
new gasket when refitted.
When replacing the assembly ensure the sealing grommet is correctly fitted.
14.4.Combustion Chamber and Heat Exchanger.
Refer to Fig. 14.2.
Remove loose debris from combustion chamber using a
soft brush and vacuum cleaner. Carefully flush any
remaining debris through the condensate trap (ensure
the water is kept away from electrical components).
14.5 Condensate Drain
Refer to Fig. 14.5.
Remove DC fan supply.
Remove the clips securing the flexible tubes to the
siphon adapter by twisting the clips slightly to disengage
the clip jaws from each other.
Remove black flexible tubes from siphon adapter.
Lift off the siphon adapter.
Remove the drain connection downstream of the
condense trap.
Remove the two condense trap securing screws. Lift up
and carefully remove the condense trap taking care not
to spill any water which may be left in the unit. As the
unit is lifted remove the flexible pipe on the outlet.
Remove the cap at the base of the condense trap.
Remove any solids found.
Remove the float to clean it.
Flush water through the trap to remove any remaining
solids.
Check for any debris in the outlet pipe of the
condensate drain and clean as necessary.
Reassemble and refit the condense trap.
When refitting the cap ensure that a watertight seal is
achieved, but do not use excessive force.
Remove the siphon adaptor from the silicone tubes,
using a suitable container, flush the heat exchanger until
the water appears clear in the container.
14.6 Inner Casing Panel Seal Check.
Refer to Fig. 14.7.
Check the condition of the seal, replace as required.
To r eplace remove the old seal, thoroughly clean the
casing surfaces. Fit the new seal, it is supplied to the
correct length.
14 Servicing
Instructions for Installation and Servicing ecoMAX pro24
Fig. 14.6
Fig. 14.7
SEAL
FRONT
CASING
PANEL
INNER
CASING
PANEL
CAP
SEAL
SIPHON
ADAPTER
CONDENSE
TRAP
FLOAT
SCREW
Fault Finding 15
Instructions for Installation and Servicing ecoMAX pro 25
15 Fault Finding
Fig. 15.1
15 Fault Finding
Instructions for Installation and Servicing ecoMAX pro26
15 Fault finding
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’ 13.1)
2. Check that the external electricity supply to the boiler
is on, and a supply of 230V is present at the boiler
terminal strip
3. Check that the gas supply to the boiler is on, that it
has been correctly purged and that an inlet pressure
of 20mbar is available at the gas valve (see section
‘gas supply’ 13.3)
code description comment
F1 Ignition fault (lockout) No gas; Insufficient gas; Incorrect gas valve adjustment; Electrode defect;
Failed to light Ignition lead defect; Electronic igniter defective; Check air inlet duct;
Check connections to igniter unit
F4 Ignition fault (lockout) As above
Went out when lit
F5 Overheat fault Overheat stat operated; Maximum temperature exceeded;
Check thermistor connections; Air in system with thermistor at maximum
setting; Faulty overheat stat connection; Check that pump is wired into
appliance and not from programmer. This would cause no pump overrun
F6 Central heating flow NTC fault Flow NTC cable defective/broken NTC faulty
Flow thermistor not fitted correctly
F10 Central heating return NTC fault Return NTC cable defective/broken NTC faulty
Check that thermistor attached correctly to pipe.
F11 No reception by main board Connection fault between main PCB and interface; Faulty interface;
Faulty main PCB (processor)
F12 No reception by the local user interface As F.11
F13 Main board fault As F.11
F14 Central heating flow t° > 95° C System fault; Possible external pump failure; Check NTC on flow
Check that pump is wired into appliance and not from programmer.
This would cause no pump overrun
F16 Flame detection fault
(flame presence >5 s after burner stop) Gas valve defective
F17 Power supply <170 V Check electrical supply / polarity
F18 Local user interface fault Connections; Faulty interface
F19 Central heating NTC unplugged Check NTC connection
F20 MMI software incompatible with IRIS software Possible connection fault
F24 Central heating return t° >90°C System fault; Possible external pump failure; Check NTC on return;
Check that pump is wired into appliance and not from programmer.
This would cause no pump overrun.
F25 Maximum temperature rise slope Possible external pump failure; Air in system restricting movement of water.
Insufficient circuit flow
F26 Maximum delta t Check NTC on return; System fault – too restrictive?; Possible pump failure
4. Ensure the heating system is full of water and
charged to between 1 and 1.5 bar, on sealed systems
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
8. Check that all manual circuit controls ie. bypass,
radiator valves are correctly adjusted
Fault codes
Fault codes take priority over all other display functions
in the event of a system fault occurring.
Short Spare Parts 16
Instructions for Installation and Servicing ecoMAX pro 27
16 Short Spare Parts
Key No. Part No. Description
1 190260 Fan assembly
2 090750 Spark electrode
3 091258 Igniter unit
4 053574 Gas control valve
5 101771 Heating flow & return NTC (2)
6 101191 Overheat stat
7 130837 Control box P.C.B.
8 287452 DC Fan supply
9 256271 Mains/Reset Switch
10 User interface/Display Unit PCB
11 050469 Burner - 18 E
11 050470 Burner - 28 E
12 256275 230V Controls Interface
1
2
3
4
6
7
9
10
8
5
11
12
Fig. 16.1
17 Boiler Specification
ecoMAX pro ecoMAX pro
18 E 28 E Units
Maximum CH heat input (net) 18.6 28.6 kW
CH heat output (80/60 °C) 5.0 - 18.3 5.3 - 28.2 kW
CH heat output (50/30 °C) 5.3 - 20.0 5.7 - 30.6 kW
Maximum DHW heat input (net) 20.02 30.58 kW
SEDBUK Band A A
SAP Seasonal Efficiency 90.4 90.6 %
NOx Class 5 5
Electrical rating IPX4D IPX4D
Inlet gas working pressure
required (natural gas) 20 20 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 37.8 MJ/m
3
Maximum gas rate 1.81 2.7 mbar
Minimum gas rate 0.48 0.52 mbar
Burner % CO2 - 9.0 +/-0.2 9.0 +/-0.2 %
Gas connection 15 mm Compression 15 mm Compression
Water connections 22 mm Compression 22 mm Compression
Condensate drain (internal diameter min.) 19 19 mm
Internal fuse ratings Fan supply PCB 3.15 AT Fan supply PCB 3.15 AT A
Main PCB 125 mAT Main PCB 125 mAT A
Maximum CH system pressure 3 3 bar
Weight 31 33 kg
Electrical supply 230/~50 230/~50 V~/Hz
External fuse 3 3 A
Power input 60 60 W
Case height 600 600 mm
Case width 375 375 mm
Case depth 334 334 mm
17 Boiler Specification
ecoMAXpro_00 GB 10/2002 X· Subject to alteration
Head Office: Vaillant Ltd.
Service Solutions 0870 6060 777
Vaillant House
Trident CloseMedway City Estate
Rochester
Kent ME2 4EZ
Technical Advice 01634 292392
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