Vaillant ecoMAX pro Instructions For Use Installation And Servicing

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
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
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