Vaillant ecoMAX pro SERIES, ecoMAX pro 18 E, ecoMAX pro 28 E 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
28 E
Table of Contents
Instructions for Use, Installation and Servicing ecoMAX pro2
Page
1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 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
2.6.1 Insulation Pads . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . 7
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
14 Natural Gas to LPG conversion
(ecoMAX pro 28E only) . . . . . . . . . . . . . . . . . . 22
Table of Contents
Instructions for Use, Installation and Servicing ecoMAX pro 3
Page
15 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
15.2 Spark Electrode . . . . . . . . . . . . . . . . . . . . . . . . . 24
15.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
15.4 Combustion Chamber and Heat Exchanger. . . 26
15.5 Inner Casing Panel Seal Check . . . . . . . . . . . . . 26
16 Combustion analysis . . . . . . . . . . . . . . . . . . . . 27
17 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
17.1 Status Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
17.2 Fault Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
17.3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
17.4 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
18 Short Spare Parts . . . . . . . . . . . . . . . . . . . . . . 33
19 Boiler Specification . . . . . . . . . . . . . . . . . . . . . 34
1 List of contents
Instructions for Use, 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
9
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
91 Natural Gas to LPG conversion databadge
oversticker
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 Use, 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 factory set for use on Natural Gas (G20).
ecoMAX pro 28E only can be field adjusted for use on
LPG (propane G31), see page 22-23 for instructions.
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 Use, 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 Use, Installation and Servicing ecoMAX pro 7
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.
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
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.
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.
4 General Information
Instructions for Use, Installation and Servicing ecoMAX pro8
4 General Information
Important notice
The boiler is supplied in one pack and the flue is
supplied separately.
This boiler is factory set for use on Natural Gas (G20),
ecoMAX pro 28E only can be field adjusted for use on
LPG (propane G31).
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 Regulations
(Scotland), The Building Regulations (Northern Ireland),
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, the current IEE wiring 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.
In IE the installation must be carried out in accordance
with the current edition of IS 813 'Domestic Gas
Installations', the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.
4.3 Gas Supply
The gas installation must be in accordance with the
current issue of BS6891. In IE this is the current edition
of IS813.
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.
The data label includes the product Gas Council number;
18E - 41 044 30
28E - 41 044 31
Fig. 4.1
Fig. 4.2
150
4 General Information Water system 5
Instructions for Use, 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. In IE reference should be made to the current edition of the ETCI
rules.
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, 2002: 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. See also section 5.9.1.
Fig. 5.1
Fig. 5.2
28 E Pressure Loss Graph
Flow Rate (litres/hour)
1289 l/hr = 20 diff @ 28kW
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 Use, 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. In IE
the requirements given in the current edition of IS 813
and the current Building Regulations must be followed.
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 Use, 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 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. For IE your
attention is drawn to the current edition of IS 813.
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).
For IE the current edition of IS 813, 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'
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