Vaillant ecoMAX SERIES, ecoMAX 613/2 E, ecoMAX 618/2 E, ecoMAX 622/2 E, ecoMAX 635 E Instructions For Installation And Servicing
...
For the installer
ecoMAX 613/2 E
ecoMAX 618/2 E
ecoMAX 622/2 E
ecoMAX 635 E
ecoMAX 824/2 E
ecoMAX 828/2 E
ecoMAX 835 E
GB
Instructions for installation and servicing
ecoMAX
Wall hung room sealed fan assisted condensing boilers
2
Table of contents
Instructions for installation and servicing ecoMAX2
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Boiler specification . . . . . . . . . . . . . . . . . . . 5
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Boiler connections . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Scale drawing and fitting dimensions . . . . . . . 7
2.5 Functional diagrams . . . . . . . . . . . . . . . . . . . . . 8
2.6 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Identification plate . . . . . . . . . . . . . . . . . . . . . . . 10
3 General requirements . . . . . . . . . . . . . . . . . 10
3.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . 10
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Contents included with boiler (ecoMAX 800) . 11
3.4 Contents included with boiler (ecoMAX 600) . 11
3.5 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7.1 Standard 100 mm flue system . . . . . . . . . . . . . 12
3.7.2 Optional 125 mm flue system (ecoMAX 635, 835) 12
3.8 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9.1 Cupboard or compartment ventilation . . . . . . 14
3.10 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.11 Guide to system requirements . . . . . . . . . . . . . 14
3.11.1 Water circulation system . . . . . . . . . . . . . . . . . . 14
3.11.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . . 14
3.11.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 14
3.11.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.11.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 15
3.12 Pump specifications . . . . . . . . . . . . . . . . . . . . . 15
3.12.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 15
3.12.2 System by–pass . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.12.3 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.13 Condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Boiler installation sequence . . . . . . . . . . . . 16
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1.1 Select position of boiler . . . . . . . . . . . . . . . . . . 16
4.1.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1.3 Using boiler template . . . . . . . . . . . . . . . . . . . . 16
4.2 Rear flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Other flue options . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Fitting the boiler hanging bracket . . . . . . . . . . 17
4.5 Install the flue system . . . . . . . . . . . . . . . . . . . . 17
4.6 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . 18
4.7 Removing the front case . . . . . . . . . . . . . . . . . . 18
4.8 Cold water mains inlet and hot water outlet
(ecoMAX 800) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.10 Central heating flow and return pipework . . . 19
4.11 Pressure Relief Valve (ecoMAX 600) . . . . . . . . 20
4.12 Pressure Relief Valve (ecoMAX 800) . . . . . . . . 20
4.13 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . 21
4.14 Connection to a VANTAGE cylinder
(ecoMAX 600) . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.15 Connect the flue system to the boiler . . . . . . . 21
4.16 Electrical installation . . . . . . . . . . . . . . . . . . . . . 22
4.16.1 General requirements . . . . . . . . . . . . . . . . . . . . 22
4.16.2 Connection to the main supply . . . . . . . . . . . . 22
4.16.3 Electronic board layout . . . . . . . . . . . . . . . . . . . 23
4.16.4 Connection details for programmable
thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.17 Controls (ecoMAX 800) . . . . . . . . . . . . . . . . . . . 29
4.17.1 External electrical controls . . . . . . . . . . . . . . . . 29
4.17.2 Connection of external controls . . . . . . . . . . . . 29
4.17.3 Connection details for programmable room
thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.17.4 Connection details for time switch . . . . . . . . . 30
4.17.5 Connection details for external time
switches and boiler terminal strip . . . . . . . . . . 31
4.17.6 Vaillant optional plug in timer accessories . . . 31
4.18 Controls (ecoMAX 600) . . . . . . . . . . . . . . . . . . . 31
4.18.1 External electrical controls . . . . . . . . . . . . . . . . 31
4.18.2 Connection of external electrical controls . . . 31
4.18.3 Connection details using an external
wiring centre . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.19 Thermostatic radiator valves . . . . . . . . . . . . . . 31
4.20 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.21 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 31
4.22 Anti–cycling ‘economiser’ control . . . . . . . . . . 31
4.23 Automatic pump spin control (APS) . . . . . . . . 31
5 Commissioning part I . . . . . . . . . . . . . . . . . 34
5.1 Preliminary electrical checks . . . . . . . . . . . . . . 34
5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3 Cold water supply (ecoMAX 800) . . . . . . . . . . 34
5.4 Filling the heating system
(ecoMAX 800) . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.5 Initial system flush (”Cold”) . . . . . . . . . . . . . . . 34
5.6 Filling the heating system
(ecoMAX 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.7 Initial system flush (”Cold”) . . . . . . . . . . . . . . . 34
5.8 Filling condensate trap . . . . . . . . . . . . . . . . . . . 34
5.9 Adjusting pump speed . . . . . . . . . . . . . . . . . . . . 35
5.9.1 ecoMAX 613/2, 618/2, 622/2, 824/2, 828/2 . . . 35
5.9.2 ecoMAX 635, 835 . . . . . . . . . . . . . . . . . . . . . . . 35
5.10 Checking the gas supply settings . . . . . . . . . . . 37
5.10.1 Factory–adjusted gas settings . . . . . . . . . . . . . 37
5.10.2 Gas inlet working pressure . . . . . . . . . . . . . . . . 37
5.10.3 Check gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.11 Refitting the case . . . . . . . . . . . . . . . . . . . . . . . . 38
5.12 Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6 Functional checks (commissioning part II) . 39
6.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.2 Hot–water supply (ecoMAX 800) . . . . . . . . . . . 40
6.1.3 Heating system . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1.4 Final system flush (”Hot”) . . . . . . . . . . . . . . . . . 40
6.1.5 Handing over to the user . . . . . . . . . . . . . . . . . 40
3
Table of contents
Instructions for installation and servicing ecoMAX 3
7 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 Inspection and maintenance . . . . . . . . . . . . . . . 41
7.2 Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2.1 Removing the compact thermal module . . . . . 41
7.2.2 Inspect main heat exchanger . . . . . . . . . . . . . . 42
7.2.3 Inspect burner . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2.4 Refitting the compact thermal module . . . . . . 43
7.2.5 Cleaning the condensate trap . . . . . . . . . . . . . 43
7.2.6 Check expansion vessel . . . . . . . . . . . . . . . . . . . 43
7.3 Recommissioning the boiler . . . . . . . . . . . . . . . 44
7.4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 44
8.1 Logical fault finding procedure . . . . . . . . . . . . 44
8.1.1 Status mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.2 Diagnosis mode . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9 Parts replacement . . . . . . . . . . . . . . . . . . . 51
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . 51
9.1.1 Initial preparation . . . . . . . . . . . . . . . . . . . . . . . 51
9.1.2 Removal of burner assembly . . . . . . . . . . . . . . 51
9.2 Replacement of burner . . . . . . . . . . . . . . . . . . . 51
9.3 Replacement of fan . . . . . . . . . . . . . . . . . . . . . . 51
9.4 Replacement of gas valve . . . . . . . . . . . . . . . . . 52
9.5 Replacement of central heating
expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 52
9.6 Replacement of main heat exchanger . . . . . . . 53
9.7 Replacement of the electronic control board . 54
9.8 Check CO
2
content and adjust if necessary
(air–ratio adjustment) . . . . . . . . . . . . . . . . . . . . 54
10 Recycling and eventual scrapping . . . . . . . . 55
10.1 The appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4
1 Introduction
Instructions for installation and servicing ecoMAX4
1 Introduction
1.1 Introduction
Note:
This boiler must be installed and serviced by a
competent person in accordance with the Gas
Safety (Installation and Use) Regulations 1998.
In the UK ‘CORGI’ registered installers under
take the work to a safe and satisfactory standard.
ecoMAX 800 range
The ecoMAX 800 range is a fully automatic, wall mounted, room sealed condensing (high efficiency) combination boiler for central heating and domestic hot water.
Domestic hot water is supplied directly from the boiler,
without requiring a copper cylinder, cold water tank,
feed and expansion tank and associated pipework.
Domestic hot water has priority over central heating.
The ecoMAX 800 range consists of models with outputs
for domestic hot water of 23 kW, 28 kW and 35 kW. All
versions are available in natural gas. The 28 kW version
version is also available in LPG.
ecoMAX combination boilers incorporate a warmstart
facility that keeps the domestic hot water heat exchanger hot, providing an instantaneous delivery of domestic
hot water. The temperature in the domestic hot water
heat exchanger is limited by the boiler control system
and it is not necessary to install a scale reducer on the
cold mains to the boiler. However, in exceptionally hard
water areas to prevent scale formation in the property
hot water system pipework, a scale reducer may be fitted. The heating system can be filled using the built–in
filling loop contained within the boiler.
ecoMAX 600 range
The ecoMAX 600 range is a fully automatic, wall mounted, room sealed condensing (high efficiency) system
boiler for central heating and domestic hot water (where
a separate indirect hot water storage cylinder is also
incorporated in the system). The ecoMAX 600 range
consists of models with outputs of 13, 18, 22 and 35 kW.
All ecoMAX 600 range boilers are available in Natural
Gas. The 22 kW version is also available in LPG.
1.2 General Notes
The boilers have been designed for use with a sealed
central heating system, and come fully tested and
assembled with a built in circulating pump, expansion
vessel and diverter valve (ecoMAX 800). The boilers are
easily sited on any internal wall and can be installed with
either a horizontal or vertical RSF (room sealed fan assisted) flue.
The boilers use a standard flue system (100 mm outside
diameter) which allows flue lengths up to 8m (ecoMAX
828/2, 613/2, 618/2 and 622/2) 7m (ecoMAX 824/2) and
4 m (ecoMAX 635, 835). Flue extensions and additional
bends and elbows are available for the flue system to
increase the siting flexibility. If desired, an inhibitor may
be used in the system. Guidance on the use of inhibitors
is contained in these instructions.
All boilers have a built in diagnostic system which indicates the operational status of the boiler. This feature provides key information to aid commissioning and fault finding. The data badge is fitted to the underside of the
boiler. See text of General Requirements for installation
requirements or notes.
1.3 EC designation
ecoMAX boilers carry the ‘CE’ Mark. This demonstrates
that the boilers fulfil the essential requirements of the
Gas Appliance Directive (90/396/EEC) and the Gas
Appliance (Safety) Regulations 1992.
The ‘CE’ Mark also demonstrates that the boilers comply
with the requirements of the Electromagnetic
Compatibility Directive (89/336/EEC), the Low Voltage
Directive (72/23/EEC), the Boiler Efficiency Directive
(92/42/EEC) and the Boiler (Efficiency) Regulations 1993.
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.
5
Boiler Specification 2
Instructions for installation and servicing ecoMAX 5
Boiler Specification 2
2.1 Technical data (1)
ecoMAX ecoMAX ecoMAX Units
824/2 E 828/2 E 835 E
Maximum CH heat input (G 20) (net) 18.4 22.4 27.0 kW
Maximum CH heat input (G 31) (net) 18.4 22.4 27.0 kW
CH heat output range
80 °C flow/60 °C return 11.0 – 18.4 13.4 – 22.4 10.5 – 27.0 kW
50 °C flow/30 °C return 11.6 – 19.4 14.1 – 23.6 11.0 – 28.4 kW
SEDBUK A A A Band
SAP Seasonal Efficiency 91.1 91.1 91.1 %
Maximum DHW heat input (net) 23.0 28.0 35.0 kW
Maximum DHW output 23.0 28.0 35.0 kW
DHW flow rate ∆T = 35 K rise 9.4 11.5 14.3 l/min
Appr. DHW flow rate at factory set temp. rise (DT = 42 °C) 7.9 9.6 11.9 l/min
Mains water pressure required for max. flow rate 0.5 0.5 0.5 bar
Minimum water flow rate 1.5 1.5 1.5 l/min
Mains water pressure required for min. flow rate 0.2 0.2 0.2 bar
Maximum inlet water pressure 10 10 10 bar
Inlet gas working pressure required
(natural gas) 20 20 20 mbar
Inlet gas working pressure required
(Propane) 37 37 37 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 37.8 37.8 MJ/m
3
Gas supply (G31) Gross CV (s.t.) 95.65 95.65 95.65 MJ/m
3
Gas rate (natural gas) max. 2.43 2.96 3.7 m3/h
Gas rate (Propane) max. 1.78 2.18 2.7 kg/h
CH temperature flow range 30 – 85 30 – 85 30 – 85 °C
Minimum CH water flow (for 20 °C rise) 790 960 1160 l/h
Pump pressure available 0.25 0.25 0.25 bar
10 l expansion vessel pre–charge pressure 0.75 0.75 0.75 bar
Maximum CH system pressure 2.5 2.5 2.5 bar
Connections heating flow/return 22 22 22 mm
Gas inlet 15 15 15 mm
Pressure relief discharge pipework (min.) 15 15 15 mm
Condensate drain (min. internal drain) 19 19 19 mm
Weight 40 41 48 kg
Primary water content 1.8 2.0 2.4 l
Volume of condensate (max.) 2.1 2.5 3.3 l/h
Maximum flue gas temperature 70 70 70 °C
Electrical supply voltage 230/50 230/50 230/50 V ~/Hz
Internal fuse (slow) main voltage 4 4 4 A
Internal fuse (slow) low voltage 4 4 4 A
Power input 115 115 140 W
2.2 Dimensions
Fig. 2.1
2 Hanging bracket
3 Heating–system return
4 Cold–water inlet (ecoMAX 800/2 only)
5 Gas connection
6 Hot–water outlet (ecoMAX 800/2 only)
7 Heating–system flow
70
190
480
800
2
100
380*
7
Ø 20
100 100
Ø 20
5
3
7
Ø 20
20
R 1
/2
180
4
6
*(ecoMAX 635, 835: 450)
6
2 Boiler Specification
Instructions for installation and servicing ecoMAX6
2.1 Technical data (2)
ecoMAX 613/2 E 618/2 E 622/2 E 635 E Units
Maximum CH heat input (G 20) (net) 13.5 18.4 22.4 34.9 kW
Maximum CH heat input (G 31) (net) 13.5 18.4 22.4 34.9 kW
CH heat output range
80 °C flow/60 °C return 4.6 – 13.5 11.0 – 18.4 13.4 – 22.4 10.5 - 34.9 kW
50 °C flow/30 °C return 4.8 – 14.2 11.6 – 19.4 14.1 – 23.6 11.0 - 36.7 kW
SEDBUK A A A A Band
SAP Seasonal Efficiency 91.2 91.2 91.2 91.2 %
Inlet gas working pressure required
(natural gas) 20 20 20 20 mbar
Inlet gas working pressure required
(Propane) 37 37 37 37 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 37.8 37.8 37.8 MJ/m
3
Gas supply (G31) Gross CV (s.t.) 95.65 95.65 95.65 95.65 MJ/m
3
Gas rate (natural gas) max. 1.43 1.95 2.37 3.7 m3/h
Gas rate (Propane) max. 1.05 1.43 1.74 2.7 kg/h
CH temperature flow range 30 – 85 30 – 85 30 – 85 30 - 85 °C
Minimum CH water flow (for 20 °C rise) 580 790 960 1480 l/h
Pump pressure available 0.25 0.25 0.25 0.25 bar
10l expansion vessel pre–charge pressure 0.75 0.75 0.75 0.75 bar
Maximum CH system pressure 2.5 2.5 2.5 2.5 bar
Connections heating flow/return 22 22 22 22 mm
Gas inlet 15 15 15 15 mm
Pressure relief discharge pipework (min.) 15 15 15 15 mm
Condensate drain (min. internal drain) 19 19 19 19 mm
Weight 39 39 40 41 kg
Primary water content 1.8 1.8 2.0 2,2 l
Volume of condensate (max.) 1.2 2.1 2.5 3,3 l/h
Maximum flue gas temperature 70 70 70 70 °C
Electrical supply voltage 230/50 230/50 230/50 230/50 V ~/Hz
Internal fuse (slow) main voltage 4 4 4 4 A
Internal fuse (slow) low voltage 4 4 4 4 A
Power input 115 115 115 115 W
7
Boiler Specification 2
Instructions for installation and servicing ecoMAX 7
2.3 Boiler connections
Fig. 2.2
2.4 Scale drawing and fitting dimensions
Dimensions when combined with A ØB C*
the following system comp.: with 87° elbow
air/flue system Ø 60/100 235 60/100 _
air/flue system Ø 80/125 253 80/125 _
VANTAGE 120 _ _ 1101
VANTAGE 150 _ _ 1101
VANTAGE 200 _ _ _
Tab. 2.1 Dimensions used in combinations
*) Note: Dimension C must be observed if a Vaillant VANTAGE 120, 150 and
200 hot–water tank is to be installed under the heating unit.
Fig. 2.3 Fitting dimensions
94
1
Top edge of appliance
750
C
A
Air/flue duct centrer
3
717
Dimensions for
embedded installation
100 100
4
684
120
6
Ø B
Ø22
Ø22
25
33.5
100100
Ø 15
750
703
150
79
70
Ø15
113
8
2 Boiler Specification
Instructions for installation and servicing ecoMAX8
2.5 Functional diagrams
Fig. 2.4 Functional diagram ecoMAX 800/2, 835
1 Air duct
2 Main heat exchanger
3 Burner
4 Condensate trap
5 Temperature sensor (NTC 1)
6 Temperature sensor (NTC 2)
7 Automatic air vent
8 Circulating pump
9 DHW heat exchanger
10 Temperature sensor (NTC 3)
11 Automatic bypass valve
12 CH flow service valve
13 Domestic hot water outlet
14 Gas service valve
15 Cold water inlet
16 CH return service valve
17 Pressure relief valve
18 Aqua sensor
19 Diverter valve
20 Pressure gauge
21 Main ON/OFF control
22 Boiler display
23 Electronic box
24 Gas valve
25 Fan
26 Expansion vessel
27 Expansion vessel charging valve
28 Flue gas duct
Fig. 2.5 Functional diagram ecoMAX 600/2, 635
1 Air duct
2 Main heat exchanger
3 Burner
4 Condensate trap
5 Temperature sensor (NTC 1)
6 Temperature sensor (NTC 2)
7 Automatic air vent
8 Circulating pump
10 Automatic bypass valve
12 CH flow service valve
14 Gas service valve
16 CH return service valve
17 Pressure relief valve
20 Pressure gauge
21 Main ON/OFF control
22 Boiler display
23 Electronic box
24 Gas valve
25 Fan
26 Expansion vessel
27 Expansion vessel charging valve
28 Flue gas duct
28
27
26
2
4
5
6
7
8
10
12
3
1
25
24
22
23
21
20
17
16
14
28
27
26
2
4
5
6
7
8
9
10
11
12
13
3
1
25
24
22
23
21
20
19
18
17
16
14
9
Boiler Specification 2
Instructions for installation and servicing ecoMAX 9
2.6 Design
Fig. 2.6 Functioning elements, ecoMAX 800/2 configuration
1 Expansion vessel
2 Air suction pipe
3 Burner assembly
4 Ignition electrode
5 Diverter valve
6 DHW heat exchanger
7 Aqua sensor
8 Electronic box
9 Circulating pump
10 Gas valve assembly
11 Auto air vent
12 Main Heat exchanger
13 Air/flue gas duct
Fig. 2.7 Functioning elements, ecoMAX 600/2 configuration
1 Expansion vessel
2 Air suction pipe
3 Burner assembly
4 Ignition electrode
8 Electronic box
9 Circulating pump
10 Gas valve assembly
11 Auto air vent
12 Main Heat exchanger
13 Air/flue gas duct
1
2
3
4
8
9
10
11
12
13
1
2
3
4
6
5
7
8
9
10
11
12
13
10
2 Boiler Specification
3 General requirements
Instructions for installation and servicing ecoMAX10
2.7 Identification plate
The identification plate of the Vaillant ecoMAX is supplied ready–attached to the bottom of the unit.
Fig. 2.8 Identification plate (example)
3 General requirements
3.1 Preliminary remarks
This appliance should only be installed in conjunction with
a Vaillant flue system. Install the flue system as detailed
in the separate flue installation instructions supplied
with this boiler.
3.2 Related documents
The installation of the boiler must be in accordance with
the relevant requirements of Gas Safety (Installation
and Use) Regulations 1998, Health and Safety Document
No. 635 (The Electricity at Work Regulations 1989),
BS7671 (IEE Wiring Regulations) and the Water Supply
(Water Fitting) Regulations 1999, or The Water Bylaws
2000 (Scotland). It should also be in accordance with the
relevant requirements of the Local Authority, Building
Regulations, including amendments to the Approved
Documents Part L and J 2002, The Building Regulations
(Scotland). The Building Regulations (Northern Ireland)
and the relevant recommendations of the following
British Standards:
BS 5440: Flues and ventilation of gas fired boilers not
exceeding 70 kW net:
– Part 1: Flues
– Part 2: Ventilation
BS 5449: Specification for forced circulation hot water
for domestic premises.
BS 5546: Specification for gas hot water supplies for
domestic premises.
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water central heating systems.
Institute of Gas Engineers Publication IGE/UP/7/1998:
”Guide for gas installations in timber framed housing”
Important:
The appliance must be installed and serviced by
a Competent Person as stated in the Gas Safety
(Installation and Use) Regulations 1998. In IE,
the installation must be in accordance with the
current edition of I.S.813 ‘Domestic Gas
Instal–lations’, the current Building Regulations
and reference should be made to the current
ETCI rules for electrical installation.
Important:
When tightening or loosening screwed connec-
tions always use suitable open–ended spanners
(not pipe wrench, or extensions, etc.).
Incorrect use and/or unsuitable tools can lead to
damage being caused (e.g. gas or water leakage)!
11
General requirements 3
Instructions for installation and servicing ecoMAX 11
3.3 Contents included with boiler (ecoMAX 800/2)
Ensure that all contents are included before commencing installation.
Fig. 3.1 Items supplied with unit (ecoMAX 800)
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Boiler
2 1 Hanging bracket
3 3 Installation and Servicing, Users and
Flue Installation Instructions
4 1 Installation and connection accessories
5 2 Guarantee Card and Benchmark log book
6 1 Template
7 4 Copper tails for gas and water pipework
8 3 Flow and return service valve, gas service
valve
9 1 Pressure relief valve/double check valve
10 1 Lower cover (packed inside boiler)
Table 3.1 Items supplied with unit (ecoMAX 800)
3.4 Contents included with boiler (ecoMAX 600/2)
Ensure that all contents are included before commencing installation.
Fig. 3.2 Items supplied with unit (ecoMAX 600)
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Boiler
2 1 Hanging bracket
3 3 Installation and Servicing, Users and
Flue Installation Instructions
4 1 Installation and connection accessories
5 2 Guarantee Card and Benchmark log book
6 1 Template
7 4 Copper tails for gas and water pipework
8 3 Flow and return service valve, gas service
valve
9 1 Pressure relief valve
10 1 Lower cover (packed inside boiler)
Table 3.2 Items supplied with unit (ecoMAX 600)
4
5
2
6
7
3 1
10
9
10
9
1
4
5
2
6
7
8
3
12
3 General requirements
Instructions for installation and servicing ecoMAX12
3.5 Boiler location
The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location must
also provide adequate space for servicing and air circulation around the boiler. The boiler may be installed in
any room, although particular attention is drawn to the
requirements of BS7671 (IEE Regulations), the electrical
provisions of the Building Standards (Scotland)
Regula–tions, and in IE the current edition of IS813 and
the current ETCI rules, in respect of the installation of a
boiler in a room containing a bath or shower.
Note:
Where a room sealed boiler is installed in a room
containing a bath or shower, any electrical
switch or boiler control utilising mains electricity
should be so situated that it cannot be touched
by a person using the bath or shower.
Where the installation of the boiler will be in an unusual
location, special procedures may be necessary and BS
5546 and BS 6798 give detailed guidance on this aspect.
The boiler must be mounted on a flat, vertical wall, which
must be sufficiently robust to take the weight of the boiler. The boiler may be installed on a combustible wall,
subject to the requirements of the Local Authorities and
Building Regulations.
A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. (An
existing cupboard or compartment may be used provided that it is modified for the purpose). Details of essential features of cupboard/compartment design including
airing cupboard installations are given in BS 6798. If the
boiler is to be fitted in a timber framed building, it should
be fitted in accordance with Institute of Gas Engineers
Publication IGE/UP/7/1998 ”Guide for Gas Installation in
Timber Framed Housing”.
3.6 Gas supply
The gas supplier should ensure the availability of an
ade–quate supply of gas. A gas meter may only be
connected to the service pipe by the supplier of gas or
their contrac–tor. An existing meter should be checked to
ensure that it is capable of passing the rate of gas supply required.
Installation pipes should be fitted in accordance with
BS 6891. In IE the current edition of IS 813. Pipework
from the meter to the boiler must be of an adequate
size. Do not use pipes of a smaller size than the boiler
gas connection (15 mm). The complete installation must
be tested for soundness and purged as described in
BS 6891.
3.7 Flue system
3.7.1 Standard 100mm flue system
Fig. 3.3 Art.–No. 303 930
The standard 100 mm flue system (Art. No. 303 930) is
suitable for installations up to 740 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
8 m for ecoMAX 828/2, 613/2, 618/2 and 622/2, 7 m for
ecoMAX 824/2 and 4 m for ecoMAX 635, 835. Both 90°
bends and 45° elbows are also available to increase siting flexibility.
Fig. 3.4 Art.–No. 303 900
3.7.2 Optional 125 mm flue system
A concentric flue system of 125 mm outside diameter is
available and can be used to achieve flue lengths up to
13 m for ecoMAX 613/2, 25 m for ecoMAX 618/2, 824/2,
30 m for ecoMAX 622/2 and 828/2 and 21 m for ecoMAX
635, 835. A vertical flue system is also available. Refer
to flue system installation instructions for full details.
1530
880
70
800
40
13
Fig. 3.5 Art.–No. 303 209
Fig. 3.6 Art.–No. 303 200
3.8 Flue termination
The following details refer to both flue systems.
a.The terminal must be positioned such that the produc-
ts of combustion can disperse freely at all times.
b.A plume of water vapour will sometimes be visible
from the flue terminal. Positions where this could be a
nuisance should be avoided.
c. If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people
have access then a suitable terminal guard must be
provided and fitted (made by Tower Flue Components,
Tonbridge, TN9 1TB).
Fig. 3.7 Flue termination
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 sheilded as to
prevent ignition or damage to any pary of the building.
Terminal position mm
A Directly below an opening, above an opening or
horizontal to an opening, air brick, opening window, etc. 300
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent for vertical Flue 500
Table 3.3 Terminal position for a fan assisted concentric flue
A
BCD
A
G
H, I
F
J
B
F
M
L
L
K
K
G
G
F
F
E
A
A
1530
880
70
70
1103
70
15
13
General requirements 3
Instructions for installation and servicing ecoMAX 13
14
3 General requirements
Instructions for installation and servicing ecoMAX14
Note:
In addition, the terminal should not be nearer
than 150 mm to an opening in the building fabric
formed for the purpose of accommodating a
built–in element such as a window.
BS 5440–1 It is recommended that the fanned flue terminal should be positioned as follows:
a) at least 2m from an opening in the building directly
opposite, and
b) so that the products of combustion are not directly
directed to discharge across a boundary.
1) Dimensions B, C and D:
These clearances may be reduced to 25 mm without
affecting the performance of the boiler. In order to
ensure that the condensate plume does not affect
adjacent surfaces the terminal should be extended as
shown in fig. 3.8.
2) Dimension F:
This clearance may be reduced to 25 mm without
affecting the performance of the boiler. However, in
order to ensure that the condensate plume does not
affect adjacent surfaces a clearance of 300 mm is pre
ferred. For IE, recommendations are given in the current edition of IS 813.
Fig. 3.8
3.9 Air supply
Detailed recommendations for air supply are given in BS
5440: Part 2.
It is not necessary to have an air vent in the room or
internal space in which the boiler is installed.
3.9.1 Cupboard or compartment ventilation
The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during
operation is very low. For cupboard or compartment
installations it is therefore not necessary to provide any
high or low level permanent air vents for cooling purposes.
3.10 Electrical supply
A 230 V, ~ 50 Hz single phase electricity supply fused to
3 Amp. must be provided in accordance with the latest
edition of BS7671 (IEE Wiring Regulations) and any other
local regulations that may apply. In IE reference should
be made to the current edition of the ETCI rules. The
method of connection to the mains electricity supply must
provide a means of completely isolating the boiler and
its ancillary controls. Isolation is preferably by the use of
a fused three pin plug and unswitched shuttered socket
outlet, both complying with the requirements of BS 1363.
Alternatively, a 3 Amp. fused doublepole switch with a 3
mm contact separation on both poles may be used.
This appliance must be earthed.
3.11 Guide to system requirements
3.11.1 Water circulation system
Detailed recommendations for the water circulation
system are given in BS 6798 and BS 5449: Part 1 (for
small bore and micro bore central heating systems).
Pipework not forming part of the useful heating surface
should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through
roof spaces and ventilated underfloor spaces. Draining
taps must be located in accessible positions which permit the draining of the whole system including the boiler
and the hot water system. Draining taps should be at
least 1/2 in. BSP nominal size and be in accordance with
BS 2879. The boiler is suitable for use with minibore or
microbore systems. Copper tubing to BS 2871: Part 1
should be used for water carrying pipework. All capillary
joints in all DHW pipework must be made with lead free
solder. Particularly where a new boiler is to be fitted to
an existing system, it is good practice that the system is
thoroughly cleansed. This cleansing should take place
prior to the fitting of the new boiler and be in accordance with BS 7593. For advice on the application of system
cleansers contact Sentinel, Betz Dearborn Ltd. Widnes,
Cheshire, WA8 8UD. Tel: 0151 495 1861, or Fernox, Alpha
Fry Technologies, Tandem House, Marlow Way, Croydon,
CR0 4XS. Tel 0870 6015000
3.11.2 Filling and make up
The system can be filled using the built in filling loop
(ecoMAX 800) or via a separate filling point fitted at a
convinient position on the heating circuit. The connection
must be removed when filling is completed. Where local
Water Authority regulation does not allow temporary
connection, a sealed system filler pump with break tank
must be used. The heating system will not be filled automatically from the domestic hot water side. (Alternative
methods of filling sealed systems are given in BS 5449).
3.11.3 Pressure relief valve
A pressure relief valve is provided with the boiler. This
safety device is required on all sealed C.H. systems and
is preset at 3 bar and provided with a 15 mm compression connection for a discharge pipe, which must be of no
less than 15 mm in diameter. The pressure relief valve
must not be used for draining purposes.
balcony/eaves
flue extended to
clear any overhang
flue adequately
supported
gutter
15
General requirements 3
Instructions for installation and servicing ecoMAX 15
3.11.4 Pressure gauge
This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing.
3.11.5 Expansion vessel
ecoMAX boilers incorporate a 10 litre expansion vessel
which is suitable for a sealed heating system with a
maximum water content of 100 litres.
If the nominal capacity of the built in expansion vessel is
not sufficient for the heating system (for instance in
case of modernization of old open systems) an additional expansion vessel can be installed external to the boiler. It should be fitted in the return pipe as close as possible to the boiler in accordance with BS 5449: Part 1.
Guidance on the sizing of an additional expansion vessel
is given in Table 3.4.
Vessel Volume [L]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0
Total water content of system litres
25 2.7 3.9
50 5.4 7.8
100 10.9 15.6
125 13.6 19.5
150 16.3 23.4
175 19.1 27.3
200 21.8 31.2
225 24.5 35.1
250 27.2 39.0
275 30.0 42.9
300 32.7 46.8
325 35.7 50.7
350 38.1 54.6
375 40.9 58.5
400 43.6 62.4
425 46.3 66.3
450 49.0 70.2
475 51.8 74.1
500 54.5 78.0
For system volumes other than those
given above, multiply the
system volume by the factor across 0.109 0.156
Table 3.4 Sizing of additional expansion vessel
3.12 Pump specifications
3.12.1 Circulating pump
The circulating pump is included in the boiler. The pump
head available for the heating system is shown in fig. 3.9.
Circulating pump (ecoMAX 635 and 835 only):
The ecoMAX 635 and 835 boilers are fitted with a modulating circulating pump. The pump head available for the
heating system is shown in figure 3.10.
Fig. 3.9 Pump specifications ecoMAX 613/2, 618/2, 622/2,
824/2, 828/2
Fig. 3.10 Pump specifications ecoMAX 635, 835
3.12.2 System by–pass
An automatic system by–pass is included within the boiler. The boiler is suitable for use in systems with thermostatic radiator valves and no additional by–pass is
required.
3.12.3 Venting
The boiler is fitted with an automatic air vent. Additional
provision should be made to enable the heating system
to be vented during filling and commissioning either by
automatic air vents or manually.
3.13 Condensate trap
The boiler is fitted with a condensate trap incorporating
a water trap of 75 mm.
400
300
200
100
0
0 200 400 600 800 1000 1200 1600
Lift
[
mbar
]
1800
Volumeflow [l/h
]
1900
1400
100 %
53 %
60 %
70 %
85 %
400
300
200
100
0
0 200 400 600 800 1000 1200 1600
Lift
[
mbar
]
Volumeflow [l/h
]
1800
1400
Position IIIPosition II
16
4 Boiler installation sequence
Instructions for installation and servicing ecoMAX16
4 Boiler installation sequence
4.1 General
Fig. 4.1
The boiler should be mounted on a flat and vertical area
of wall of sufficient area for the boiler plus the required
clearances for installation and servicing (fig. 3.8). These
are shown on the installation template supplied with the
boiler and are:
– 5 mm either side of the boiler
– 145 mm below the boiler
– 205 mm* above the boiler when utilising the 100 mm
outside diameter flue
– 220 mm* above the boiler when utilising the 125 mm
outside diameter flue
– 500 mm in front of the boiler**
Note:
If the boiler is to be fitted in a timber framed
building, it should be fitted in accordance with
British Gas publication DM2 ‘Guide for gas
installations in timber framed housing’.
** This clearance is only required to enable easier access to the boiler for
servicing and may be provided by an openable door, etc.
4.1.1 Select position of boiler
Refer to section ‘Boiler location’ for information
regarding siting the appliance. In general the boiler must
be positioned such that:
• There is adequate space around the boiler for service
and maintenance
• The boiler can be correctly flued, i.e. the flue terminal
position is sited in accordance with these instructions
and the air/flue duct can be installed in accordance
with the flue installation instructions supplied.
• All necessary pipework can be connected, including
the pressure relief valve and condensate drain.
4.1.2 Unpack the boiler
To unpack the boiler, cut both plastic carton straps, open
box and lift out the polystyrene top packing. Lift the
cardbox box upwards.
Note:
Care should be taken not to scratch the white
surface of the boiler casing.
Packed in the boiler carton are the following:
• Boiler
• Flow and return central heating service valves
• Gas service valve
• Pressure relief valve and double check valve
(ecoMAX 800)
• Pre–formed copper pipework (for central heating flow
and return, gas and pressure relief valve connections)
• Boiler installation template
• Boiler hanging bracket
• Fixing screws, wall plugs and washers
• Installation and user instructions
• Flue installation instructions
• Guarantee card, envelope and Benchmark log book.
4.1.3 Using boiler template
Fix the paper template to the wall ensure that the
template is vertical.
The template shows:
– The position of the fixing holes for the boiler
mounting bracket (1).
– The position of the connections.
– The position of the flue exit hole.
Mark the position of the hanging bracket fixing holes (1).
Drill 2 holes Ø 8 mm for the hanging bracket.
Note:
Use alternative fixing holes where necessary.
min
min 5
min 5
min 500**
min 145
205/220*
17
Boiler installation sequence 4
Instructions for installation and servicing ecoMAX 17
4.2 Rear flue exit
Mark the position of the air/flue duct and its circumference.
4.3 Other flue options
Flue instructions for other flue systems such as vertical
RSF flues, flues run to the side of the boiler and the use
of additional bends etc. are detailed in the flue
installation instructions provided with the boiler.
Remove the template from the wall and plug the drilled
holes using the wallplugs supplied.
Fig. 4.2 Using Boiler template
4.4 Fitting the boiler hanging bracket
Fig. 4.3 Fitting the boiler
Fix the hanging bracket (2) to the wall using the screws
supplied. (it may be necessary to use additional or
alternative fixings to ensure adequate support).
Note:
If the boiler is to be fitted in a timber framed
building ensure that the bracket is secured to a
substantial part of the timber frame capable of
taking the weight of the boiler.
4.5 Install the flue system
Install the flue system (refer to separate air/flue duct
installation instructions)
85
50
240
75
75
23
50
3
1
2
Boiler casing
Minimum
Clearances
Reqd.
Flow
D. H.W.
out
Cold
Mains in
Gas in Return
Condensale
discharge
Minimum Clearances
Reqd.
Flue hole
(60/100 mm
flue system)
Fixing holes and
Position for
optional
pre-instalation
connection
Flue hole
(80/125 mm
flue system)
Please use
the new
Boiler hanging
bracket
ecoMAX 824/2
ecoMAX 828/2
ecoMAX 835
ecoMAX 613/2
ecoMAX 618/2
ecoMAX 622/2
ecoMAX 635
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