Vaillant ecoMAX 635 Instructions For Installation And Servicing Download Page 31 | Manualshive

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Instructions for installation and servicing ecoMAX

31

7.4 Test

Carry out the following checks once the maintenance
tasks have been completed:
• Start the unit up according to the instructions supplied

with the appliance.

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

leaks.

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

attachment.

• Check for excess ignition and ensure that the flame

burns regularly and smoothly.

• Check the heating system and hot–water supply for

correct functioning.

• Complete the Benchmark gas boiler commissioning

checklist.

Fig. 7.8 Test for correct functioning

I

0

Servicing 7

80020014605_00GB_032006 22.02.2006 21:36 Uhr Seite 31

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Summary of Contents for ecoMAX 635

Page 1: ...For the installer ecoMAX 635 GB Instructions for installation and servicing ecoMAX Wall hung room sealed fan assisted condensing boilers...

Page 2: ...4 3 Electronic board layout 17 4 14 4 Connection details for programmable thermostats 19 4 15 Controls 19 4 15 1 External electrical controls 19 4 15 2 Connection of external electrical controls 19 4...

Page 3: ...placement of central heating expansion vessel 37 9 6 Replacement of main heat exchanger 38 9 7 Replacement of the electronic control board 38 9 8 Check CO2 content and adjust if necessary air ratio ad...

Page 4: ...1 m Flue extensions and additional bends and elbows are availa ble for the flue system to increase the siting flexibility If desired an inhibitor may be used in the system Guidance on the use of inhib...

Page 5: ...7 8 MJ m3 Gas supply G31 Gross CV s t 95 65 MJ m3 Gas rate natural gas max 3 7 m3 h Gas rate Propane max 2 7 kg h CH temperature flow range 30 85 C Minimum CH water flow for 20 C rise 1480 l h Pump pr...

Page 6: ...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 Press...

Page 7: ...Air suction pipe 3 Burner assembly 4 Ignition electrode 8 Electronic box 9 Circulating pump 10 Gas valve assembly 11 Auto air vent 12 Main Heat exchanger 13 Air flue gas duct 2 6 Identification plate...

Page 8: ...liances in industrial and commercial premises BS 6644 Installation of gas fired hot water boilers of rated inputs between 60 kW and 2 MW 2nd and 3rd family gases BS 5449 Forced circulation hot water c...

Page 9: ...framed building it should be fitted in accordance with Institute of Gas Engineers Publication IGE UP 7 1998 Guide for Gas Installation in Timber Framed Housing 3 5 Gas supply The gas supplier should e...

Page 10: ...at loss from the appliance casing during operation is very low Compartment ventilation is requi red if the flue used in not concentric and air is supplied from the room or compartment the boiler is in...

Page 11: ...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...

Page 12: ...cess to the boiler for servicing and may be provided by an openable door etc 4 1 2 Unpack the boiler To unpack the boiler cut both plastic carton straps open box and lift out the polystyrene top packi...

Page 13: ...either side at the bottom edge Lower the boiler slowly onto the hanging bracket so that the cross member at the rear of the boiler fully engages onto the hanging bracket 4 7 Removing the front case T...

Page 14: ...heating flow and return service valves to the appliance Connect the 22 mm copper pipe tails to the service valves as shown in the illustration and tighten the nuts Connect the central heating pipewor...

Page 15: ...mini mum diameter of 22mm with no length restriction and should incorporate a trap with a 75mm 3 seal The connection should preferably be made down stream of the sink waste trap If the connection is o...

Page 16: ...and adjacent to the boiler A 3 core flexible cord according to BS6500 tables 6 8 or 16 3 x 0 75 to 3 x 1 5 mm2 should be used Attention This appliance must be earthed Note Do not use boiler terminal c...

Page 17: ...verter valve Connection for multi function module 306 253 Room thermostat 24 V Connections 7 8 and 9 Caution Do not connect directly to mains sup ply danger of irreparable damage to electronic system...

Page 18: ...e Pump NTC flow Gas valve assembly NTC backflow X 2 4 red X 2 10 white X 2 15 blue Plug in coupling Electronic control box 9 8 7 5 4 3 N L N L Pump 2 Pump Contact therm L N 24V I 230V RT 24V 230V RT 2...

Page 19: ...N 3 4 1 3 4 3 4 5 5 7 4 15 Controls 4 15 1 External electrical controls The boiler terminals 3 4 and 5 are for connecting exter nal electrical controls such as a programmer room ther mostat etc Termi...

Page 20: ...heating ope ration the hot water operation is unaffected by this con trol and hot water can be drawn at any time Note To temporarily override the anti cycling control turn the main boiler on off switc...

Page 21: ...2 4 4 3 3 3 3 3 2 2 2 2 1 1 L 2 1 L 1 1 1 1 3 C B E E E E Vaillant VRT 9090 ACL Drayton Digistat 2 3 4 ACL Drayton RTS 1 2 Danfoss Randall RX 1 Danfoss Randall RMT 230 Danfoss Randall RET 230 Tower SS...

Page 22: ...T6300 ST6400 Horstmann Channel Plus H21 H27 Note Earth not required Link L 2 5 Siemens Landis Staefa RWB29 Potterton Myson EP 2002 EP 3002 EP 6002 Note Link L 5 Sunvic Select 207 N L 2 3 4 5 3 not use...

Page 23: ...l the complete system is full all air locks have been cleared and the boiler pressure gauge reads 1 5 bar Release any air from the pump by slackening the centre screw The boiler is equipped with an au...

Page 24: ...boiler check the data badge and ensure that the correct gas type appliance has been installed The boiler is supplied ready adjusted and no further gas adjustments are necessary however both the gas i...

Page 25: ...at the gas meter Check that the gas rate is as stated in Table 5 1 Fig 5 2 Measuring the inlet working pressure 5 9 Refitting the case Fig 5 3 Removing Refitting the case Note Ensure that the front pa...

Page 26: ...tment of heating system part load Appliance Heating Output in kW ecoMAX 635 10 to 35 Tab 5 2 Heating system part load adjustment ranges 6 Functional checks Commissioning Part II 6 1 Functional checks...

Page 27: ...tions 6 1 4 Handing over to the user Set the maximum radiator temperature control to the desired setting Set the maximum hot water temperature control to the desired setting Instruct the user in the s...

Page 28: ...ted with a combustion analysis test point A suitable combustion analyser can be connected to this point to establish the com bustion performance of the boiler It is not necessary to check the CO2 cont...

Page 29: ...removed and dismantled from the gas valve as this part is sealed and gas checked during production Fig 7 3 Renewing the seals 1 and checking the burner flange insulation 2 7 2 2 Inspect main heat exc...

Page 30: ...h water Refill with water to about 10 mm from the top Screw the bottom section back onto the condensate trap Danger Note that if the boiler is run with an empty con densate trap there is a danger that...

Page 31: ...th the appliance Check the unit for any signs of escaping gas or water leaks Check the air flue duct system for leaks and correct attachment Check for excess ignition and ensure that the flame burns r...

Page 32: ...Do not press any key for approximately four minutes The display will now revert back to showing the cur rent flow temperature Key to status codes Code Meaning ecoMAX 635 S 0 No heat demand heating op...

Page 33: ...ature Current value in C d 41 Actual return temperature Current value in C d 44 Actual ionisation current value Current value 100 in A d 46 Outside temperature correction Correction value in K only wh...

Page 34: ...disconnected System pressure too low Waterswitch activated F 27 No demand to gas valve Electronic board defective Gas valve defective No gas Insufficient gas Incorrect gas valve adjustment F 28 Boiler...

Page 35: ...of a range of special unit functions Please refer to Table 8 4 below for detailed information Test programs P 1 to P 6 are activated by operating the Power ON switch and pressing the button at the sam...

Page 36: ...analysis test point A suitable combustion analyser can be connected at this point to establish the com bustion performance of the boiler 9 1 2 Removal of burner assembly Remove screw and disconnect ai...

Page 37: ...a good seal is made Reassemble burner gas valve and fan assembly in reverse order Recommission boiler as previously detailed Ensure combustion analysis is carried out after part replace ment as detai...

Page 38: ...ove the display unit and if fitted the built in timer from the electronics box Clip the new circuit board into position in the electronics box reconnect all plug in wires and refit back cover of the s...

Page 39: ...ton is operated for 15 minutes Reposition air suction pipe and tighten screw 4 Raise control panel Adjustment Natural gas H Propane Unit settings Tolerance Tolerance CO2 after 5 min 9 0 1 0 10 0 0 5 V...

Page 40: ...appliance The Vaillant ecoMAX consists largely 92 of metal components designed for eventual recycling by incorpo ration into the smelting process of a steelworks This gives these parts virtually unlim...

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Page 44: ...0020014605_00GB 03 2006 Subject to alteration...

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