Vaillant ecoMAX SERIES Instructions For Installation And Servicing Download Page 2

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Table of contents

Instructions for installation and servicing ecoMAX

Introduction . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

EC designation . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler specification . . . . . . . . . . . . . . . . . . .

2.1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Boiler connections . . . . . . . . . . . . . . . . . . . . . . .

2.4

Scale drawing and fitting dimensions . . . . . . .

2.5

Functional diagrams . . . . . . . . . . . . . . . . . . . . .

2.6

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Identification plate . . . . . . . . . . . . . . . . . . . . . . .

General requirements . . . . . . . . . . . . . . . . .

3.1

Preliminary remarks . . . . . . . . . . . . . . . . . . . . .

3.2

Related documents . . . . . . . . . . . . . . . . . . . . . .

3.3

Contents included with boiler (ecoMAX 800) .

3.4

Contents included with boiler (ecoMAX 600) .

3.5

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7

Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1

Standard 100 mm flue system . . . . . . . . . . . . .

3.7.2

Optional 125 mm flue system (ecoMAX 635, 835)

3.8

Flue termination . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1

Cupboard or compartment ventilation . . . . . .

3.10

Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . .

3.11

Guide to system requirements . . . . . . . . . . . . .

3.11.1

Water circulation system . . . . . . . . . . . . . . . . . .

3.11.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . .

3.11.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . .

3.11.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . .

3.12

Pump specifications . . . . . . . . . . . . . . . . . . . . .

3.12.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . .

3.12.2 System by–pass . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.3 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13

Condensate trap . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler installation sequence . . . . . . . . . . . .

4.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1

Select position of boiler . . . . . . . . . . . . . . . . . .

4.1.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . .

4.1.3

Using boiler template . . . . . . . . . . . . . . . . . . . .

4.2

Rear flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Other flue options . . . . . . . . . . . . . . . . . . . . . . .

4.4

Fitting the boiler hanging bracket . . . . . . . . . .

4.5

Install the flue system . . . . . . . . . . . . . . . . . . . .

4.6

Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . .

4.7

Removing the front case . . . . . . . . . . . . . . . . . .

4.8

Cold water mains inlet and hot water outlet
(ecoMAX 800) . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10

Central heating flow and return pipework . . .

4.11

Pressure Relief Valve (ecoMAX 600) . . . . . . . . 20

4.12

Pressure Relief Valve (ecoMAX 800) . . . . . . . . 20

4.13

Condensate drain . . . . . . . . . . . . . . . . . . . . . . . .

4.14

Connection to a VANTAGE cylinder
(ecoMAX 600) . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15

Connect the flue system to the boiler . . . . . . .

4.16

Electrical installation . . . . . . . . . . . . . . . . . . . . .

4.16.1 General requirements . . . . . . . . . . . . . . . . . . . .

4.16.2 Connection to the main supply . . . . . . . . . . . .

4.16.3 Electronic board layout . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . .

4.17.6 Vaillant optional plug in timer accessories . . .

4.18

Controls (ecoMAX 600) . . . . . . . . . . . . . . . . . . .

4.18.1 External electrical controls . . . . . . . . . . . . . . . .

4.18.2 Connection of external electrical controls . . .

4.18.3 Connection details using an external

wiring centre . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.19

Thermostatic radiator valves . . . . . . . . . . . . . .

4.20 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . .

4.21

Circulating pump . . . . . . . . . . . . . . . . . . . . . . . .

4.22

Anti–cycling ‘economiser’ control . . . . . . . . . .

4.23

Automatic pump spin control (APS) . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . .

5.9.1

ecoMAX 613/2, 618/2, 622/2, 824/2, 828/2 . . .

5.9.2 ecoMAX 635, 835 . . . . . . . . . . . . . . . . . . . . . . .

5.10

Checking the gas supply settings . . . . . . . . . . .

5.10.1 Factory–adjusted gas settings . . . . . . . . . . . . .

5.10.2 Gas inlet working pressure . . . . . . . . . . . . . . . .

5.10.3 Check gas rate . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11

Refitting the case . . . . . . . . . . . . . . . . . . . . . . . . 38

5.12

Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

83 41 77_12 GB04.04.qxd 22.09.2004 12:34 Uhr Seite 2

Summary of Contents for ecoMAX SERIES

Page 1: ...ller 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 conde...

Page 2: ...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 suppl...

Page 3: ...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...

Page 4: ...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 N...

Page 5: ...t 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 m3 G...

Page 6: ...ssure required Propane 37 37 37 37 mbar Gas supply G20 Gross CV s t 37 8 37 8 37 8 37 8 MJ m3 Gas supply G31 Gross CV s t 95 65 95 65 95 65 95 65 MJ m3 Gas rate natural gas max 1 43 1 95 2 37 3 7 m3 h...

Page 7: ...ir flue system 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 a...

Page 8: ...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 Ai...

Page 9: ...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...

Page 10: ...wing 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 pr...

Page 11: ...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 content...

Page 12: ...g 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 19...

Page 13: ...ntilation 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 hor...

Page 14: ...tch 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 cir...

Page 15: ...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...

Page 16: ...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 in...

Page 17: ...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 b...

Page 18: ...bottom of the unit Push in the two retaining clips 2 on the bottom of the appliance until the case is released Grasp the front case 3 by its bottom edge pull it towards the front and remove it by lif...

Page 19: ...mportant note ecoMAX 835 boiler only The gas supply pipe must not be less than 22 mm diameter 4 10 Central heating flow and return pipework Fig 4 7 Central heating flow and return pipework picture sho...

Page 20: ...ition which ensures that any discharge of water or steam from the valve can not create a hazard to persons in or about the premi ses or cause damage to any electrical components or external wiring and...

Page 21: ...p If the connection is only possible upstream then a air break is needed between the two traps This is normally provided by the sink waste c terminating in a gully 5 below grid level 6 and above the w...

Page 22: ...appliance must be earthed Note DO NOT use boiler terminal connections 7 8 9 Important Ensure that all cords pass through the cable clamps in the rear of the control box and are securely fixed Ensure t...

Page 23: ...2 13 1 Coding resistance 1 1 1 X 6 Diagnostic connection Diverter valve Connection for multi function module 306 253 Room thermostat 24 V Connections 7 8 and 9 Caution DO NOT connect directly to mains...

Page 24: ...ction Diverter valve 835 only Connection for multi function module 306 253 Room thermostat 24 V Connections 7 8 and 9 Caution DO NOT connect directly to mains supply danger of irreparable damage to el...

Page 25: ...ity reversing valve Gas valve assembly NTC backflow X 2 4 red X 2 10 white X 2 15 blue Plug in coupling Pump X 2 9 red 22 VDC X 2 24 blue earth X 2 12 blue earth X 2 7 grey PWM X 2 3 black Hall signal...

Page 26: ...embly 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 230V X 4 X 10 X 7 X 8 X 6 X 2...

Page 27: ...unit Ignition electrode 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 Contact therm 24V I 230V RT 24V 23...

Page 28: ...ctrode 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...

Page 29: ...PRT17 L N 4 L N 3 3 4 1 2 3 4 3 L N 2 3 4 L N 3 4 1 3 4 3 4 5 5 4 17 Controls ecoMAX 800 4 17 1 External electrical controls The boiler terminals 3 4 and 5 are for connecting exter nal electrical cont...

Page 30: ...eries Danfoss Randall Set 1E TS975 Danfoss Randall TS715 Gr sslin Towerchron QE1 QM1 Honeywell ST610A ST6100C Horstmann Channel Plus H11 H17 425 Coronet Horstmann Centaur Plus C11 C17 L N 2 3 4 L N 4...

Page 31: ...ideal for use in systems with thermostatic radiator val ves no separate system bypass is required For opti mum fuel economy where TRV s are used they must be used in conjunction with a boiler control...

Page 32: ...not used Connection details for control systems utilising 3 port motorised valve via external wiring centre junction box Diagram only applies to the specific controls mentioned L N L N 3 4 5 E N L CE...

Page 33: ...used not used Connection details for control systems utilising 2 x 2 port motorised valves via external wiring centre junction box Diagram only applies to the specific controls mentioned L N L N 3 4 5...

Page 34: ...g boiler operation to ensure any residual air or system gases are released Check the heating system and boiler connections are sound 5 5 Initial system flush Cold The whole of the heating system must...

Page 35: ...re when using this selection opti on the automatic modulation is switched off Note Where a mixing valve is fitted in the heating cir cuit underfloor heating circuit the pump set ting in the diagnostic...

Page 36: ...simultaneously or Do not press any key for approximately four minu tes The display will now return to its normal state current heating system flow temperature e g 45 C 5 sec Appliance Maximum net heat...

Page 37: ...d with adjustment or attempt to put the unit into service if the inlet working pressure lies outside the 17 25 mbar range LPG DO NOT proceed with adjustment or attempt to put the unit into service if...

Page 38: ...ut range rating The boilers are fully modulating for central heating and it is therefore not necessary to range rate the boiler However if desired it is possible to range rate the boiler as follows 1...

Page 39: ...X 618 2 E 11 to 19 ecoMAX 622 2 E 13 to 23 ecoMAX 635 10 to 35 ecoMAX 824 2 E 11 to 19 ecoMAX 824 2 E 13 to 23 ecoMAX 835 E 10 to 27 Tab 5 2 Heating system part load adjustment ranges 6 Functional che...

Page 40: ...porary filling connection Refit the boiler casing Attach the bottom cover to the boiler by sliding the front edge of the cover into the lip at the bottom front edge of the appliance chassis Carefully...

Page 41: ...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 42: ...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 43: ...wise it must also be replaced 7 2 5 Cleaning the condensate trap Fig 7 6 Cleaning the condensate trap Unscrew the bottom section 1 of the condensate trap see fig 7 6 Clean the bottom section of the tr...

Page 44: ...on and a supply of 230 V is present between boiler terminals L and N 3 Check that the gas supply to the boiler is on that it has been correctly purged and that an inlet pressure of 20 mbar is availab...

Page 45: ...hot water operation X S 14 Burner ignited hot water operation X S 15 S 16 Fan over run hot water operation X S 17 Pump over run hot water operation X S 20 Warmstart demand warm start X S 21 Pump and...

Page 46: ...now show d 0 Use or buttons to scroll up or down to the desi red diagnosic number Press i button to display the corresponding diagno sic information If necessary you can now alter the value by pressi...

Page 47: ...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 when VRC 410s is fitte...

Page 48: ...are displayed alternately for about two seconds each 8 1 4 Fault memory The fault memory stores details of the ten most recent faults Press the i and buttons simultaneously Use the button to scroll ba...

Page 49: ...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 50: ...umber Now press the i button to start up the unit and activate the test program Test programs can be aborted by pressing the i and buttons at the same time Test programs are also cancelled if no butto...

Page 51: ...ission and check boiler function as described in commissioning section Note The boiler is fitted with a combustion analysis test point A suitable combustion analyser can be connected at this point to...

Page 52: ...fan assembly to burner manifold using the new sealing gasket supplied Equally tighten the four screws 1 to ensure a good seal is made Reassemble burner gas valve and fan assembly in reverse order Reco...

Page 53: ...d in the flow pipe to allow easier access to the return connection The flow pipe can be carefully eased out of the way by bending at the flexible connection Disconnect primary return connection 6 from...

Page 54: ...bustion is suspected Remove the case from the unit Activate full gas rate mode by simultaneously pressing the and buttons on the display system ecoMAX 800 fully open the hot water tap to maxi mum wate...

Page 55: ...lant s in house rules set strict standards in this respect The selection process used for choosing raw materials includes full considera tion of their recycling characteristics and of the break down a...

Page 56: ...83 41 77_12 GB 10 2004 Subject to alteration...

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