Vaillant ECOmax VUW 236 EH Instructions For Installation And Servicing Download

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ECOmax VUW 236 EH

G.C. No. 47 044 23

ECOmax VUW 286 EH

G.C. No. 47 044 24

Wall hung room sealed fan assisted

condensing combination boilers

INSTRUCTIONS FOR INSTALLATION AND SERVICING

HEATING, CONTROLS, HOT WATER

Summary of Contents for ECOmax VUW 236 EH

Page 1: ...max VUW 236 EH G C No 47 044 23 ECOmax VUW 286 EH G C No 47 044 24 Wall hung room sealed fan assisted condensing combination boilers INSTRUCTIONS FOR INSTALLATION AND SERVICING HEATING CONTROLS HOT WA...

Page 2: ...inspection 35 6 2 Routine maintenance 35 6 3 Recommisioning the boiler 37 7 Parts replacement 38 7 1 Initial preparation 38 7 2 Fan 40 7 3 Air pressure sensor 41 7 4 Burner 41 7 5 Electrodes 42 7 6 C...

Page 3: ...to aid in commis sioning and fault finding ECOmax range consists of models with outputs for domestic hot water of 22 7 and 28 3 kW The boiler is easily sited on any internal wall and can be installed...

Page 4: ...rking pressure required Natural Gas 20 20 mbar Gas supply G20 Gross C V s t 37 8 37 8 MJ m3 Gas burner pressure max DHW 3 0 3 0 mbar Gas rate max DHW 2 38 2 96 m3 h CH flow temperature range 35 90 35...

Page 5: ...14 Boiler condensate drain 23 Frame of appliance lower connection GW 399 1 fig 2 2 2 Dimensions All dimensions in mm 1a Air flue duct to the rear 1b Air flue duct to the side 2 Appliance bracket 3 He...

Page 6: ...rap 10 DHW heat exchanger 11 Boiler display 12 User control panel 13 DHW outlet 14 CH flow service valve 15 Gas service valve 16 Air pressure sensor 17 Ignition electrodes 18 Temperature sensors NTCs...

Page 7: ...oilers not exceeding 60 kW 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 pr...

Page 8: ...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 gui dance on this aspect The boiler must be mounted...

Page 9: ...of a smaller size than the boiler gas connection 15mm The complete installation must be tested for soundness and purged as described in BS 6891 3 4 Flue system The standard horizontal flue system Acc...

Page 10: ...w an openable window or other opening e g air brick 300 B Below gutters soil pipes or drain pipes 751 C Below eaves 2001 D Below balconies 2001 E From vertical drain pipes and soil pipes 25 F From int...

Page 11: ...c tricity supply fused to 3 amps must be provided in accordance with the latest edition of the I E E Wiring Regulati ons and any other local regulations that may apply THIS APPLIANCE MUST BE EARTHED T...

Page 12: ...advice on the application of system cleansers contact sentinel Grace Dearbom Ltd Widnes Cheshire WA8 8 UD Tel 0151 495 1861 3 7 2 Filling and make up The system should be filled with water via a separ...

Page 13: ...al expansion ves sel can be installed external to the boi ler in the return pipe as close as pos sible to the boiler in accordance with BS 5449 Part 1 Guidance on the sizing of an addi tional expansio...

Page 14: ...front of the boiler This clearance is only required to enable easier access to the boiler for servicing and may be provided by an openable door etc NOTE If the boiler is to be fitted in a timber frame...

Page 15: ...e boiler for service and maintenance the boiler can be correctly flued i e the flue terminal position is sited in accordance with Section 3 4 1 and the air flue duct can be installed in accordance wit...

Page 16: ...fixing holes where necessary 4 3 2 3 Rear exit flue Mark the position of the centre of the flue duct and its circumference e g by drilling through the template 1 4 3 2 4 Other flue options Refer to th...

Page 17: ...ed ucing valve must be fitted to the cold water inlet 4 4 3 Pressure relief valve discharge The connection group contains the pressure relief valve required for a sealed system 5 Connect a dis charge...

Page 18: ...nd olives 5 over the flow and return tails of the boiler as far as possible Fix these temporarily in this position using tape or similar 4 6 2 Fitting the boiler fig 16 Lift the boiler up to the wall...

Page 19: ...e boiler condensate drain must have a conti nous fall and preferably be installed and terminated within the building to prevent freezing The discharge pipe must terminate in a suitable position e g co...

Page 20: ...uct instal lation instructions for full details of installation of the air flue duct This Section is included for further refer ence only e g in case the boiler has to be removed from the wall 4 7 1 H...

Page 21: ...t into the socket of the boiler flue outlet With correct assembly there will be a gap between the boiler and flue assembly of 10 mm fig 25 Fit the 55 mm long x 95 mm diameter air duct clamp 3 fig 26 o...

Page 22: ...on to the mains should be readily accessible and adjacent to the boiler A 3 core flex ible cord according to BS6500 tables 6 8 or 16 3x0 75 to 3x1 5 mm2 should be used Warning This appliance must be e...

Page 23: ...32 shows the connection details where a time switch is used without a room thermostat to control the boiler Important The arrowed numbers indicate connection into the relevant terminal in the boiler t...

Page 24: ...e taken such as the installation of an external frost thermostat This frost thermostat should be connected across the boiler terminals 3 and 4 in paral lel with any external heating controls 4 9 5 Cir...

Page 25: ...is adequate ventila tion extinguish naked flames and do not smoke whilst purging After purging the gas service valve connection must be re tightened and tested for soundness The boiler itself does no...

Page 26: ...air release valve To allow this to vent the boiler the cap on top 2 fig 35 must be slackened by 1 2 turns This cap must be left slackened during boiler operation to ensure any residual air or system...

Page 27: ...or temperature control 3 fig 36 to 9 Turn the boiler on off control 1 fig 36 to on Set the boiler central heating control 2 fig 36 to the Heating and Hot Water position The boiler will now operate for...

Page 28: ...20mbar this should be investigated before con tinuing with the commissioning pro cedure Lower pressures than 20mbar are indicative of an incorrectly sized or partially blocked gas supply Turn off the...

Page 29: ...e 4 for the required output settings The selected rating will be display ed on the boiler display as adjust ments are made After setting refit cover screw 2 fig 42 and resecure control panel 1 fig 41...

Page 30: ...5 11 2 Functional check of DHW operation using built in diagnostics Set the boiler central heating con trol to the Hot Water only position Enter status mode by pushing the right hand diagnostic button...

Page 31: ...ay should now show S 0 Turn on all external controls room thermostat timer etc and turn maximum radiator temperature control to 9 The display will now step through the following codes S 1 fan running...

Page 32: ...t functioning To exit from status mode push the right hand button once The display will now show the primary flow tempera ture Reset the maximum radiator temperature control to the required setting ac...

Page 33: ...oor fig 45 GW 459 0 5 15 Hand over to user Set the maximum hot water tempera ture control to the required setting For normal circumstances the maxi mum hot water temperature should be set between 7 an...

Page 34: ...s electricity supply by disconnecting the plug at the socket outlet if there is an isolating switch only remove the fuse from the switch Turn OFF the gas supply at the gas service valve fitted to the...

Page 35: ...ner Inspect for signs of excessi ve lifting or sooting Check the heating and hot water system in particular the condition of the radiator valves evidence of leak age from the heating system and drippi...

Page 36: ...sits from the heat exchan ger using a brush and jet of water Ensure water is kept away from all eletrical components Remove the lower part of the condensate trap 1 fig 54 by unscrewing Empty and clean...

Page 37: ...ly Operate burner and check flame picture see Section 6 1 Check boiler functioning either visually or by using the built in dia gnostic feature see Section 5 11 Check burner pressure see Section 5 10...

Page 38: ...box cover and terminal box cover are in position and water is kept away from all electrical compo nents Always test for gas soundness and always carry out functional checks after any service work and...

Page 39: ...he boiler into a suitable container by undoing the drain points one turn 7 1 3 Removal of front casing 7 1 3 1 Door fig 57 Remove bottom hinge screw 3 and pull the bottom door panel forwards and down...

Page 40: ...nd lower control box forward from top 7 2 Replacement of fan Isolate the boiler from the electrical supply Remove front casing as in Section 7 1 3 and remove combustion chamber cover as in Section 7 1...

Page 41: ...mber cover as in Section 7 1 5 Remove the 2 burner retaining springs 6 fig 64 by lifting the top of the spring up and pulling for ward Disconnect the 2 fan electrical connections 1 fig 64 Slide the fa...

Page 42: ...retaining nuts 3 Remove ignition electrodes 4 Fit new sealing gasket supplied with electrode Replace electrode Reassemble in reverse order Carry out electrical checks see Section 5 1 7 5 2 Flame sens...

Page 43: ...ining clip 1 fig 67 forward to release sump Remove two securing clips 6 fig 68 by pulling the top of the securing clip up and forward Rotate sump draw handle 2 fig 67 until it is pointing forward then...

Page 44: ...g 71 Disconnect boiler from electricity supply Remove front casing as in Section 7 1 3 and remove combustion chamber cover as in Section 7 1 5 Identify sensor s to be replaced Pull off connecting wire...

Page 45: ...ve fan and burner assembly as in Section 7 4 Remove condensate sump as in Section 7 6 Pull off wires from heat exchanger NTC 1 fig 73 ignition electrode 2 fig 73 sensing electrode 3 fig 73 and earth w...

Page 46: ...reverse order Refill and repressurise the boiler see Section 5 4 7 11 2 Boiler installed with air flue duct to the rear or vertical flue installation where less than 600 mm vertical clearance exists a...

Page 47: ...ossible on the central heating return in an accessible position In these cir cumstances the replacement expansi on vessel must be correctly sized igno ring the original expansion vessel which can be l...

Page 48: ...s in Section 7 1 3 Lower front panel as in Section 7 1 6 Remove screw 1 and slide spark generator forward to release from boiler chassis Disconnect leads by undoing two cable grips 2 and pull out Pull...

Page 49: ...1 Release CH water pressure and drain boiler as in Section 7 1 2 Remove front casing as in Section 7 1 3 Lower front control panel as in Section 7 1 6 Unscrew cap 4 of auto air release and remove inn...

Page 50: ...t casing as in Section 7 1 3 Lower front control panel as in Section 7 1 6 Remove screw 1 fig 85 and lift ignition transformer clear of diverter valve Remove tube 1 fig 86 by pulling to left Remove fo...

Page 51: ...sure and drain boiler as in Section 7 1 2 Remove front casing as in Section 7 1 3 Lower front control panel as in Section 7 1 6 Undo union 1 at rear of pressure gauge depress side springs on pressure...

Page 52: ...water section as in Section 7 19 Remove the 6 screws 1 and lift water section cover Remove diaphragm Reassemble in reverse order Carry out electrical checks see Section 5 1 Refill and repressurise th...

Page 53: ...ove DHW heat exchanger Reassemble in reverse order using new sealing rings supplied Refill and repressurise the boiler see Section 5 4 7 22 Replacement of printed circuit boards PCBs Before commencing...

Page 54: ...board Remove two screws 2 fig 95 and remove rectifier board Reassemble in reverse order Carry out electrical checks see Section 5 1 7 22 3 Replacement of mother board fig 96 Remove rectifier board as...

Page 55: ...98 Squeeze together the board retai ning clips 5 fig 98 and lift board out of control box Reassemble in reverse order NOTE When refitting the CPU board ensure that the user control spindles a fig 99...

Page 56: ...remove suppressor 5 fig 102 Lift cable grommets 4 fig 100 out of grommet channel Squeeze together retaining clip points 5 fig 100 and lift panel up at the front and forward to remove Replace in rever...

Page 57: ...de indicating what the problem may be The fault code will appear as a letter F followed by a two digit number e g boiler display showing fault code F 21 fig 106 3 Diagnostic Mode In order to assist wi...

Page 58: ...ating cycle To display the status mode depress the right button 1 fig 107 once e g boiler display showing status code S 4 fig 109 The status mode is helpful in diagnos ing faults where a fault code is...

Page 59: ...eco nomiser control is not engaged see Section 4 9 7 8 2 2 Procedure Note Always check the operation of the boiler for central heating first be fore checking hot water operation Do not open a hot tap...

Page 60: ...by pressing red Reset button Shutdown by overheat thermostat F21 F25 F48 F50 4A fuse F4 defective alternating display Replace fuse with spare provided Faulty Fuse F21 Enter diagnostic mode see Section...

Page 61: ...e Section 8 1 select d 10 and press the right button circulation Operate the boiler if d10 1 check the electrical connections to pump and that the pump is not seized Repair replace the pump as necessa...

Page 62: ...rough various stages from initial demand for heat CH or DHW to eventual shutdown when heat demand is satisfied the sequence can be fol lowed by using the Status Mode In the unlikely event that a fault...

Page 63: ...temperature is set to The faults shown here between 7 9 are only to be 1 Lack of primary water flow to heating system suspected if the check central heating service valves are fully radiators are not...

Page 64: ...pliance gas supply partially blocked or under code S14 will be sized displayed until the hot check gas rate at gas meter check gas supply water tap is closed pipework The faults shown here 3 Diverter...

Page 65: ...65 9 Electrical diagrams 9 1 Functional flow diagram fig 113 GW 536 0...

Page 66: ...66 9 2 Wiring diagram fig 114 GW 535 0...

Page 67: ...67 9 3 Schematic appliance circuit diagram fig 115...

Page 68: ...n transformer 09 1246 283 661 10 Manometer 10 1250 255 328 11 Pressure sensor 28 5530 283 561 12 Transformer 28 7438 283 660 13 Packing ring 98 0149 259 030 14 Washer 98 1511 262 335 15 Packing ring 9...

Page 69: ...69 fig 116 GW 659 0 fig 118 GW 661 0 fig 117 GW 660 0 fig 122 GW 665 0 fig 119 GW 662 0 fig 120 GW 663 0 fig 121 GW 664 1 fig 123 GW 666 0 fig 124 GW 667 0...

Page 70: ...ata ECOmax condensing boiler propane versions Table 1 Technical Data ECOmax propane versions VUW VU Unit 236 EP 286 EP 186 EP 226 EP Maximum CH heat input 19 1 23 7 19 1 23 7 kW CH output 80 C flow 60...

Page 71: ...in lighting the boiler for the first time during commissioning particularly with a bulk storage tank installation it is very likely that there is still air present in the gas supply Contact your gas...

Page 72: ...bject to alteration We do not accept liability for damage arising as a result of the non observance of these instructions Head Office Vaillant Ltd Vaillant House Medway City Estate Trident Close Roche...

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Vaillant ECOmax VUW 236 EH, Instructions For Installation And Servicing

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