Vaillant ECOmax VUW 236 EH Benutzerhandbuch

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

Page

1. Introduction 3

2. Boiler Specification 4

2.1 Technical Data 4

2.2 Dimensions 5

2.3 Boiler connections 5

2.4 Function diagram 6

3. General Requirements 7

3.1 Related documents 7

3.2 Boiler location 8

3.3 Gas supply 9

3.4 Flue system 9

3.5 Air suply 11

3.6 Electricity supply 11

3.7 Guide to system requirements 11

4. Boiler installation sequence 14

4.1 General 14

4.2 Boiler delivery 14

4.3 Preparation of boiler location 15

4.4 Pipework connections 17

4.5 Installing the flue system 18

4.6 Mounting the boiler 18

4.7 Connecting the flue assembly 20

4.8 Electrical installation 22

4.9 Controls 23

5. Commissioning 25

5.1 Preliminary electrical checks 25

5.2 Gas supply 25

5.3 Water supply 25

5.4 Filling the heating system 26

5.5 Initial system flush ('cold') 26

5.6 Filling condensate trap 27

5.7 Initial lighting 27

5.8 Gas inlet working pressure 28

5.9 Adjusting central heating

output (range rating) 28

5.10 Main burner pressure 29

5.11 Functional checks 30

5.12 Checking flame

supervision device 32

5.13 Final system flush ('hot') 33

5.14 Fitting case 33

5.15 Handing over to user 33

Page

6. Servicing 34

6.1 Initial 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 Condensate sump 43

7.7 Condensate trap 44

7.8 Temperature sensors (NTCs) 44

7.9 Gas valve 44

7.10 Main Heat exchanger 45

7.11 CH expansion vessel 46

7.12 Main safety isolating

transformer 47

7.13 Ignition transformer 48

7.14 Pump 48

7.15 Automatic air release 49

7.16 Automatic bypass 49

7.17 Diverter valve 50

7.18 Pressure gauge 51

7.19 Water section 51

7.20 DHW microswitch 52

7.21 DHW heat exchanger 53

7.22 Circuit boards 53

8. Fault finding 57

8.1 Introduction 57

8.2 Logical fault finding procedure 58

8.3 Fault finding using fault mode 60

8.4 Fault diagnosis using

status mode 62

9. Electrical diagrams 65

9.1 Functional flow diagram 65

9.2 Wiring diagram 66

9.3 Schematic appliance

circuit diagram 67

10. Short parts list 68

11. Supplementary information

for ECOmax 70

THE GAS SAFETY (INSTALLATION AND

USE) REGULATIONS 1994:

`In your own interest, and that of

safety, it is law that all gas appliances

are installed by competent persons, in

accordance with the above regula-

tions. Failure to install appliances

correctly could lead to prosecution.'

Leave these instructions with the user

when the installation is completed.

1. Introduction Note: This boiler must be installed and

serviced by a competent person in

accordance with the Gas Safety

(Installation and Use) Regulations

1994. In the U.K. `CORGI' Registered

Installers undertake the work to a safe

and satisfactory standard.

ECOmax 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, and has priority

over the central heating. (This has the

advantage that no copper cylinder,

cold water tank, feed and expansion

tank and associ-ated pipework are

required).

The boiler has been designed for use

with sealed systems, and comes fully

tested and assembled with built-in

circulating pump, bypass, expansion

vessel and diverter valve.

The boiler, because it has a larger

heat exchanger, extracts more heat

from the flue gases. The conversion of

this otherwise wasted heat into usable

warmth means the boiler has a higher

efficiency. Because the flue gases are

reduced to such a low temperature,

the water vapour contained in them

can condense. To discharge this con-

densate a drain is provided on the

boiler, and this must be connected to

a drainage point on site.

The boiler features a comprehensive

diagnostic system, which gives de-

tailed information on the boiler status

when operating and performance of

key components 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 with either a

horizontal or vertical RSF (Room

Sealed Fan assisted) flue. Flue

extensions and additional bends and

elbows are available for increased

siting flexibility. (The boiler is not

suitable for external installation).

If desired, an inhibitor may be used

in the system. Guidance on the use

of inhibitors is contained in these

instructions. (The boiler does not utilise

aluminium in the water system and

does not require a special inhibitor).

The boiler is designed to operate on

Natural Gas only.

The boiler contains a domestic hot

water heat exchanger. The temperatu-

re in the heat exchanger is limited by

the boiler control system and it is not

normally necessary to install a scale

reducer on the cold mains inlet to the

boiler. However, in exceptionally hard

water areas to prevent scale formation

in the property hot water system pipe-

work a scale reducer may be fitted.

The data badge is fitted on the com-

bustion chamber cover.

ECOmax boilers carry the „CE” Mark.

This demonstrates that the boilers fulfill

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 Drective

(89/336/EEC), the Low Voltage

Directive (73/23/EEC), the Boiler

Efficiency Directive (92/42/EEC)

and the Boiler (Efficiency) Regulations

1993.

ECOmax VUW 236 EH VUW 286 EH units

Countries of Destination GB, IE

Maximum CH heat input 19.5 (66,500) 24.2 (82,600) kW (Btu/h)

CH heat output range

80 °C flow/60 °C return 9.9-17.2 12.3-21.3 kW

(33,800-58,700) 42,000-72,700) (Btu/h)

50 °C flow/30 °C return 10.5-18.0 13.1-22.3 kW

(35,800-61,400) (44,700-76,100) (Btu/h)

Maximum DHW heat input 25.0 (85,300) 31.1 (106,100) kW (Btu/h)

Maximum DHW heat output 22.7 (77,500) 28.3 (96,600) kW (Btu/h)

DHW flow rate @ 35 °C rise 9.3 11.6 l/min

Mains water pressure required for max. flow rate 1.0 1.0 bar

Minimum water flow rate 2 2 l/min

Mains water pressure required for min flow rate 0.2 0.2 bar

Maximum inlet water pressure 10 10 bar

Inlet gas working 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 35-90 °C

Minimum CH water flow (for 20 °C rise) 770 960 l/h

Pump pressure available 0.25 0.25 bar

12 l expansion vessel pre-charge pressure 0.8 0.8 bar

Maximum CH system pressure 3.0 3.0 bar

Connections

Heating flow / return 3/43/4in. BSP

Cold water inlet 15 15 mm

DHW outlet 15 15 mm

Gas inlet 15 15 mm

Condensate drain (internal diameter, min) 19 19 mm

Pressure relief discharge pipework (min) 15 15 mm

Weight 56 57 kg

Boiler water content 1.5 1.6 litres

Volume of condensate (max.) 0.5 0.6 l/h

Maximum flue gas temperature 70 70 °C

Electrical supply

Voltage 230/50 230/50 V~/Hz

Fuses internal/external 2/3 2/3 A

Power input 130 130 W

2. Boiler specification

2.1 Technical data

GW 398/0

fig. 1

2.3 Boiler connections

1 Connection support bracket

2 Service valve (flow of heating

system)

3 Domestic hot water connection

4 Compression Union (gas)

5 Gas service valve (supplied with

the boiler)

6 Cold water connection with

shut-off walve

7 Service valve (return of heating

system)

8 Discharge pipe

9 Pressure relief valve

10 Compression union (return of

heating system)

11 Compression union (flow of

heating system)

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 Heating system return 3/4” Rp

(3/4” B.S.P.)

4 Cold water connection (15 mm)

5 Gas connection (15 mm)

6 Hot water connection (15 mm)

11 Heating system flow 3/4” Rp

(3/4” B.S.P.)

12 Pre-assembled connection set

with service valves (flow and

return) pressure relief valve,

cold and hot water connection

13 Pressure relief valve 3/4” Rp

(3/4” B-S.P.)

14 Boiler condensate drain

(18 mm O. D.)

* with standard horizontal flue

accessory.

(max. = 6880 mm with extensions)

GW 512/1

fig. 3

2.4 Function diagram

1 Air duct

2 Flue gas duct

3 Fully modulating automatic gas

valve

4 Fully modulating fan

5 Fully modulating low NOx burner

6 Combustion chamber

7 Flame sensing electrode

8 High efficiency heat exchanger

9 Condensate trap

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)

19 Expansion vessel charging valve

20 Expansion vessel

21 Automatic bypass valve

22 Automatic air vent

23 Circulating pump

24 Diverter valve

25 Pressure gauge

26 Water section

27 Pressure relief valve

28 CH return service valve

29 Cold water shut off valve

3. General requirements 3.1 Related documents

The installation of the boiler must be in

accordance with the relevant require-

ments of Gas Safety (Installation and

Use) Regulations 1994, Health and

Safety Document No. 635 (The Elec-

tricity at Work Regulations 1989),

BS7671 (IEE Wiring Regulations) and

the bylaws of the local Water Under-

taking. It should be in accordance

with any relevant requirements of the

Local Authority, Building Regulations,

Building Standards (Scotland) Regu-

lations and the relevant recommen-

dations of the following British

Standards:-

BS 5440: Flues and ventilation of gas

fired boilers 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 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 dome-

stic hot water central heating systems.

BRITISH GAS PUBLICATION DM2:

Guide for Installation 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 1994

3.2 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 servi-

cing and air circulation around the

boiler. The boiler may be installed in

any room, although particular atten-

tion is drawn to the requirements of

the I.E.E. Regulations and, in Scot-

land, the electrical provisions of the

Building Regulations, in respect of the

installation of the 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 gui-

dance on this aspect.

The boiler must be mounted on a flat,

vertical wall, which must be sufficient-

ly robust to take the weight of the boi-

ler. 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 construc-

ted specifically for this purpose.

(An existing cupboard or compartment

may be used provided that it is modi-

fied for the purpose). Details of essen-

tial features of cupboard/compart-

ment design including airing cup-

board 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 British Gas Publica-

tion DM2 `Guide for Gas Installations

in Timber Framed Housing'.

GW 319/0

fig. 4

3.3 Gas supply

The gas supplier should ensure the

availability of an adequate supply of

gas.

A gas meter may only be connected

to the service pipe by the supplier of

gas or their contractor.

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.

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 (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

(Accy No 300931) is suitable for

installations up to 1 metre measured

from the centre of the boiler flue outlet

to the outside face of the wall

(A, fig. 4). One metre flue extensions

(Accy No 300923) are available to

extend this length up to 6880 mm.

90 ° elbows (Accy No 300934) and

45 ° bends (Accy No 300949) are

also available to increase siting flexi-

bility.

A vertical flue system is also available

(Accy No 300945).

Refer to the flue installation instructions

for full details.

3.4.1 Flue Termination

1. The terminal must be positioned

such that the combustion products can

disperse freely at all times.

2. Flue gases from high efficiency con-

densing boilers are emitted at relative-

ly low temperatures, leading to a ten-

dency for a plume of water vapour to

be visible at or near the terminal.

More care should therefore be taken

when choosing the site for a terminal

of a condensing boiler. If possible

avoid placing the terminal below a

window, next to a door or close to

opposing walls. It is also recommen-

ded that the flue is not terminated

beneath a car port roof.

3. If the terminal is fitted less than 2m

above a balcony, above ground or

above a flat roof to which people

have access then a suitable guard

must be provided and fitted (available

from Tower Flue Components,

Tonbridge, TN9 1TB: reference

CGDK3BL).

Table 1:

Terminal position for fan-assisted flue.

(minimum distance - see fig. 5) mm

A- Directly below 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 internal or external

corners 3002

G-Above ground or balcony

level 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

wall for Vertical Flue 500

2Dimension F: This clearance may be

reduced to 25mm 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 preferred.

fig. 5

GW 524/0

1 Dimensions B, C and D: These clear-

ances may be reduced to 25mm with-

out affecting the performance of the

boiler. In order to ensure that the con-

densate plume does not affect adja-

cent surfaces the terminal should be

extended as shown in fig. 6.

fig. 6

GW 445/0

Note: Vertical flues must not terminate

within 600 mm of an openable win-

dow, air vent or any other ventilation

opening.

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