Table of Contents
Related Manuals for Vaillant ecoMAX SERIES
Summary of Contents for Vaillant ecoMAX SERIES
- Page 1 For the installer Instructions for installation and servicing ecoMAX Wall hung room sealed fan assisted condensing boilers ecoMAX 613/2 E ecoMAX 618/2 E ecoMAX 622/2 E ecoMAX 635 ecoMAX 824/2 E ecoMAX 828/2 E ecoMAX 835...
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Page 2: Table Of Contents
..Contents included with boiler (ecoMAX 800) . 4.17.6 Vaillant optional plug in timer accessories . . . Contents included with boiler (ecoMAX 600) . 4.18 Controls (ecoMAX 600) . - Page 3 Table of contents Servicing ......41 Inspection and maintenance ....Initial inspection .
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Page 4: Introduction
The ecoMAX 600 range is a fully automatic, wall moun- ted, room sealed condensing (high efficiency) system Vaillant Ltd. support the Benchmark initiative. boiler for central heating and domestic hot water (where Within the information pack, you will find a a separate indirect hot water storage cylinder is also Benchmark Log Book. -
Page 5: Boiler Specification 2
Boiler Specification 2 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 Maximum CH heat input (G 31) (net) 18.4 22.4 27.0 CH heat output range 80 °C flow/60 °C return 11.0 –... -
Page 6: Technical Data
2 Boiler Specification 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 Maximum CH heat input (G 31) (net) 13.5 18.4 22.4 34.9 CH heat output range 80 °C flow/60 °C return 4.6 –... -
Page 7: Boiler Connections
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. Ø15 Ø B Ø22 Ø22... -
Page 8: Functional Diagrams
2 Boiler Specification 2.5 Functional diagrams Fig. 2.4 Functional diagram ecoMAX 800/2, 835 Fig. 2.5 Functional diagram ecoMAX 600/2, 635 Air duct Air duct Main heat exchanger Main heat exchanger Burner Burner Condensate trap Condensate trap Temperature sensor (NTC 1) Temperature sensor (NTC 1) Temperature sensor (NTC 2) Temperature sensor (NTC 2) -
Page 9: Design
Boiler Specification 2 2.6 Design Fig. 2.6 Functioning elements, ecoMAX 800/2 configuration Fig. 2.7 Functioning elements, ecoMAX 600/2 configuration Expansion vessel Expansion vessel Air suction pipe Air suction pipe Burner assembly Burner assembly Ignition electrode Ignition electrode Diverter valve Electronic box DHW heat exchanger Circulating pump Aqua sensor... -
Page 10: Identification Plate
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. -
Page 11: Contents Included With Boiler (Ecomax 800)
General requirements 3 3.3 Contents included with boiler (ecoMAX 800/2) 3.4 Contents included with boiler (ecoMAX 600/2) Ensure that all contents are included before commen- Ensure that all contents are included before commen- cing installation. cing installation. Fig. 3.1 Items supplied with unit (ecoMAX 800) Fig. -
Page 12: Boiler Location
3 General requirements 3.5 Boiler location 3.7 Flue system The location chosen for the boiler must permit the provi- 3.7.1 Standard 100mm flue system sion of a satisfactory flue termination. The location must also provide adequate space for servicing and air circu- lation around the boiler. -
Page 13: Flue Termination
General requirements 3 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. -
Page 14: Air Supply
3 General requirements Note: edition of BS7671 (IEE Wiring Regulations) and any other In addition, the terminal should not be nearer local regulations that may apply. In IE reference should than 150 mm to an opening in the building fabric be made to the current edition of the ETCI rules. -
Page 15: Pressure Gauge
General requirements 3 3.11.4 Pressure gauge 3.12 Pump specifications This is factory fitted to the boiler and indicates the pri- 3.12.1 Circulating pump mary circuit pressure to facilitate filling and testing. The circulating pump is included in the boiler. The pump head available for the heating system is shown in fig. -
Page 16: Boiler Installation Sequence
4 Boiler installation sequence 4 Boiler installation sequence 4.1.1 Select position of boiler Refer to section ‘Boiler location’ for information 4.1 General regarding siting the appliance. In general the boiler must be positioned such that: • There is adequate space around the boiler for service and maintenance •... -
Page 17: Rear Flue Exit
Boiler installation sequence 4 4.2 Rear flue exit 4.4 Fitting the boiler hanging bracket Mark the position of the air/flue duct and its circumfe- rence. 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. -
Page 18: Fitting The Boiler
4 Boiler installation sequence 4.6 Fitting the boiler 4.8 Cold water mains inlet and hot water outlet • Lift the boiler (3) up to the wall so that it is slightly (ecoMAX 800) above the hanging bracket (1). Note: Lift the boiler from either side at the bottom edge. -
Page 19: Gas Supply
Boiler installation sequence 4 4.9 Gas supply 4.10 Central heating flow and return pipework Fig. 4.6 Fitting the gas connection ecoMAX 800 Fig. 4.7 Central heating flow and return pipework (picture shows ecoMAX 800) (picture shows ecoMAX 800) • Connect the compression gas service cock and 15 mm Before connecting the heating circuit to the boiler, all copper outlet tail as supplied with the appliance and pipework and radiators must be thoroughly flushed to... -
Page 20: Pressure Relief Valve (Ecomax 600)
4 Boiler installation sequence 4.11 Pressure Relief Valve (ecoMAX 800) 4.12 Pressure Relief Valve (ecoMAX 600) Fig. 4.8 Fitting the pressure relief valve (ecoMAX 800) Fig. 4.9 Fitting the pressure relief valve (ecoMAX 600) The pressure relief valve and filling loop connection is A pressure relief valve is provided within the boiler card- provided within the boiler cardboard box and should be board box and should be assembled as shown below. -
Page 21: Condensate Drain
(1, fig.4.11) must be filled with water as described in relevant section. 4.14 Connection to a VANTAGE cylinder (ecoMAX 600) • For connecting a Vaillant VANTAGE cylinder please refer to the VANTAGE installation instructions provi- ded with the cylinder. -
Page 22: Electrical Installation
4 Boiler installation sequence 4.16 Electrical installation Note: 4.16.1 General requirements DO NOT use boiler terminal connections 7–8–9. All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations). • Refit the terminal box cover by pushing into place until In IE, reference should be made to the current edition of it clips back into position. -
Page 23: Electronic Board Layout
4.16.3 Electronic board layout4.16.3 Electronic board layou Diagnostic connection Diverter valve Connection for multi–function module 306 253 Edge connector for Vaillant weather compensator Under–floor heating overload thermostat, 20 V (remove bridge for connection) Room thermostat 24 V: Connections 7, 8 and 9... - Page 24 4.16.3 Electronic board layout (continued) Diagnostic connection Diverter valve (835 only) Connection for multi–function module 306 253 Edge connector for Vaillant weather compensator Under–floor heating overload thermostat, 20 V (remove bridge for connection) Room thermostat 24 V: Connections 7, 8 and 9...
- Page 25 Boiler installation sequence 4 4.16.3 Electronic board layout (continued) flow backflow Ignition electrode X 2/4 red X 2/10 white X 2/15 blue Plug-in coupling Fan unit Gas valve assembly X 2/12 blue (earth) Water Switch X 2/7 grey (PWM) X 2/3 black (Hall signal) X 2/9 red (22 VDC) X 2/17 red (22 VDC) X 2/24 blue (earth)
- Page 26 4 Boiler installation sequence 4.16.3 Electronic board layout (continued) Ignition electrode flow backflow X 2/4 red X 2/10 white X 2/15 blue Plug-in coupling Fan unit Gas valve assembly Water Switch X 2/12 blue (earth) X 2/7 grey (PWM) X 2/3 black (Hall signal) X 2/9 red (22 VDC) X 2/17 red (22 VDC) X 2/24 blue (earth)
- Page 27 Boiler installation sequence 4 4.16.3 Electronic board layout (continued) backflow Ignition electrode flow X 2/4 red X 2/10 white X 2/15 blue Plug-in coupling Fan unit Gas valve assembly X 2/12 blue (earth) X 2/7 grey (PWM) X 2/3 black (Hall signal) X 2/9 red (22 VDC) X 2/17 red (22 VDC) X 2/24 blue (earth)
- Page 28 4 Boiler installation sequence 4.16.3 Electronic board layout (continued) backflow Ignition electrode flow X 2/4 red X 2/10 white X 2/15 blue Plug-in coupling Fan unit Gas valve assembly Water Switch X 2/12 blue (earth) X 2/7 grey (PWM) X 2/3 black (Hall signal) X 2/9 red (22 VDC) X 2/17 red (22 VDC) X 2/24 blue (earth)
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Page 29: Connection Details For Programmable
REV 11, REV 15, REV 22 Smiths Timeguard ProgramaSTAT PRT11, PRT17 Sunvic TLX 6501 Sunvic TLX RFP, TLX RFD Vaillant VRT 230, 220 Fig. 4.20 4.17 Controls (ecoMAX 800) 4.17.2 Connection of external controls 4.17.1 External electrical controls 4.17.3 Connection details for programmable room... -
Page 30: Connection Details For Time Switch
4 Boiler installation sequence 4.17.4 Connection details for time switch ACL Drayton Tempus 1, Tempus 2 Lyfestyle LP111, LP711 ACL Drayton Switchmaster SM300 ACL Drayton Switchmaster 980 Danfoss Randall 103 Series Danfoss Randall Set 1E, TS975 Danfoss Randall TS715 Grässlin Towerchron QE1, QM1 Honeywell ST610A, ST6100C... -
Page 31: Connection Details For External Time Switches And Boiler Terminal Strip
To protect remote or exposed parts of the heating system or property additio- 4.17.6 Vaillant optional plug in timer accessories nal frost protection measures must be taken such as the Refer to the instructions supplied with the optional installation of an external frost thermostat. - Page 32 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Cylinder thermostat Room thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC ACL Drayton Digistat 2, 3, 4 Tower CS1 ACL Drayton RTS 1, 2 Honeywell L641...
- Page 33 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Cylinder thermostat Room thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC ACL Drayton Digistat 2, 3, 4 Tower CS1 ACL Drayton RTS 1, 2 Honeywell L641...
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Page 34: Commissioning Part I
5 Commissioning Part I 5 Commissioning Part I system via 1/2” BSP drain taps (opened full bore to remo- ve any installation debris prior to lighting the boiler). 5.1 Preliminary electrical checks Refill the heating system. Check the operation of the Check the electrical installation by carrying out short pressure relief valve by rotating the knob on the valve. -
Page 35: Adjusting Pump Speed
Commissioning Part I 5 5.9 Adjusting pump speed 5.9.1 ecoMAX 613/2, 618/2, 622/2, ecoMAX 824/2, 828/2 The units are fitted with a two–speed pump. The pump is delivered with the switch (1) set to position III. Important note (ecoMAX 824/828 only): 53 % 70 % 85 %... - Page 36 5 Commissioning Part I When altering values the display will flash. 4 Press and hold the ”i”–button to save the required value to memory. When the value is saved, the display will stop flashing. ≈ 5 sec 5 Diagnostic mode is cancelled as follows: Press the ”i”...
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Page 37: Checking The Gas Supply Settings
Commissioning Part I 5 5.10 Checking the gas supply settings 5.10.3 Check gas rate 5.10.1 Factory–adjusted gas settings The boiler is fitted with a fully modulating automatic gas valve which ensures that the precise air/gas ratio is pro- Caution: vided under all operating conditions. Before operating the boiler check the data badge The gas rate has been set during production and does and ensure that the correct gas type appliance... -
Page 38: Refitting The Case
5 Commissioning Part I 5.11 Refitting the case 5.12 Adjusting the central heating output (range rating) The boilers are fully modulating for central heating, and Note: it is therefore not necessary to range rate the boiler. Ensure that the front panel retaining cords are However, if desired, it is possible to range rate the boiler, positioned such that they will not become trap- as follows:... -
Page 39: Functional Checks (Commissioning Part Ii) 6
Commissioning Part I 5 Functional checks (commissioning part II) 6 6 Functional checks (commissioning part II) 5 Finally, keep the ”i” button pressed for about five seconds, or until the display stops flashing. The value is now saved to memory. The display will now return to 6.1 Functional checks its normal state (current heating–system flow tempera- 6.1.1 Procedure... -
Page 40: Hot-Water Supply (Ecomax 800)
To ensure regular servicing, it is strongly recommen- the heating system is functioning correctly. ded that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details. • Record central heating operating pressure in the Benchmark Log Book along with the heat input (kW) and temperature difference between flow and return. -
Page 41: Servicing
Important carried out by a competent person (CORGI registered). Before starting any maintenance work: For safety reasons only genuine Vaillant spare parts • Isolate the mains electricity supply by disconnecting should be used when servicing the boiler. the plug at the socket outlet (if there is only an isola- ting switch remove the fuse from the switch). -
Page 42: Inspect Main Heat Exchanger
7 Servicing Fig. 7.3 Renewing the seals (1) and checking the burner flange insulation (2) 7.2.2 Inspect main heat exchanger With the burner and fan assembly removed it is now possible to inspect the main heat exchanger. Remove any loose deposits from the heat exchanger using a soft brush and jet of water (ensure that water is kept away from all electrical components. -
Page 43: Refitting The Compact Thermal Module
Servicing 7 7.2.4 Refitting the compact thermal module 7.2.6 Check expansion vessel • Renew the silicone gaskets (1) (see Fig 7.3) • Loosely position the burner, fan and gas valve assemb- ly in place and reconnect the two electrical connec- tions to the fan. -
Page 44: Recommissioning The Boiler
7 Servicing 8 Troubleshooting 8 Troubleshooting 7.3 Recommissioning the boiler • Carry out electrical safety checks. • Turn on the electrical supply. 8.1 Logical fault finding procedure • Open the boiler CH service valves. These checks must be carried out before attempting to •... - Page 45 Troubleshooting 8 Key to status codes Code Meaning ecoMAX 600 ecoMAX 800 No heat demand (heating operation) Pump running (heating operation) Pump running – pre ignition (heating operation) Ignition sequence (heating operation) Burner ignited (heating operation) – Heating system fan over run Pump over run (heating operation) Anti cycling mode (heating operation) S.10...
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Page 46: Diagnosis Mode
8 Troubleshooting 8.1.2 Diagnosis modes In order to assist with the pinpointing of a particular fault it is possible to use the boiler display in a diagno- stic mode to interrogate the boiler about the status of certain components (Table 8.2). •... - Page 47 Troubleshooting 8 Key to diagnosis codes Code Meaning Displayed/Adjustable values Part load setting Adjustable values in kW Water pump over run 1 – 60 min (factory–adjusted to 5 min) Maximum burner anti cycling period at 20 °C flow temperature 2 – 60 min (factory–adjusted to 20 min) Flow temperature setting Target value in °C Warmstart temperature setting (ecoMAX 800)
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Page 48: Fault Codes
8 Troubleshooting 8.1.3 Fault codes Fault codes take priority over all other display functions in the event of a system fault occurring (Table 8.3). If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each. 8.1.4 Fault memory The fault memory stores details of the ten most recent faults. - Page 49 Troubleshooting 8 Key to Fault codes Code Meaning Cause Flow–NTC: – NTC broken – NTC cable broken Flow–NTC cable defective/broken NTC faulty – Defective connection at NTC – Defective connection at electronics Return–NTC: – NTC broken – NTC cable broken Return–NTC cable defective/broken NTC faulty –...
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Page 50: Test Programs
8 Troubleshooting 8.2 Test programs The use of different test programs permits the activati- on 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 ”+”... -
Page 51: Parts Replacement
Parts replacement 9 9 Parts replacement 9.2 Replacement of burner Ensure that ALL regulations are observed. 9.1 Safety instructions The following safety instructions are to be followed when installing replacement parts! Important: Before starting any maintenance work: Isolate the mains electricity supply by dis- connecting the plug at the socket outlet (if there is only an isolating switch remove the fuse from the switch). -
Page 52: Replacement Of Gas Valve
9 Parts replacement 9.4 Replacement of gas valve • Turn off boiler. • Remove front casing. • Lower control box. • Remove burner, gas valve and fan assembly as pre- viously detailed. • Remove 4 screws (1). • Separate gas valve and fan assembly from burner manifold (2). -
Page 53: Replacement Of Main Heat Exchanger
Parts replacement 9 9.6 Replacement of main heat exchanger • Turn off boiler. • Remove front casing. • Lower control box. • Drain boiler as previously described. • Remove burner, gas valve and fan assembly as pre- viously detailed. • Disconnect condensate drain by removing spring clip (4) and pulling condensate drain (5) downwards. -
Page 54: Replacement Of The Electronic Control Board
9 Parts replacement 9.7 Replacement of the electronic control board • Clip the new circuit board into position in the electro- nics box, reconnect all plug–in wires and refit back Danger: cover of the switch box by clipping the cover back into Ensure you observe the safety precautions position. -
Page 55: Recycling And Eventual Scrapping 10
Tab. 9.2 Factory–adjusted gas settings Fig. 9.13 Carrying out air–ratio adjustment (gas supply settings) 10. Recycling and eventual scrapping The design of all Vaillant products takes into account the subsequent recycling and/or eventual safe scrapping of each component used. Vaillant’s in–house rules set strict standards in this respect.