Vaillant ECOmax 613 E Instructions For Installation And Servicing
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Vaillant ECOmax 613 E Instructions For Installation And Servicing

Wall hung room sealed fan assisted condensing system boilers
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INSTRUCTIONS FOR INSTALLATION AND SERVICING
Wall hung room sealed fan assisted condensing system boilers
Vaillant ECOmax 613 E
G.C. No. 41-044-20
Vaillant ECOmax 618 E
G.C. No. 41-044-21
Vaillant ECOmax 622 E
G.C. No. 41-044-22

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  • Page 1 INSTRUCTIONS FOR INSTALLATION AND SERVICING Vaillant ECOmax 613 E G.C. No. 41-044-20 Vaillant ECOmax 618 E G.C. No. 41-044-21 Vaillant ECOmax 622 E G.C. No. 41-044-22 Wall hung room sealed fan assisted condensing system boilers...

  • Page 2: Table Of Contents

    CONTENTS page 1 INTRODUCTION ........4 2 BOILER SPECIFICATION 2.1 Technical data .
  • Page 3 CONTENTS page 7 PARTS REPLACEMENT 7.1 Initial preparation ..... .42 7.2 Removal of burner, gas valve and fan assembly .44 7.3 Replacement of fan .
  • Page 4 The ECOmax 613 E and ECOmax a higher efficiency. Because the flue 618 E are only suitable for use with gases are reduced to such a low natural gas.

  • Page 5: Technical Data

    2 BOILER SPECIFICATION 2.1 TECHNICAL DATA ECOmax 613 E ECOmax 618 E ECOmax 622 E Units Maximum CH heat input (G 20) 15.3 20.9 25.4 Maximum CH heat input (G 31) – – 24.9 CH heat output range 80 °C flow/60 °C return 4.6 - 13.5...

  • Page 6: Dimensions

    2 BOILER SPECIFICATION 2.2 DIMENSIONS * 300 mm with 125 mm flue system fig. 1 2.3 BOILER CONNECTIONS Ø15 Ø22 Ø22 33.5 fig. 2...

  • Page 7: Functional Diagram

    2 BOILER SPECIFICATION 2.4 FUNCTIONAL DIAGRAM Air duct Main heat exchanger Temperature sensor (NTC 1) Temperature sensor (NTC 2) Condensate trap Automatic air vent Circulating pump Boiler display Main on/off control 10 Pressure gauge 11 CH flow service valve 12 Gas service valve 13 CH return service valve 14 Pressure relief valve 15 Automatic bypass valve...

  • Page 8: Related Documents

    3 GENERAL REQUIREMENTS 3.1 RELATED 3.2 BOILER LOCATION 3.3 GAS SUPPLY DOCUMENTS The installation of the boiler must be The location chosen for the boiler The gas supplier should ensure the in accordance with the relevant must permit the provision of a availability of an adequate supply of requirements of Gas Safety satisfactory flue termination.

  • Page 9: Flue System

    3 GENERAL REQUIREMENTS 3.4 FLUE SYSTEM 3.4.1 Standard concentric flue system (95 mm outside diameter) The standard horizontal concentric flue terminal (Art. No. 300 931) is suitable for installations up to 1m measured from the centre of the boiler flue outlet to the outside face of the wall (A, fig.
  • Page 10 3 GENERAL REQUIREMENTS 3.4.3 Flue termination (fig. 5) Directly below an openable window or other The following details refer to both opening (e. g. air brick) flue systems. Below gutters, soil pipes or drain pipes 1. The terminal must be positioned such that the products of Below eaves combustion can disperse freely at...

  • Page 11: Air Supply

    3 GENERAL REQUIREMENTS 3.5 AIR SUPPLY 3.7 GUIDE TO SYSTEM 3.7.2 Filling and make up The system should be filled with REQUIREMENTS Detailed recommendations for air water via a separate filling point supply are given in BS 5440: Part 2. 3.7.1 Water circulation system fitted at a convenient position on the It is not necessary to have an air vent...
  • Page 12 3 GENERAL REQUIREMENTS 3.7.3 Pressure relief valve A pressure relief valve is provided within the boiler cardbox and should be assembled as shown in 6, fig. 8. This safety device is required on all sealed C.H. systems and is pre-set at 3 bar and provided with a 15 mm compression connection for a discharge pipe, which must be of no...
  • Page 13 3 GENERAL REQUIREMENTS 3.7.6 Circulating pump The circulating pump is included in the boiler. The pump head available for the heating system is shown in fig. 9. mbar 3.7.7 System by-pass 13,3 An automatic system by-pass is included within the boiler. The boiler is suitable for use in systems with thermostatic radiator valves and no additional by-pass is required.

  • Page 14: General

    4 BOILER INSTALLATION SEQUENCE 4.1 GENERAL The boiler should be mounted on a flat and vertical area of wall of sufficient area for the boiler plus the required clearances for installation and servicing (fig. 10). These are shown on the installation template supplied with the boiler and are : - 5 mm either side of the boiler - 150 mm below the boiler...
  • Page 15 4 BOILER INSTALLATION SEQUENCE Standard accessories - 95 mm diameter flue system Art. No. Horizontal air/flue duct and terminal assembly 300 931 Optional accessories - 95 mm diameter flue system Art. No. Vertical air/flue duct and terminal assembly 300 945 1 m Extension 300 923 0,5 m Extension...

  • Page 16: Preparation Of Boiler Location

    4 BOILER INSTALLATION SEQUENCE 4.2.2 Unpack the boiler (fig. 11) To unpack the boiler, cut both plastic carton straps and lift the cardbox upwards. Note: Care should be taken not to scratch the white surface of the boiler casing. Packed in the boiler carton are the following: boiler •...

  • Page 17: Installing The Flue System

    4 BOILER INSTALLATION SEQUENCE 4.3.2 Using the boiler template (fig. 12) 4.3.2.1 Once a suitable location has been chosen, fix the paper template to the wall ensuring that the centreline of the template is vertical using a spirit level or plumbline. The template shows the position of the fixing holes for the boiler hanging bracket and the position of the...

  • Page 18: Mounting The Boiler

    4 BOILER INSTALLATION SEQUENCE 4.5 MOUNTING THE BOILER 4.5.1 Fitting the boiler (fig. 13) Lift the boiler up to the wall so that it is slightly above the hanging bracket. Note: Lift the boiler from under the front edge of the side panels. Lower the boiler slowly onto the hanging bracket so that the cross member at the top rear of the boiler...
  • Page 19 4 BOILER INSTALLATION SEQUENCE fig. 15 fig. 16...
  • Page 20 4 BOILER INSTALLATION SEQUENCE 4.5.2 Pipework connections (fig. 17) 4.5.2.1 Central heating flow and return The central heating flow and return services valves are supplied separately within the boiler cardbox. Connect the 20 mm compression connection of the central heating service valves to the boiler and tighten.
  • Page 21 4 BOILER INSTALLATION SEQUENCE 4.5.2.3 Pressure relief valve 4.5.3 Gas supply The pressure relief valve required for The boiler is supplied with a 20 mm a sealed central heating system is x 15 mm compression gas service supplied loose within the appliance valve (2, fig.
  • Page 22 4 BOILER INSTALLATION SEQUENCE 4.5.4 Condensate drain (fig. 20) Connect the boiler condensate drain (1) to the condensate discharge pipe (2). The condensate discharge pipe should be a minimum of 19 mm internal diameter (32 mm internal diameter for any pipework installed external to the property) and be made of an acid resistant material (e.g.

  • Page 23: Connecting Flue Assembly To Boiler

    4 BOILER INSTALLATION SEQUENCE 4.6 CONNECTING FLUE ASSEMBLY TO BOILER Note: Refer to air/flue duct installation instructions for full details of installation of air/flue duct. This section is included for further reference only e.g. in case the boiler has to be removed from the wall.
  • Page 24 4 BOILER INSTALLATION SEQUENCE 4.6.2 Vertical flue (95 mm diameter flue systems) Note : Refer to separate instructions supplied with 125 mm diameter flue system for connection method. Lower the flue assembly and engage the flue duct spigot into the socket of the boiler flue outlet.

  • Page 25: Electrical Connections

    4 BOILER INSTALLATION SEQUENCE 4.7 ELECTRICAL CONNECTION 4.7.1 General electrical requirements All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations). The boiler is supplied for connection to 230 V~, 50 Hz supply fused at 3 A rating.

  • Page 26: Controls

    4 BOILER INSTALLATION SEQUENCE Connection details for programmable thermostats 4.8 CONTROLS Vaillant Calotrol 4.8.1 External electrical (VRT 9083 and VRT 9084) controls ACL Drayton Digistat 2 and 3 The boiler terminals 3, 4 and 5 are for connecting external electrical...
  • Page 27 230 V schematic layout, fig. 34). ROOM SWITCH 50 Hz 3 A FUSE THERMOSTAT CONTACTS 4.8.2.3 Vaillant optional plug in timer accessories Refer to the instructions supplied with CLOCK the optional accessories for connection details. fig. 34 4.8.3 Thermostatic radiator 4.8.6 Anti-cycling ‘economiser’...

  • Page 28: Preliminary Electrical Checks

    5 COMMISSIONING 5.1 PRELIMINARY ELECTRICAL CHECKS Check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity. Warning: During boiler commissioning mains voltage is present at the boiler terminal strip.

  • Page 29: Initial System Flush (`Cold`)

    5 COMMISSIONING 5.4 INITIAL SYSTEM FLUSH (‘COLD’) The whole of the heating system must be flushed out at least twice: once cold, and once hot as instructed later in Section 5.14. Open all radiator or heating valves and the boiler CH service valves and drain the heating system and boiler completely from the lowest points of the system via 1/2"...

  • Page 30: Initial Lighting

    5 COMMISSIONING 5.6 INITIAL LIGHTING 1 Main on/off control 2 Boiler display Important: The boiler should only 3 Reset button be operated for short periods of 4 Central heating time, such as during initial temperature button lighting, when checking the gas 5 Operating status inlet working pressure or display window...

  • Page 31: Gas Inlet Working Pressure

    If the gas rate is found to be outside the tolerances detailed, check that an inlet pressure of 20 mbar (natural gas) or 37 mbar (Propane) is available. If the inlet pressure is correct at 20 or 37 mbar contact Vaillant Technical Department on 01634 292392.

  • Page 32: Fitting The Front Casing

    5 COMMISSIONING 5.9 FITTING THE FRONT 5.10 ADJUSTING THE CASING CENTRAL HEATING OUTPUT (RANGE Note: Ensure that the front panel RATING) retaining strings are positioned such that they will not become ECOmax 600 is fully modulating for trapped in the casing. central heating, and it is therefore not necessary to range rate the boiler.

  • Page 33: Functional Checks

    5 COMMISSIONING 5.11 FUNCTIONAL CHECKS 5.11.1 Introduction The boiler display (1 and 2, fig. 43) normally indicates boiler operating status and boiler flow temperature. Whilst this display is showing the boiler has internally self checked and is operating normally. The operating status of the boiler is permanently displayed by a series of codes which appear in the status window (2, fig.

  • Page 34: Checking Flame Supervision Device

    5 COMMISSIONING Note: The anti-cycling economiser Status code Boiler operating status Approx. duration ensures that energy wasteful short cycling of the boiler cannot External controls not calling for heat occur, by preventing the boiler igniting for a pre-set period of 5 Fan running and proving minutes after central heating operation.

  • Page 35: Fitting The Bottom Cover

    5 COMMISSIONING 5.14 FITTING THE BOTTOM COVER Slide the front edge of the bottom • cover into the lip at the front bottom edge of the appliance chassis (fig. 44) Carefully push the rear of the • bottom cover upwards until the spring retaining clips (1, fig.
  • Page 36 5 COMMISSIONING 5.15.1 Adjustment of central 5.15.2 Switching off the central heating temperature heating To adjust the maximum central Normally the central heating will be heating temperature switched off by the external heating Press the central heating • system controls. However, if required, temperature button (3, fig.
  • Page 37 Leave the installation and service If the boiler fails to light after instructions with the user. pressing the reset button contact your installer or Vaillant Service Solutions. 5.15.6 Diagnostic Button (10, fig. 43) ECOmax 600 appliances have a built in diagnostic system which assists during commissioning and fault finding.

  • Page 38: Initial Inspection

    6 SERVICING To ensure the continued safe and efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate.
  • Page 39 6 SERVICING 6.2.2 Remove front case Lower control panel cover. • Remove screw (1, fig. 48). • Release the front case spring • retaining clips located beneath the front edge of the appliance (fig. 49). Remove the front casing by •...
  • Page 40 6 SERVICING 6.2.6 Clean condensate syphon (fig. 52) Remove the lower part of the condensate trap (1) by unscrewing. Empty contents of trap and clean (ensuring that any debris that has fallen whilst cleaning the main heat exchanger is removed). Refill with water to about 10 mm from the top and refit to boiler.
  • Page 41 6 SERVICING 6.2.8 Recommissioning the boiler Loosely position the burner, fan • and gas valve assembly in place and reconnect the two electrical connections to the fan (7 and 8, fig. 51). Refit the burner, fan and gas • valve assembly. Ensure that the burner manifold gasket is correctly fitted and that a good seal is obtained.

  • Page 42: Initial Preparation

    7 PARTS REPLACEMENT Important: Before starting any maintenance work: Isolate the mains electricity supply • by disconnecting the plug at the socket outlet (if there is only an isolating switch remove the fuse from the switch). Turn off the gas supply at the gas •...
  • Page 43 7 PARTS REPLACEMENT 7.1.2 Removal of front casing (fig. 56 - 58) Lower control panel cover. • Remove screw (1, fig. 56). • Release the front case spring • retaining clips located beneath the front edge of the appliance (2, fig. 57). Remove the front casing by •...

  • Page 44: Removal Of Burner, Gas Valve And Fan Assembly

    7 PARTS REPLACEMENT 7.1.4 Releasing CH water pressure and draining boiler (fig. 60) Isolate the electrical supply to the • boiler. Remove front casing, as detailed • in Section 7.1.2. Remove boiler bottom cover by • releasing the two spring retaining lugs (1, fig 54) and lowering the rear of the bottom cover.

  • Page 45: Replacement Of Fan

    7 PARTS REPLACEMENT 7.3 REPLACEMENT OF FAN (FIG. 62) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Remove burner, gas valve and • fan assembly as detailed in Section 7.2.

  • Page 46: Replacement Of Burner

    7 PARTS REPLACEMENT 7.5 REPLACEMENT OF BURNER (FIG. 63) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Remove burner, gas valve and • fan assembly as detailed in Section 7.2.

  • Page 47: Replacement Of Main Heat Exchanger

    7 PARTS REPLACEMENT 7.8 REPLACEMENT OF MAIN HEAT EXCHANGER (FIG. 65) • Turn off boiler as in Section 7.1.1. • Remove front casing as in Section 7.1.2. • Lower control box as in Section 7.1.3. • Drain boiler as in Section 7.1.4. Remove burner, gas valve and •...

  • Page 48: Replacement Of Central Heating Expansion Vessel

    7 PARTS REPLACEMENT 7.9 REPLACEMENT OF CENTRAL HEATING EXPANSION VESSEL (FIG. 67) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Drain boiler as in Section 7.1.4. •...

  • Page 49: Replacement Of Main Transformer

    7 PARTS REPLACEMENT 7.11 REPLACEMENT OF MAIN TRANSFORMER (FIG. 70) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Disconnect HT lead from rear of •...

  • Page 50: Replacement Of Automatic Air Release

    7 PARTS REPLACEMENT 7.13 REPLACEMENT OF AUTOMATIC AIR RELEASE (FIG. 72) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Drain boiler as in Section 7.1.4. •...

  • Page 51: Replacement Of Pressure Gauge

    7 PARTS REPLACEMENT 7.15 REPLACEMENT OF PRESSURE GAUGE (FIG. 74) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Drain boiler as in Section 7.1.4. •...

  • Page 52: Replacement Of Pressure Relief Valve

    7 PARTS REPLACEMENT 7.17 REPLACEMENT OF PRESSURE RELIEF VALVE (FIG. 76) Turn off boiler as in Section • 7.1.1. Remove front casing as in Section • 7.1.2. Lower control box as in Section • 7.1.3. Drain boiler as in Section 7.1.4. •...

  • Page 53: Introduction

    8 FAULT FINDING 8.1 INTRODUCTION Once the required diagnostic code is displayed, press the button; this instructs the microprocessor to carry ECOmax 600 boilers have an inbuilt out the particular check and the advanced multifunction diagnostic relevant information is displayed. display (1, fig.

  • Page 54: Logical Fault Finding Procedure

    8 FAULT FINDING 8.2 LOGICAL FAULT 8.2.2 Procedure FINDING Note: Always check the operation of the boiler for central heating PROCEDURE first before checking hot water operation. Do not open a hot 8.2.1 These checks must be water tap unless instructed to do carried out before so by the fault finding guide.

  • Page 55: Fault Diagnosis Using The Boiler Fault Mode

    8 FAULT FINDING 8.3 FAULT DIAGNOSIS Note: There are two different letters which may appear as fault USING THE BOILER code. The letter ‘E’ denotes that the boiler has detected a fault FAULT MODE. and that further operation has been blocked for a set period of time before the boiler will automatically re-attempt ignition.
  • Page 56 8 FAULT FINDING Fault code Description of fault Possible causes 1. Insufficient water in primary heat exchanger – repair as necessary Water deficiency protection activated 2. Lack of pressure in boiler/system – repair as necessary 3. Pump blocked/malfunctioning/not connected 1. Spark electrode/earth probe short circuit – repair as necessary Flame Simulation 2.

  • Page 57: Fault Diagnosis Using Boiler Status Codes

    8 FAULT FINDING 8.4 FAULT DIAGNOSIS USING BOILER STATUS CODES Note: If a fault code (e.g. F21) is displayed refer to Section 8.3. ‘Fault diagnosis using the boiler fault mode’. 8.4.1 Introduction fig. 83 As the boiler operates, passing through the various stages from initial demand for central heating to Status code Boiler operating status...

  • Page 58: Fault Diagnosis Using Boiler Status Codes: Central Heating Mode

    8 FAULT FINDING 8.4.3 Fault diagnosis using boiler status codes: Central Heating Mode Symptom : Radiators not getting hot. Status code Description of fault Possible causes Check settings of all external controls. If no external External controls not calling for heat controls are fitted, ensure that terminals 3 and 4 are linked.

  • Page 59: Functional Flow Diagram

    MAIN ON/OFF SWITCH PUMP GAS VALVE SPARK ELECTRODE ELECTRONIC CIRCUIT BOARD NTC1 IGNITION TRANSFORMER NTC2 TRANSFORMER GU_Ecomax_097/1GB...

  • Page 60: Wiring Diagram

    Spark electrode Main transformer Pump Main on/off switch X12 PE X8/01 brown X1/13 X12 L X12 N X8/03 blue/black X1/11 X12 T3 Remove bridge when X8/06 blue connecting room thermostat X12 T4 X1/09 X8/07 X12 T5 brown X1/07 X12 T7 not to be used black X1/05 X12 T8 not to be used...

  • Page 61: Schematic Appliance Circuit Diagram

    9 ELECTRICAL DIAGRAMMS 9.3 SCHEMATIC APPLIANCE CIRCUIT DIAGRAM fig. 86...
  • Page 62 10 SHORT PARTS LIST fig. 87 fig. 88 fig. 89 fig. 90 fig. 91 fig. 92 fig. 93 fig. 94 fig. 95 fig. 96 fig. 97...

  • Page 63: Gas Conversion From Lpg To Natural Gas Operation

    Automatic air vent 061707 a competent person (e.g. „CORGI“ registered Installer) in accordance Transformer 287448 with the Gas Safety Regulation 1998 or by a Vaillant service engineer. For conversion the provided conversion instructions (Article No. 222354) must be used.
  • Page 64 Head Office Sales 01634 292310 Vaillant Ltd., Vaillant House, Service Solutions 0870 6060 777 Medway City Estate, Trident Close, Technical Advice 01634 292392 Rochester, Kent ME 2 4 EZ Training 01634 292370...

This manual is also suitable for:

Ecomax 618 eEcomax 622 e41-044-2041-044-2141-044-22

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