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Related Manuals for Vaillant ecoMAX 635
Summary of Contents for Vaillant ecoMAX 635
- Page 1 For the installer Instructions for installation and servicing ecoMAX Wall hung room sealed fan assisted condensing boilers ecoMAX 635...
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Page 2: Table Of Contents
Table of contents Introduction ......4.15 Controls ....... Introduction . - Page 3 Table of contents Replacement of fan ..... . 36 Replacement of gas valve ....36 Replacement of central heating expansion vessel .
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Page 4: Introduction
In the UK ‘CORGI’ registered installers underta- ke the work to a safe and satisfactory standard. ecoMAX 635 The ecoMAX 635 is a fully automatic, wall mounted, room sealed condensing (high efficiency) system boiler for central heating and domestic hot water (where a separate indirect hot water storage cylinder is also incorporated in the system). -
Page 5: Boiler Specification 2
Boiler Specification 2 Boiler specification 2.1 Technical data ecoMAX Units Maximum CH heat input (G 20) (net) 34.9 Maximum CH heat input (G 31) (net) 34.9 CH heat output range 80 °C flow/60 °C return 10.5 - 34.9 50 °C flow/30 °C return 11.0 - 36.7 SEDBUK Band... -
Page 6: Dimensions
Fig. 2.1 2 Hanging bracket 3 Heating–system return 5 Gas connection 7 Heating–system flow 2.3 Boiler connections Fig. 2.3 Functional diagram ecoMAX 635 Air duct 2 Main heat exchanger 3 Burner 4 Condensate trap 5 Temperature sensor (NTC 1) 6 Temperature sensor (NTC 2) -
Page 7: Design
Boiler Specification 2 2.5 Design 2.6 Identification plate The identification plate of the Vaillant ecoMAX is sup- plied ready–attached to the bottom of the unit. Fig. 2.5 Identification plate (example) Fig. 2.4 Functioning elements, ecoMAX 635 configuration Expansion vessel 2 Air suction pipe... -
Page 8: General Requirements
This appliance should only be installed in conjunction (Installation and Use) Regulations 1998. In IE, with either a Vaillant flue system or an alternative ap- the installation must be in accordance with the proved system (details of flue approval categories can be current edition of I.S.813 ‘Domestic Gas... -
Page 9: Boiler Location
General requirements 3 3.4 Boiler location The location chosen for the boiler must permit the provi- sion of a satisfactory flue termination. The location must also provide adequate space for servicing and air circu- lation around the boiler. The boiler may be installed in any room, although particular attention is drawn to the requirements of BS7671 (IEE Regulations), the electrical provisions of the Building Standards (Scotland) -
Page 10: Air Supply
3 General requirements The flue assembly shall be so placed or sheilded as to 3.8 Air supply prevent ignition or damage to any pary of the building. Detailed recommendations for air supply are given in BS 5440: Part 2. It is not necessary to have an air vent in the room or Terminal position internal space in which the boiler is installed. -
Page 11: Filling And Make Up
The heating system will not be 3.11.1 Circulating pump filled automatically from the domestic hot water side. The ecoMAX 635 is fitted with a modulating circulating (Alternative methods of filling sealed systems are given pump. The pump head available for the heating system in BS 5449). -
Page 12: Boiler Installation Sequence
4 Boiler installation sequence 4 Boiler installation sequence 4.1.2 Unpack the boiler To unpack the boiler, cut both plastic carton straps, open 4.1 General box and lift out the polystyrene top packing. Lift the cardbox box upwards. Note! Care should be taken not to scratch the white surface of the boiler casing. -
Page 13: Fitting The Boiler Hanging Bracket
Reqd. Boiler casing Please use the new Boiler hanging bracket ecoMAX 635 Fig. 4.3 Fitting the boiler Fixing holes and Position for optional 4.5 Install the flue system pre-instalation Install the flue system (refer to separate air/flue duct... -
Page 14: Gas Supply
3 General requirements • Tighten all connections. (Ensure the gas supply pipe- work is adequately sized such that a 20 mbar gas pres- sure is available at the boiler inlet at full flow rate). 4.9 Central heating flow and return pipework Fig. -
Page 15: Condensate Drain
General requirements 3 least 450mm above the invert of the stack). A trap giving a water seal of at least 75mm (3) should be incorporated into the pipe run, and there must be an air break (4) in the discharge pipe upstream of the trap. -
Page 16: Connection To A Unistor Cylinder
4 Boiler installation sequence 4.12 Connection to a uniSTOR cylinder Green/yellow (earth) wire – boiler terminal Earth sign • For connecting a Vaillant uniSTOR cylinder please Blue (neutral) wire – boiler terminal N Brown (live) wire – boiler terminal L refer to the uniSTOR installation instructions provided with the cylinder. -
Page 17: Electronic Board Layout
4.14.3 Electronic board layout 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 Caution: Do not connect directly to mains sup-... -
Page 18: Electronic Board Layout
X 2/17 red (22 VDC) X 2/24 blue (earth) Pump 24V I 230V X 10 Contact therm RT 24V 230V RT 230V Pump 2. Pump Coding resistance Electronic control box Fig. 4.13: Connection wiring ecoMAX 635 Instructions for installation and servicing ecoMAX... -
Page 19: Connection Details For Programmable Thermostats
REV 11, REV 15, REV 22 Smiths Timeguard ProgramaSTAT PRT11, PRT17 Sunvic TLX 6501 Sunvic TLX RFP, TLX RFD Vaillant VRT 230, 220 Fig. 4.14 4.15 Controls 4.15.2 Connection of external electrical controls 4.15.1 External electrical controls 4.15.3 Connection details using an external wiring... -
Page 20: Thermostatic Radiator Valves
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 Vaillant VRT 30 Tower STTCSW ACL Drayton Digistat 2, 3, 4 Honeywell L641... - Page 21 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Room thermostat Cylinder thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC Vaillant VRT 30 Tower STTCSW ACL Drayton Digistat 2, 3, 4 Honeywell L641...
- Page 22 4 Boiler installation sequence Lifestyle LP241, LP 522, LP 722 not used not used Tempus 6, Tempus 7 not used not used Danfoss Randall CP 715, FP715 Note: *Earth not required not used not used Danfoss Randall Set 2E, Set 3E Note: *Earth not required, Link L - 2 - 5...
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Page 23: Commissioning Part I 5
After 5.7 Adjusting pump speed purging, the gas service valve connection must be The ecoMAX 635 is fitted with an automatic modulating retightened and tested for soundness. (The boiler itself pump which regulates according to the resistance of the does not require purging as this will be done by the heating circuit. -
Page 24: Checking The Gas Supply Settings
(current heating–system flow temperature, e.g. 45°C). 2 Press the ”i”–button to display the diagnostic informa- tion (e. g. factory setting ”auto” = pump modulation on). Appliance ecoMAX 635 Maximum net heat input in kW 34.9 Maximum gas rate Natural gas in m 3 /h 3.70... -
Page 25: Check Gas Rate
Commissioning Part I 5 • Turn off the appliance, remove U gauge. Note! • Tighten the test point screw and test for soundness. Ensure that the front panel retaining cords are • Record appliance working gas inlet pressure (mbar) in positioned such that they will not become trap- the Benchmark gas boiler commissioning checklist. -
Page 26: Functional Checks (Commissioning Part Ii)
Fig. 5.6 Adjustment of heating system part–load Appliance Heating Output in kW ecoMAX 635 10 to 35 Tab. 5.2 Heating system part–load adjustment ranges Fig. 6.2 Heating mode display messages Instructions for installation and servicing ecoMAX... -
Page 27: Final System Flush ("Hot")
To ensure regular servicing, it is strongly recommen- 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... -
Page 28: Servicing
(CORGI registered). valve, conversion to or from Natural Gas/ LPG For safety reasons only genuine Vaillant spare parts or if incorrect combustion is suspected. should be used when servicing the boiler. -
Page 29: Inspect Main Heat Exchanger
Servicing 7 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 30: Refitting The Compact Thermal Module
7 Servicing 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 31: Test
Servicing 7 7.4 Test Carry out the following checks once the maintenance tasks have been completed: • Start the unit up according to the instructions supplied with the appliance. • Check the unit for any signs of escaping gas or water leaks. -
Page 32: Troubleshooting
8 Troubleshooting Key to status codes 8.1 Logical fault finding procedure Code Meaning ecoMAX 635 These checks must be carried out before attempting to No heat demand use the fault finding guide. 1. Carry out electrical safety checks (See Section (heating operation) ‘Preliminary Electrical Checks’). - Page 33 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 External controls heat demand...
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Page 34: Fault Codes
8 Troubleshooting 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 –... - Page 35 Troubleshooting 8 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.
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Page 36: Parts Replacement
9 Parts replacement 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! Note! 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 37: Replacement Of Central Heating Expansion Vessel
Parts replacement 9 • Remove 2 screws (3) securing gas valve to fan. 9.5 Replacement of central heating expansion vessel • Disconnect gas inlet supply connection from gas valve • Turn off boiler. by removing four screws. Refit the gas inlet supply •... -
Page 38: Replacement Of Main Heat Exchanger
9 Parts replacement 9.6 Replacement of main heat exchanger 9.7 Replacement of the electronic control board • Turn off boiler. • Remove front casing. Danger! • Lower control box. Ensure you observe the safety precautions • Drain boiler as previously described. when replacing this component. - Page 39 Parts replacement 9 Code Meaning Displayed/Adjustable values Circuit board Setting for setting (default) ecoMAX 635 Heating system part load Adjustable values in kW 45 kW system-dep. Heating system pump over run 1 - 60 min. 5 min. system-dep. Heating system max. off-period 1 - 60 min.
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Page 40: Recycling And Eventual Scrapping
10 Recycling and eventual scrapping 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. The selection process used for...
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