Vaillant ECOmax VUW 236 EH Instructions For Installation And Servicing
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Vaillant ECOmax VUW 236 EH Instructions For Installation And Servicing

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

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  • Page 1 INSTRUCTIONS FOR INSTALLATION AND SERVICING 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 HEATING, CONTROLS, HOT WATER...

  • Page 2: Table Of Contents

    Page Page 1. Introduction 6. Servicing 6.1 Initial inspection 2. Boiler Specification 6.2 Routine maintenance 2.1 Technical Data 6.3 Recommisioning the boiler 2.2 Dimensions 7. Parts replacement 2.3 Boiler connections 2.4 Function diagram 7.1 Initial preparation 7.2 Fan 3. General Requirements 7.3 Air pressure sensor 3.1 Related documents 7.4 Burner...

  • Page 3: Introduction

    1. Introduction Note: This boiler must be installed and The boiler features a comprehensive serviced by a competent person in diagnostic system, which gives de- accordance with the Gas Safety tailed information on the boiler status (Installation and Use) Regulations when operating and performance of 1994.

  • Page 4: Boiler Specification

    2. Boiler specification 2.1 Technical data 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 (33,800-58,700) 42,000-72,700) (Btu/h)

  • Page 5: Dimensions

    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 ” Rp ” B.S.P.) 4 Cold water connection (15 mm) 5 Gas connection (15 mm) 6 Hot water connection (15 mm) 11 Heating system flow ”...

  • Page 6: Function Diagram

    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...

  • Page 7: General Requirements

    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.

  • Page 8: Boiler Location

    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.

  • Page 9: Gas Supply

    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.
  • Page 10 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.

  • Page 11: Air Suply

    3.5 Air supply Detailed recommendations for air sup- ply are given in BS 5440: Part 2. It is not necessary to have an air vent in the room or internal space in which the boiler is installed. 3.5.1 Cupboard or compart- ment air supply ECOmax Room Sealed Condensing Combination Boilers are very high...
  • Page 12 Pipework not forming part of the use- ful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and venti- lated underfloor spaces. Draining taps must be located in accessible positions which permit the draining of the whole system including the boiler and the hot water system.
  • Page 13 9 A DHW expansion vessel kit (Accy. No. 8070) is available as an optional extra from Vaillant Ltd. This expansion vessel kit should be fitted to the boiler whenever either a stop valve of the loose jumper type or a non return valve are present in the cold water mains supply to the boiler (fig.

  • Page 14: Boiler Installation Sequence

    4. Boiler installation sequence 4.1 General The boiler should be mounted on a flat and vertical area of wall of suf- ficient area for the boiler plus the required minimum clearances for installation and servicing (fig. 11). These are shown on the installation template supplied with the boiler and are:- 5 mm either side of the boiler...

  • Page 15: Preparation Of Boiler Location

    4.2.1 Installation accessories Table 3: Installation Accessories Table 3 lists the standard and optional Standard Accessories Accy. No. accessories which are available for 1) Pre-assembled connection group 9313 ECOmax. incl. isolating valves (flow and return), pressure 4.2.2 Unpack the boiler relief valve, cold and hot water connections (fig.
  • Page 16 4.3.2 Using the boiler template (fig. 13) 4.3.2.1 Once a suitable location has been chosen, fix the paper installation template on the wall ensuring that the centerline of the template is vertical using a spirit level or plumb line. The template shows the positions of the fixing holes for the boiler hanging bracket and connection group.

  • Page 17: Pipework Connections

    4.4 Pipework connections (fig. 14) Figure 14 shows the central heating, domestic hot water, mains cold water and pressure relief valve connections. 4.4.1 Central heating flow and return Before connecting the heating circuit to the connection group, all pipework and radiators must be thoroughly flushed to remove any installation debris.

  • Page 18: Installing The Flue System

    4.5 Installing the flue system At this stage install the flue system (refer to separate air/flue duct installa- tion instructions). 4.6 Mounting the boiler 4.6.1 Preparation (fig. 15) Remove the boiler from the carton. Lay the boiler on its back and remove the four plastic sealing caps from boiler flow and return and domestic water connections.
  • Page 19 4.6.3 Gas supply (fig. 17) The boiler is supplied with a 20 mm x 15 mm gas service valve (7). Fit the 20 mm compression fitting to the boiler gas inlet (3) and tighten. Install a gas supply pipe not less than 15 mm diameter and connect to the gas service valve.

  • Page 20: Connecting The Flue Assembly

    Note: If it is necessary to install any conden- sate pipework externally, then it should be kept as short as possible, be insulated with waterproof insu- lation and have a continuous fall of at least 2.5 ° (i.e. 45mm fall for every metre length).
  • Page 21 Ensure that the air/flue duct and ter- minal assembly is not displaced through the wall, and that the terminal assembly projects 90 mm as shown in fig. 23. Fit the 95 mm diameter x 25mm long air duct clamp (4, fig. 24) over the elbow and the boiler flue outlet spigot.

  • Page 22: Electrical Installation

    4.8 Electrical installation 4.8.1 General electrical requirements All electrical work shall be carried out by a competent person and shall com- ply with the current edition of the IEE regulations (BS7671). The boiler is supplied for connection to a 230V~ 50Hz supply fused at 3A rating.

  • Page 23: Controls

    IMPORTANT Ensure that all cords Connection details for programmable thermostat and boiler terminal strip pass through the terminal box Vaillant Calotrol entrance grommets and are securely (VRT 9083 and VRT 9084) fixed by the cable clamps. Ensure that the power supply cord is connected...
  • Page 24 4.9.3 Thermostatic radiator valves The boiler has a built-in automatic bypass valve making it ideal for use in systems with thermostatic radiator valves (no separate system bypass is required). For optimum fuel economy it is recom- mended that where TRVs are used they are used in conjunction with a programmable roomstat or separate timer and room thermostat to ensure...

  • Page 25: Commissioning

    5. Commissioning 5.1 Preliminary electrical checks Check the electrical installation by carrying out short circuit, earth conti- nuity and resistance to earth tests and a check for correct polarity. 5.2 Gas supply The complete gas installation inclu- ding the gas meter must be inspected, fig.

  • Page 26: Filling The Heating System

    5.4 Filling the heating system The boiler primary circuit and the hea- ting system should be filled using a fil- ling method as described in Section 3.7.2. Ensure that the boiler CH service valves (3, fig. 34) are open. Partially open the filling valve and allow water to enter the system.

  • Page 27: Filling Condensate Trap

    5.6 Filling condensate trap Remove the lower part of the conden- sate trap (1, fig. 35) by unscrewing and fill with water to about 10 mm from the top. Refit in boiler. 5.7 Initial lighting • Check that the boiler combustion chamber (5, fig.

  • Page 28: Gas Inlet Working Pressure

    NOTE: The water flow limiter built into the boiler ensures that the maximum domestic hot water flow rate does not exceed the nominal setting (equivalent to a hot water temperature rise of 35 °C). Adjustment is only required if the user requires a higher temperature rise than this setting.

  • Page 29: Main Burner Pressure

    Check that the burner pressure is as shown in Table 5. (If the burner Maximum Gas 2.38 m 2.96 m pressure is not correct within the Rate (DHW) tolerance shown contact Vaillant (84.04 ft (104.52 ft Ltd. Technical Department). • Turn off the hot tap.

  • Page 30: Functional Checks

    • Push both buttons under the diag- nostic display simultaneously. The flow temperature will now be displayed. • Reset the maximum hot water tem- perature selector to the required setting (see Section 5.15). 5.11 Functional checks 5.11.1 Introduction The boiler display (8, fig. 43) normal- ly indicates the primary flow tempera- fig.
  • Page 31 • S.17 - pump overrun (display duration: 20 secs to 80 secs) • S.0 - no water demand By stepping correctly through these codes the boiler has demonstrated correct functioning for DHW. To exit from status mode push the right hand button once.

  • Page 32: Checking Flame Supervision Device

    (Note: This control ensures that energy wasteful short-cycling of the boiler cannot occur, by preventing the boiler from igniting for a preset period of 5 minutes after central heating opera- tion. The hot water operation is unaf- fected by this control and hot water can be drawn at any time.

  • Page 33: Final System Flush ('Hot')

    To ensure regular servicing, it is the door. strongly recommended that arrange- ments are made for a Maintenance Agreement. Please contact Vaillant Service Department (FREEPHONE 0800 318076) for further details. Leave the user instructions in the pur- pose provided pocket on the front of the control panel (5, fig 46).

  • Page 34: Servicing

    6. Servicing To ensure the continued safe and effi- cient 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 instal- lation conditions and usage, but in general once per year should be ade- quate.

  • Page 35: Initial Inspection

    6.1 Initial Inspection Before commencing any servicing or maintenance work, carry out an initial inspection of the system as follows:- Inspect the flue, pipework and elec- trical connections for indications of damage or deterioration. Inspect the air supply and ventilation arrangements of the installation, en- suring that the requirements of Section 3.5 are met.
  • Page 36 6.2.3 Inspect burner Remove 5 combustion chamber re- taining screws (3, fig. 51). Slacken 2 side panel spring retaining screws (2, fig. 51) and remove screw (4, fig. 51). Remove combustion chamber front cover. Unplug the 2 electrical connections (1, fig. 52) from combustion fan. Remove the 2 burner retaining clips (6, fig.

  • Page 37: Recommisioning The Boiler

    Open CH service valves, and repres- surise boiler and heating system if necessary (see Section 5.4). 6.3 Recommisioning the boiler • Refit the combustion chamber front cover. Ensure that the panel is cor- rectly fitted and a good seal is obtained.

  • Page 38: Parts Replacement

    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 an isolating switch only, remove the fuse from the switch). • Turn OFF the gas supply at the gas service valve fitted to the boiler.
  • Page 39 7.1.1 Turning off the boiler (fig. 56) • Isolate the electrical supply to the boiler • Turn off the gas service valve (1) • Turn off boiler CH service valves (2) • Turn off DHW cold water service valve (3). 7.1.2 Releasing CH water pressure and draining boiler (fig.

  • Page 40: Fan

    7.1.5 Removal of combustion chamber cover (fig. 59). • Remove front casing as in Section 7.1.3, • Slacken the 2 case retaining screws (2). • Undo the 5 captive inner casing screws (3). • Remove screw (4). • Lift combustion chamber cover (5) off boiler.

  • Page 41: Air Pressure Sensor

    7.3 Replacement of air pressure sensor (fig. 63) • Isolate the boiler from the electrical supply. • Remove front casing as in Section 7.1.3. • Disconnect plug (3) from air pressu- re sensor. • Pull the front of the air pressure sensor (1) down to release from gas valve (2) and remove by unhooking from rear retaining clip.

  • Page 42: Electrodes

    7.5 Replacement of electrodes • Isolate the boiler for the electrical supply. • Remove front casing as in Section 7.1.3, and remove combustion chamber cover as in Section 7.1.5 7.5.1 Ignition electrodes (fig. 65). • Pull off HT lead (1) •...

  • Page 43: Condensate Sump

    7.6 Replacement of condensate sump • Isolate the boiler from the electrical supply. • Remove front casing as in Section 7.1.3 and remove combustion chamber cover as in Section 7.1.5 • Pull the condensate sump retaining clip (1, fig. 67) forward to release sump.

  • Page 44: Condensate Trap

    7.7 Replacement of condensate trap (fig. 70) • Isolate boiler from the electricity supply. • Remove front casing as in Section 7.1.3, remove combustion chamber cover as in Section 7.1.5 and lower front control panel as in Section 7.1.6 • Undo the 2 unions (1) and pull trap down to remove from boiler.

  • Page 45: Main Heat Exchanger

    7.10 Replacement of main heat exchanger • Turn off the boiler as in Section 7.1.1. • Release CH water pressure and drain boiler as in Section 7.1.2. • Remove front casing as in Section 7.1.3 and remove combustion chamber cover as in Section 7.1.5 •...

  • Page 46: Ch Expansion Vessel

    7.11 Replacement of CH expansion vessel In the unlikely event of a failure of the CH expansion vessel follow proce- dure 7.11.1 or 7.11.2 depending upon the installation circumstances. 7.11.1. Boiler installed with air/flue duct to left/- right hand side, or vertical flue installation (where 600mm vertical fig.

  • Page 47: Main Safety Isolating Transformer

    • Disconnect the flue from the top of boiler as described in Section 4.7. • Remove boiler from wall and slacken two screws (1, fig. 76). • Slide expansion vessel upwards and out of boiler casing. • Reassemble in reverse order. •...

  • Page 48: Ignition Transformer

    • Undo screws (7, fig. 80) and remove transformer by pulling it down and to the right. • Reassemble in reverse order. • Carry out electrical checks (see Section 5.1). 7.13 Replacement of ignition transformer (fig. 81) • Isolate the boiler from the electricity supply.

  • Page 49: Automatic Air Release

    • Undo the 3 pump screws (3, fig. 82). • Pull pump forward to remove. • Remove back of control box by undoing 2 screws (1, fig. 78). • Disconnect pump supply plug and lift clear of board. • Fit new `0' rings (supplied with pump) to connecting tubes.

  • Page 50: Diverter Valve

    • Undo union (1, fig. 84) and remove bypass (2, fig. 84). • Reassemble in reverse order using sealing washers supplied. • Refill and repressurise the boiler (see Section 5.4). 7.17 Replacement of diverter valve • Turn off boiler as in Section 7.1.1. •...

  • Page 51: Pressure Gauge

    7.17.1 Replacement of diverter valve diaphragm (fig. 87). • Remove diverter valve as in Section 7.17 • Remove the 4 screws (1). • Lift top off diverter valve and remo- ve diaphragm. • Replace in reverse order. • Carry out electrical checks (see Section 5.1).

  • Page 52: Dhw Microswitch

    • Remove retention clip (3, fig. 90). • Remove screw (5, fig. 90). • Pull water section forward to relea- se from pipe (4, fig. 90) and lift water section out of boiler. • Pull off clear water section lid and disconnect the wires to DHW microswitch.

  • Page 53: Dhw Heat Exchanger

    7.21 Replacement of DHW heat exchanger (fig. 92) • Turn off boiler as in Section 7.1.1. • 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.
  • Page 54 7.22.1 Replacement of boiler display board (fig. 94) • Slide the connecting plug (1) for- wards to release from connecting pins. • Move retaining clips (2) outwards and slide board upwards to remove. • Reassemble in reverse order. • Carry out electrical checks (see Section 5.1) 7.22.2 Replacement of rectifier fig.
  • Page 55 7.22.4 Replacement of CPU board • Remove rectifier and mother boards as in 7.22.2 and 7.22.3. • Pull off central heating control knob (2, fig. 97) from front of control box. • Remove lower control box cover (5, fig. 94) by undoing two screws (6, fig.
  • Page 56 • Disconnect three cable plugs (1, fig. 100). • Disconnect two earth wires (2, fig. 100) from earth terminal strip. • Remove screw (3, fig. 100). • Remove wiring terminal box cover by undoing two screws (1, fig. 101). • Disconnect wires from relay panel at wiring connector strip.

  • Page 57: Fault Finding

    8. Fault finding 8.1 Introduction ECOmax has an inbuilt advanced multifunction boiler display (1, fig. 104) to assist you with fault finding in the unlikely event of a boiler mal- function. The display features the following 4 modes:- 1. Normal Mode Under normal conditions the boiler display will show the boiler flow tem- fig.

  • Page 58: Logical Fault Finding Procedure

    Once the required diagnostic code is displayed the right hand button (1, fig. 107) should be pressed; this will instruct the microprocessor to carry out that particular check. To return from a diagnostic enquiry, depress the right button (1, fig. 107) once more.
  • Page 59 4) Ensure the heating system is full of water and charged to approx. 1 Bar. If not refill system and vent (see section 5.4: Filling the heating system). Ensure boiler flow and return service valves are open. Check condensate trap is filled (see Section 5.6).

  • Page 60: Fault Finding Using Fault Mode

    8.3 Fault diagnosis using the Fault Code Displayed Possible Causes / Description boiler fault mode F0/F20 1. Loose wire/poor connections to NTC 'T0' (alternating display) - Repair as necessary. Interruption to NTC 2. Faulty component - Replace NTC 'T0' (Section 7.8) flow sensor 'T0'* F1/F20 1.
  • Page 61 if yes:- (1) No flame visible before boiler shuts off: gas valve or gas valve connections defective, repair or replace as necessary (see Section 7.9) (2) Flame is visible before boiler shuts off: Turn the central heating control to the 'hot water only' position and push the red 'reset' button.

  • Page 62: Status Mode

    F31 or F34 1. Initially check both air/flue duct and condensate Air pressure discharge are free of obstruction. sensor fault - Remedy as necessary. 2. Air pressure sensor connections not correctly located in gas valve. - Relocate sensor as necessary, check conection lead. 3.

  • Page 63: Fault Diagnosis Using

    8.4.3 Fault Diagnosis using Status Code Displayed Possible Causes / Description boiler Status Mode: Central Heating S0 or S30 External controls not calling for heat Operation - Check settings of all external heating controls. Symptom: radiators not getting hot. If no external controls fitted, ensure terminals 3 & 4 of the boiler terminal strip are linked.

  • Page 64: Hot Water Operation

    8.4.4 Fault Diagnosis using the Status Code Displayed Possible Causes / Description boiler Status Mode: Hot Water Operation Note: Set central heating control to 1. Water section not operating. "Hot Water only" position and open a Symptom:- Boiler will not - Poor mains inlet water flow/pressure, check hot water tap.

  • Page 65: Electrical Diagrams

    9. Electrical diagrams 9.1 Functional flow diagram fig. 113...

  • Page 66: Wiring Diagram

    9.2 Wiring diagram fig. 114...

  • Page 67: Schematic Appliance Circuit Diagram

    9.3 Schematic appliance circuit diagram fig. 115...

  • Page 68: Short Parts List

    10. Short parts list Description Part No. GC No. Top of water Section cpl. 01-3050 283 517 Ignition electrode 04-3120 283 569 De-aerator 06-1707 263 935 Front shell cpl. top 07-8103 283 596 Front shell cpl. lower part 07-8104 283 595 Side wall, cpl.
  • Page 69 fig. 116 fig. 117 fig. 118 fig. 119 fig. 120 fig. 121 fig. 122 fig. 123 fig. 124...

  • Page 70: Supplementary Information For Ecomax

    11. Supplementary The appliance delivered is designed for use with propane. information for Please read the instructions for ECOmax: Propane installation therefore as follows. versions Propane gas burning appliances must not be installed in a room or internal space below ground level, e.g. cellar ECOmax VUW 236 EP or basement.
  • Page 71 Commissioning Check that the gas supply pressure, IMPORTANT: gas rate and heat input are in • When commissioning a new accordance with the Technical Data installation for the first time, ensure in Table 1 of these instructions. that all air has been purged from the storage tank and installation pipework before attempting to light the boiler.
  • Page 72 HEATING, CONTROLS, HOT WATER 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...

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