To be left with the user Instructions for Use, Installation and Servicing ecoMAX pro GB 18 E Wall hung condensing boilers for traditional open vented systems 28 E
Table of Contents Page 1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Contents included with ecoMAX pro boiler . . . . . . . . . . . . . 4 4 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Gas Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
Table of Contents Page 15 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Spark Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 Combustion Chamber and Heat Exchanger. . . . . . . . . . . . . 15.5 Condensate Drain . . . . . . . . . . . .
List of Contents Vaillant Ltd. support the Benchmark initiative. Ensure that all contents are included before commencing installation. Within the information pack you will find a Benchmark Log Book. It is very important that this is completed correctly at the time of installation, commissioning and handover to the user. 12621 1.1 Contents included with ecoMAX pro boiler Items supplied with unit (ecoMAX pro) Fig 1.
2 Introduction 2.1 General Information Thank you for choosing a Vaillant boiler. The information given in this booklet will enable you to obtain the best performance from your boiler. The Benchmark logbook should be completed by the installer and/or commissioning engineer and handed to the user. NOTE: This boiler must be installed and serviced by a competent person in accordance with the Gas Safety (Installation and Use) Regulations 1998.
Important information 2 Sheet Metal Parts This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges. Sealed Components Under no circumstances must the User interfere with any sealed component as this could result in a potentially dangerous situation arising. Electrical Supply Failure This boiler must be earthed. The boiler will not work without an electrical supply.
2 Introduction 3 Operating the Boiler 3.1 Sealed Central Heating Systems only CAUTION: A sealed water system must be filled and pressurised by a competent person. Only light the boiler when you are sure that the system and boiler have been filled and pressurised. The pressure should read at least 0.7 bar, when the system is cold. If the needle displays a value below this, follow the instructions left by your installer to refill the system. Alternatively your installer should be called to refill the system.
4 General information IMPORTANT NOTICE: The boiler is supplied in one pack and the flue is supplied separately. This boiler is factory set for use on Natural Gas (G20), ecoMAX pro 28E only can be field adjusted for use on LPG (propane G31). Where no British Standards exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship. Refer to Manual Handling Operations, 1992 regulations.
12623 4 General information 12624 Fig 4.1 Fig 4.
4 General information 5 Water system 5.1 Draining Tap A draining tap must be provided at the lowest point of the system, which will allow the entire system and hot water system to be drained. Draining taps shall be to the current issue of BS 2879. 5.2 Safety Valve A safety valve need not be fitted to an open-vented system. See also section 5.9.1. 12625 4.5 Electrical Supply The boiler must be earthed. All system components shall be of an approved type and all wiring to current I.E.E. wiring regulations.
5 Water system 5.4 Bypass A bypass is not required on the central heating system unless all radiators are fitted with thermostatic radiator valves or the system controls could allow the boiler and pump to operate when there is no flow. Where a bypass has to be fitted, the bypass must be placed at least 1.5 metres away from the boiler. 5.
5 Water system 5.9 Sealed water Systems The installation must comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2. For IE your attention is drawn to the current edition of IS 813. See Fig. 5.4 for a suggested layout. NOTE: A higher initial design pressure requires a larger volume expansion vessel.
5 Water system 6.4 Room Ventilation The boiler is room sealed, so when it is installed in a room or space, a permanent air vent is not required. 6.5 Compartment Ventilation If the boiler is installed in a compartment, a permanent air vent is not required. Leave existing air vents. 12629 5.10 Water Treatment For optimum performance the boiler and its associated central heating system should be flushed in accordance with BS7593: 1992 using a cleanser.
7 Flue NOTE: Vertical flues must not terminate within 600-mm of an openable window, air vent or any other ventilation opening. The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of the building. 12630 7.1 Flue Position and Length The standard horizontal flue is fitted onto the top of the boiler. See Fig. 7.1 and 7.2 to determine whether a standard flue can be used. Flue system The standard 100mm flue system (Art. No.
7 Flue 8 Installation preparation TERMINAL POSITION mm A1) Directly below an opening, above an opening or horizontal to an opening i.e.
8 Installation Preparation 9 Boiler fixing 12688 8.3 Rear flue exit Mark the position of the air/flue duct and its circumference. 8.4 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. are detailed in the flue installation instructions. Remove the template from the wall and plug the drilled holes using the wallplugs supplied. 9 Boiler fixing Fig 8.2 12689 8.
12691 10 Gas, Water and Condensate connections 10.1 Gas Connection Before connection check the supply of local gas. The gas supply can be connected from below, or through the wall at the rear of the boiler. Ensure the supply pipe is fully engaged in the compression fitting on the gas service valve inlet. See Fig. 10.1. and refer to section 4.3. 12692 Fig 10.1 10.2 Water Connections Provision is made for the water connections to be made from above the boiler, see Fig. 10.
11.2 Extension pipes Refer to Figs. 11.3 and 11.4. Note maximum permitted flue lengths. When extension pipes are required please note the length of the extensions, which should be taken into account when calculating the length that requires cutting. For example: Distance from outside wall to butt joint on the flue elbow ‘Y’ = 1500 mm. Standard flue length = 633 mm. Extension pipe length = 970 mm. Length of extension pipe air duct = 1500 - 633 = 867mm.
11 Flue Preparation and installation 11.3 Flue Assembly The flue assembly is a push fit design with securing collars. Remove all burrs from cut pipes. Fig. 11.5 shows the components supplied in the standard kit and the flue adapter. Having cut the air and flue ducts as described in sections 11.1- 11.2 assemble the flue as follows, the flue can be fitted externally or internally. Fit the rubber sealing collar behind the locating lugs on the flue terminal, see diagram 11.5.
12 Electrical connections Refit the terminal box to the underside of the boiler using the two retaining screws. 12.2 Electrical connections – testing Carry out preliminary electrical system checks as below; 1.Test insulation resistance to earth of mains cable. 2. Test the earth continuity and short circuit of cables. 3. Test the polarity of the mains. 12698 WARNING: This boiler must be earthed.
13 Commissioning 13.1 Preliminaries - All Systems A competent person should carry out commissioning, in accordance with the current issue of BS 6798. 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. Make sure that the system has been thoroughly flushed out with cold water. Refill the system with water, making sure that all the air is properly vented from the system and pump, Fig.
13 Commissioning 13.5 Testing - Gas The boiler is supplied ready adjusted and no further gas adjustments are necessary, however both the gas inlet working pressure and the maximum gas rate should be checked at least 10 minutes after the burner has lit. The gas inlet working pressure can be checked at the pressure test point on the gas valve (Fig 13.2.). The gas inlet working pressure should be 20 mbar when the boiler is firing at full rate.
14 Conversion The ecoMAX pro 28E is able to be field adjusted for use on LPG – propane G31 gas. To enable conversion the use of a combustion analyser is necessary. • Press the ‘-‘ key and scroll through until ‘96’ (installer mode) is shown on the screen, then press the ‘mode’button again.
12705 14 Conversion "A" throttle – "Pmax" rotate to increase Appliance CO2 content at nominal load for LPG in vol. % ecoMAX pro 28E 10.5 % ± 0.2 % "B" offset adjustment "Pmin" rotate to increase Fig 14.4 12706 • Again in screen ‘8’, Set the appliance fan speed/burner to minimum by pressing the ‘-‘ key until ‘1’ (burner to Pmin) is shown on the right hand side of the screen. Press the ‘mode’ button again. Fig 14.5 • Check the CO2 value, which should be 10.5 % ± 0.2 %.
15 Servicing 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 service valve fitted to the boiler • When removing any water carrying components ensure that the water is kept away from all electrical components. • Always use new seals and O-rings when replacing parts.
HEAT EXCHANGER COMBUSTION CHAMBER FRONT SECURING NUTS (5 OFF) ELECTRODE CONNECTOR IGNITION LEAD GAS CONTROL FAN VALVE Fig 15.4 COMBUSTION CHAMBER BURNER 12708 SECURING NUTS (5 OFF) GAS PIPE BRACKET & SEAL Fig 15.2 12709 COMBUSTION ANALYSER TEST POINT FLUE ADAPTER 12711 15.3 Burner Refer to Figs. 15.2, 15.3, 15.4 and 15.5. Isolate the gas supply at the gas service cock. Disconnect the gas supply at the union nut of the gas service cock. NOTE: Do not disconnect at the gas valve.
15.4 Combustion Chamber and Heat Exchanger Refer to Fig. 15.2. Remove loose debris from combustion chamber using a soft brush and vacuum cleaner. Carefully flush any remaining debris through the condensate trap (ensure the water is kept away from electrical components). 15.5 Condensate Drain Remove DC fan supply. Remove the clips securing the flexible tubes to the siphon adapter by twisting the clips slightly to disengage the clip jaws from each other. Remove black flexible tubes from siphon adapter.
16 Combustion analysis Press the ‘+‘ key and scroll through until ‘8’ is shown on the left of the screen, then press the ‘mode’ button again. 12704 NOTE: The boiler is fitted with a combustion analysis test point. A suitable combustion analyser can be connected to this point to establish the combustion performance of the boiler. It is not necessary to check the CO2 content or adjust the air ratio of the boiler during initial commissioning or for the annual service.
16 Combustion analysis 17 Fault finding 12706 Again in screen ‘8’, Set the appliance fan speed/burner to minimum by pressing the ‘-‘ key until ‘1’ (burner to Pmin) is shown on the right hand side of the screen. Press the ‘mode’ button again. Fig 14.5 Check the CO2 value, which should be 8.8 % ± 0.2 %. If adjustment proves necessary then proceed as follows. Adjustment of the CO2 at minimum rate is very coarse, so carefully adjust the CO2 with the (‘B’) offset adjustment using a 2mm allen key to 8.
17 Fault finding No.
17 Fault finding 17.2 Fault Memory The fault memory stores details of the five most recent faults. To display the fault memory, proceed as follows; •With the interface in ‘normal’ mode, press and hold the ) for 10 seconds until a flashing ‘0’ ‘mode’ button ( appears. • Press the ‘mode’ button again. • The 5 fault memory screens are now available to be viewed, memory 1 being the most recent. Within each memory screen, 5 additional screens provide further information to assist the installer/engineer. No.
17 Fault finding 17.3 Fault Codes Fault codes take priority over all other display functions in the event of a system fault occurring.
17 Fault finding (wiring diagram) 12452 17.4 Fault Finding Fig. 17.
18 Short spare parts Key No. Part No. Description 1 190260 Fan assembly 2 090750 Spark electrode 3 091258 Igniter unit 4 053574 Gas control valve 5 101771 Heating flow & return NTC (2) 6 101191 Overheat stat 7 130837 Main PCB 8 256271 Mains/Reset Switch 9 130839 Main user display interface 10 050469 Burner - 18 E 10 050470 Burner - 28 E 11 130838 230V interface PCB Fig. 18.
19 Boiler specification ecoMAX pro 18 E ecoMAX pro 28 E Units Maximum CH heat input (net) 18.9 28.6 kW CH heat output (80/60 °C) 5.0 - 18.3 5.3 - 28.2 kW CH heat output (50/30 °C) 5.3 - 20.0 5.7 - 30.6 kW SEDBUK Band A A SAP Seasonal Efficiency 90.4 90.6 NOx Class 5 5 % Electrical rating IP40 IP40 required (natural gas) 20 20 mbar Gas supply (G20) Gross CV (s.t.) 37.8 37.8 MJ/m3 Maximum gas rate 2.00 3.02 M3/h Minimum gas rate 0.53 0.
83 49 39 GB_02 (2000225283A/11/04) 11 2004 · Subject to alteration
