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- ECOmax VUW 236 EH
- Instructions For Installation And Servicing
Vaillant ECOmax VUW 236 EH Instructions For Installation And Servicing
Summary of ECOmax VUW 236 EH
Page 1
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 instructions for installation and servicing heating, controls, hot water.
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2 page 1. Introduction 3 2. Boiler specification 4 2.1 technical data 4 2.2 dimensions 5 2.3 boiler connections 5 2.4 function diagram 6 3. General requirements 7 3.1 related documents 7 3.2 boiler location 8 3.3 gas supply 9 3.4 flue system 9 3.5 air suply 11 3.6 electricity supply 11 3.7 guide to ...
Page 3: 1. Introduction
3 3 1. Introduction note: this boiler must be installed and serviced by a competent person in accordance with the gas safety (installation and use) regulations 1994. In the u.K. `corgi' registered installers undertake the work to a safe and satisfactory standard. Ecomax is a fully automatic, wall mo...
Page 4: 2. Boiler Specification
4 4 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 kw (33,800-58,700) 42,000-72,700) (btu/h) 50 °c flow/30 °c return 10.5-18.0 13.1-22.3 kw (35,800-61,400)...
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5 5 gw 398/0 fig. 1 2.3 boiler connections 1 connection support bracket 2 service valve (flow of heating system) 3 domestic hot water connection 4 compression union (gas) 5 gas service valve (supplied with the boiler) 6 cold water connection with shut-off walve 7 service valve (return of heating sys...
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6 6 gw 512/1 fig. 3 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 displa...
Page 7: 3. General Requirements
7 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...
Page 8
8 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 draw...
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9 gw 319/0 fig. 4 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...
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 ...
Page 11
11 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
12 fig. 7 gw 400/0 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 permi...
Page 13
Safety valve setting (bar) 3.0 initial system pressure (bar) 1.0 1.5 total water content of system vessel volume (l) litres 25 2.7 3.9 50 5.4 7.8 100 10.9 15.6 125 13.6 19.5 150 16.3 23.4 175 19.1 27.3 200 21.8 31.2 225 24.5 35.1 250 27.2 39.0 275 30.0 42.9 300 32.7 46.8 325 35.7 50.7 350 38.1 54.6 ...
Page 14: 4. Boiler Installation
14 fig. 11 gw 403/0 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 wi...
Page 15
15 4.2.1 installation accessories table 3 lists the standard and optional accessories which are available for ecomax. 4.2.2 unpack the boiler (fig. 12) open the boiler carton and remove: a. Protective cardboard sheet b. Top and bottom decorative panels c. Polystyrene packaging note: care should be t...
Page 16
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 boi...
Page 17
17 fig. 14 gw 406/0 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...
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18 fig. 15 vc/vcw 442/2 fig. 16 gw 424/0 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 th...
Page 19
19 fig. 17 gw 407/1 fig. 18 gw 525/0 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
20 fig. 19 gw 411/1 fig. 20 gw 333/0 fig. 21 gw 334/0 fig. 22 gw 335/0 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 eve...
Page 21
21 fig. 23 gw 336/0 fig. 24 gw 337/0 fig. 25 gw 367/0 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 boil...
Page 22
22 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. Connection...
Page 23
4 3 n l n l 4 23 important ensure that all cords pass through the terminal box entrance grommets and are securely fixed by the cable clamps. Ensure that the power supply cord is connected such that the current carrying conduc- tors become taut before the earthing conductor should the supply cord sli...
Page 24
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...
Page 25: 5. Commissioning
25 fig. 34 gw 410/0 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 in...
Page 26
26 fig. 35 gw 411/1 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 th...
Page 27
27 fig. 36 gw 495/0 fig. 37 gw 407/0 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. 36) is correctly fitte...
Page 28
28 fig. 38 gw 458/0 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...
Page 29
Range rating output to central heating kw (btu/h) (diagnostic code (with return temperature = 60 °c) d. Ø reading) vuw 236 e vuw 286 e 80 (maximum) 17.2 (58,700) 21.3 (72,700) 70 15.1 (51,500) 18.6 (63,500) 60 12.9 (44,000) 16.0 (54,600) 50 10.8 (36,800) 13.3 (45,400) 47 (minimum) 9.9 (33,800) 12.3 ...
Page 30
30 fig. 43 gw 459/0 • 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. 4...
Page 31
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. (the display will now show the primary flow temper- atu...
Page 32
32 (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. To ...
Page 33
33 fig. 44 gw 438/0 5.13 final system flush (`hot') allow the boiler and system to reach maximum temperature and check that the heating system is watertight. Turn the boiler off and rapidly drain both boiler and system while still hot. Refill the system and release all air as described in section 5....
Page 34: 6. Servicing
34 fig. 46 gw 413/0 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 on...
Page 35
35 fig. 47 gw 419/0 fig. 48 gw 414/0 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 v...
Page 36
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 burn...
Page 37
37 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. • turn on gas and electrical supply. • operate bu...
Page 38: 7. Parts Replacement
38 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 boi...
Page 39
39 fig. 56 gw 415/0 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. 56) • isolate...
Page 40
40 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. • check condition of case seal, and if neces...
Page 41
41 fig. 62 gw 460/0 fig. 63 gw 461/0 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...
Page 42
42 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) • pull off earth wire (2). • remove the 2 retaining nuts (3)...
Page 43
43 fig. 67 gw 464/1 fig. 69 gw 434/0 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
44 fig. 71 (natural gas) gw 427/0 fig. 71a (propane) gw 1 285/0 fig. 70 gw 465/0 fig. 72 gw 437/0 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 ...
Page 45
45 fig. 73 (natural gas) gw 428/0 fig. 73a (propane) gw 1286/0 fig. 74 gw 466/1 fig. 75 gw 467/0 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 c...
Page 46
46 fig. 76 gw 468/0 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 install...
Page 47
47 • 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. • re-mount the boiler (see section 4.6). • re-commission the boiler (s...
Page 48
48 fig. 80 (natural gas) gw 526/0 fig. 80a (propane) gw 1287/0 fig. 81 gw 496/0 • 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) • ...
Page 49
49 fig. 82 gw 469/0 fig. 83 gw 470/0 • 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. • reassemble ...
Page 50
50 • 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. • release ch water pressure and drain boiler as...
Page 51
51 fig. 88 gw 473/0 fig. 89 gw 458/0 fig. 87 gw 472/0 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 s...
Page 52
52 fig. 90 gw 474/0 fig. 91 gw 475/0 • 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. • reassemble ...
Page 53
53 fig. 92 gw 476/1 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. • unscrew the 2 nuts (1). • remove...
Page 54
54 fig. 94 gw 520/0 fig. 95 gw 523/0 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 (s...
Page 55
55 fig. 97 gw 421/0 fig. 98 gw 528/0 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. 94). • lift ...
Page 56
56 fig. 100 gw 529/0 fig. 101 gw 453/0 • 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 wiri...
Page 57: 8. Fault Finding
57 fig. 104 gw 420/0 fig. 105 gw 502/0 fig. 106 gw 503/0 fig. 107 gw 459/0 fig. 108 gw 504/0 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 featu...
Page 58
58 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. You can now carry out a further di...
Page 59
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). 5) check that boiler on/off control is...
Page 60
60 8.3 fault diagnosis using the boiler fault mode * note: for location of ntc sensors refer to section 2.4: 'function diagram'. Fault code displayed possible causes / description f0/f20 1. Loose wire/poor connections to ntc 't0' (alternating display) - repair as necessary. Interruption to ntc 2. Fa...
Page 61
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. En...
Page 62
62 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. Faulty component - - ...
Page 63
Status code displayed possible causes / description s0 or s30 external controls not calling for heat - check settings of all external heating controls. If no external controls fitted, ensure terminals 3 & 4 of the boiler terminal strip are linked. S4 or s7 initially check that the boiler is not in t...
Page 64
Status code displayed possible causes / description s0 1. Water section not operating. Symptom:- boiler will not - poor mains inlet water flow/pressure, check operate for hot water availability of adequate mains water supply to production. Appliance (see section 2.1: technical data). - check/clean w...
Page 65: 9. Electrical Diagrams
65 9. Electrical diagrams 9.1 functional flow diagram fig. 113 gw 536/0
Page 66
66 9.2 wiring diagram fig. 114 gw 535/0
Page 67
67 9.3 schematic appliance circuit diagram fig. 115.
Page 68: 10. Short Parts List
68 10. Short parts list key description part no. Gc no. No. 01 top of water section cpl. 01-3050 283 517 02 ignition electrode 04-3120 283 569 03 de-aerator 06-1707 263 935 04 front shell cpl. Top 07-8103 283 596 05 front shell cpl. Lower part 07-8104 283 595 06 side wall, cpl. Left hand side 07-999...
Page 69
69 fig. 116 gw 659/0 fig. 118 gw 661/0 fig. 117 gw 660/0 fig. 122 gw 665/0 fig. 119 gw 662/0 fig. 120 gw 663/0 fig. 121 gw 664/1 fig. 123 gw 666/0 fig. 124 gw 667/0
Page 70: 11. Supplementary
70 11. Supplementary information for ecomax: propane versions ecomax vuw 236 ep ecomax vuw 286 ep the appliance delivered is designed for use with propane. Please read the instructions for installation therefore as follows. Propane gas burning appliances must not be installed in a room or internal s...
Page 71
71 commissioning check that the gas supply pressure, gas rate and heat input are in accordance with the technical data in table 1 of these instructions. Important: • when commissioning a new installation for the first time, ensure that all air has been purged from the storage tank and installation p...
Page 72
83 12 01 gb 03 heating, controls, hot water 0198 v printed in germany - imprimé en allemagne printed on 100 % recycled paper subject to alteration we do not accept liability for damage arising as a result of the non-observance of these instructions head office vaillant ltd., vaillant house, medway c...