Datasheet | Vaillant ecoMAX pro 18E Technical data

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Datasheet | Vaillant ecoMAX pro 18E Technical data | Manualzz

For the installer

Installation and maintenance manual

ecoMAX

Wall hung room sealed fan assisted condensing boiler

ecoMAX 646

GB

Contents

Notes on the documentation ...................................... 3

Other relevant documentation and service aids ........... 3

For the installer ..................................................................... 3

Symbols used .......................................................................... 3

5.2.2 Checking the connection pressure

(gas flow pressure) ................................................... 20

CO

2

content and adjusting it if needed (air ratio setting) .................................... 20

1 Description of the appliance ........................... 4

Safety instructions and regulations .............. 6

5.4.1 Instructing the user about the heating system .......................................................... 22

5.4.2 Vaillant warranty....................................................... 22

6 Adapting the appliance to the heating system ................................................................ 23 2

2.1.1 Installing and setting the appliance ..................... 6

2.1.3 Changes to the surroundings of the boiler ........ 6

2.1.4 Important instructions for propane appliances ................................................................... 6

6.2 Setting the pump run-out time .............................. 24

6.3 Setting the pump output ......................................... 24

6.3.1 Setting the pump output with direct feeding .... 24

6.3.2 Setting the pump output with hydraulic decoupling ................................................................... 24

6.4 Setting the burner lockout time ............................ 24

2.2.1 Preliminary remarks for roomsealed appliances 6

3.1

3.3

Scope of delivery and accessories ....................... 8

Dimensional drawing and connections ................ 9

7 Inspection and maintenance ........................... 25

7.1 Inspection and maintenance intervals ................. 25

7.2 Inspection and maintenance instructions ........... 25

7.2.1 Servicing the compact thermal module .............. 26

7.2.2 Cleaning the integral condensation heat exchanger ................................................................... 27 assembly clearances ................................................ 10

3.6 Removing/Attaching the appliance casing ......... 10

7.2.4 Cleaning the condensate siphon ........................... 27

7.2.5 Cleaning the condensate paths ............................. 27

7.3 Checking the gas setting ......................................... 28

7.4 Filling and bleeding the system ............................. 28

7.5 Draining the appliance and the system ............... 28

4.2 Technical instructions for the heating system .......................................................................... 11

4.2.1 Direct feeding with heating pump located in the interior of the device ................................... 11

4.2.2 Hydraulic decoupling with heating pump located on the appliance side ................................ 12

4.3 Technical instructions for recharging ................. 12

7.5.2 Draining the entire system ..................................... 28

7.5.3 Cleaning the air barrel ............................................. 28

4.8.3 Connecting accessories and external system components ................................................. 15

4.8.5 Wiring diagram .......................................................... 17

11 Technical data ................................................... 33

5.1.1 Treating the heating water..................................... 18

5.1.2 Heating side filling and bleeding ........................... 18

5.1.3 Hot water side filling and bleeding ....................... 19

5.2 Checking the gas setting ......................................... 19

Benchmark gas boiler commissioning checklist ...... 34

2 Installation and maintenance manual ecoMAX 646

Notes on the documentation

The following information is intended to guide you through the entire documentation.

Further documents apply in combination with this installation and maintenance manual.

We accept no liability for any damage caused by non-observance of these instructions.

Other relevant documentation and service aids

For the owner of the system

Brief operating instructions

Operating manual

Warranty cards

No. 00 20 00 64 61

No. 00 20 01 46 08

No. 80 29 22

For the installer

Installation Manual

Flue accessories

Checklist

No. 00 20 01 46 06

No. 00 20 02 01 60

Sticker with name of appliance No. 83 42 24

Installation template No. 12 41 82

Safety sticker No. 83 55 93

Service aids:

The following test and measuring equipment is required for inspection and maintenance:

– CO

2

measuring device

– U-pipe pressure gauge

Attachment and storage of the documents

Please pass on this installation and maintenance manual as well as the aids to the owner of the system, whose responsibility it is to ensure that the manuals and auxiliary equipment are available whenever required.

Symbols used

Please observe the safety instructions in this installation manual when installing the appliance!

Danger!

Immediate risk of serious injury or death!

Caution!

Potentially dangerous situations for product and environment!

Note!

Useful information and instructions.

• Symbol for a necessary task

Installation and maintenance manual ecoMAX 646

Notes on the documentation

3

1 Description of the appliance

1 Description of the appliance

1.1 Design

11

10

9

8

7

Fig. 1.1 Function elements

1 Connection for the flue pipe

4 Pump

4

4

5

6

10 Compact thermal module

11 Air intake pipe

Installation and maintenance manual ecoMAX 646

1

2

3

Description of the appliance 1

Appliance type

Country of destination

(designations according to ISO 3166) ecoMAX 646 GB (Great Britain)

License category

II

2H3P

Table 1.1 Type summary

Type of gas

Natural gas H - G 20 -20 mbar

(Propane - G 31 - 37 mbar)

Nominal heat output range P (kW)

13.3 - 47.7 (40/30 °C)

12.3 - 44.1 (80/60 °C)

Storage charging output

(kW)

44.1

The data badge of the Valliant ecoMAX 646 is attached at the factory to the bottom of the appliance.

The Vaillant ecoMAX 646 is a state-of-the-art appliance which has been constructed in accordance with recognised technical safety regulations. Nevertheless, danger to the life and limb of the user or third parties can still occur or the appliance or other material assets be damaged when using it.

The appliance is designed to be used as a heater for closed hot water central heating systems. Any other use or extended use is considered to be improper. The manufacturer or supplier is not liable for any damage resulting from improper use. The user alone bears the risk.

Appropriate use includes the observance of the operating and installation manual and the adherence to the inspection and maintenance conditions.

Fig. 1.2 Data badge (example)

CE marking is used to document the fact that the appliances, in accordance with the type summary, meet the basic requirements of the directive on appliances burning gaseous fuels (Council Directive 90/396/EEC) and the EC directive on electromagnetic compatibility (Council Directive 89/336/EEC). The appliances meet the basic requirements of the efficiency requirements directive

(Council Directive 92/42/EEC).

The appliances meet the basic requirements of the efficiency requirements directive (Council Directive 92/42/

EEC) as condensing appliances.

Installation and maintenance manual ecoMAX 646 5

2 Safety instructions

2

2.1.1

Safety instructions and regulations

Installing and setting the appliance

Important!

The appliance must be installed and serviced by a competent person as stated in the Gas Safety

(Installation and Use) Regulations 1998. In IE, the installation must be in accordance with the current edition of IS 813 ‚Domestic Gas Installations‘, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

Connection set for external solenoid valve:

Item no.: 306 253 or 306 248

Danger!

Only propane in accordance with DIN 51622 may be used.

Important!

When tightening or slackening screwed connections always use suitable open-ended spanners

(not pipe wrenches or extensions etc.).

Incorrect use and/or unsuitable tools can lead to damage being caused (e.g. gas or water leakage)!

If you smell gas, the following safety instructions should be observed:

• don‘t switch on any electrical switch in the danger area,

• don‘t smoke in the danger area,

• don‘t use a telephone in the danger area,

• close the gas stop cock,

• air the danger area,

• notify a gas supplier or recognised gas fitting company.

2.2.1 Preliminary remarks for roomsealed appliances

This appliance should only be installed in conjunction with either a Vaillant flue system or an alternative approved system (details of flue approval categories can be found in the technical section of the installation manual).

Install the flue system as detailed in the separate flue installation instructions supplied with this boiler.

2.1.3 Changes to the surroundings of the boiler

No changes must be made to the following devices:

– the boiler

– the gas, air, water and electricity supply pipes

– the exhaust pipe

– the discharge pipe and the safety valve for the hot water

– the constructional conditions that could affect the operational reliability of the device.

2.1.4 Important instructions for propane appliances

Bleeding the liquid gas tank when installing the system: before installing the device, make sure that the gas tank has been bled. The liquid gas supplier is responsible for the proper bleeding of the tank. Ignition problems can be caused if the tank is not bled properly. In such cases, first contact the person in charge of filling the tank.

Affixing the tank sticker:

Affix the enclosed tank sticker (propane quality) on the tank where it is clearly visible or on the bottle cabinet, if possible close to the filler nozzle.

Installing underground:

When installing in underground places, the requirements of the TRF 1996 (technical rules for liquid gas) are to be observed. We recommend the use of an external solenoid valve.

The installation of the boiler must be in accordance with the relevant requirements of Gas Safety (Installation and Use) Regulations 1998, Health and Safety Document

No. 635 (The Electricity at Work Regulations 1989),

BS7671 (IEE Wiring Regulations) and the Water Supply

(Water Fitting) Regulations 1999, or The Water Bylaws

2000 (Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, The Building Regulations (Scotland).

The Building Regulations (Northern Ireland) and the relevant recommendations of the following British

Standards:

BS 6700: Services supplying water for domestic use within buildings and their curtilages.

BS 6798: Specification for installation of gas fired boilers not exceeding 60 kW input.

BS 6891: Specification for installation of low pressure gas pipework up to 28 mm (R1) in domestic premises (2nd family gas).

BS 7593: Treatment of water in domestic hot water central heating systems. Institute of Gas Engineers Publication IGE/UP/7/1998: ”Guide for gas installations in timber framed housing”

BS. 5482 Pt. 1 Domestic butane and propane gas burning installations.

and commercial gas installation.

pressors on industrial and commercial premises.

IGE/UP10 Installation of gas appliances in industrial and commercial premises.

BS. 6644 Installation of gas fired hot water boilers of rated inputs between 60 kW and 2 MW (2nd and 3rd family gases).

6 Installation and maintenance manual ecoMAX 646

Safety instructions 2

BS. 5449 Forced circulation hot water central heating systems for domestic premises.

Note: only up to 45 kW.

BS. 6880 Low temperature hot water heating systems of output greater than 45 kW.

Part 1 Fundamental and design considerations.

Part 2 Selection of equipment.

Part 3 Installation, commissioning and maintenance.

BS. 4814 Specification for: Expansion vessels using an internal diaphragm, for sealed hot water heating systems.

BS. 5440 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases).

Part 1 Specification for installation of flues.

Part 2 Specification for installation and maintenance of ventilation for gas appliances.

Important!

When tightening or loosening screwed connections always use suitable open-ended spanners

(not pipe wrenches or extensions etc.). Incorrect use and/or unsuitable tools can lead to damage being caused (e.g. gas or water leakage)! Preliminary remarks: This appliance should only be installed in conjunction with a

Vaillant flue system. Install the flue system as detailed in the separate flue installation instructions supplied with this boiler.

A compartment used to enclose the boiler must be designed and constructed specifically for this purpose.

(An existing cupboard or compartment may be used provided that it is modified for the purpose). Details of essential features of cupboard/compartment design including airing cupboard installations are given in BS 6891. In

IE the current edition of IS 813. If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication

IGE/UP/7/1998 “Guide for Gas Installation in Timber

Framed Housing”.

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. Installation pipes should be fitted in accordance with BS 6891. Pipework from the meter to the boiler must be of an adequate size. Do not use pipes of a smaller size than the boiler gas connection (15 mm,

22 mm for 837/637). The complete installation must be tested for soundness and purged as described in BS

6891.

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 servicing and air circulation 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 Regulations (Scotland) and in

IE the current edition of IS 813 and the current ETCI rules, in respect of the installation of a boiler in a room containing a bath or shower.

Note!

Where a room sealed boiler is installed in a room containing a bath or shower, any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

Where the installation of the boiler will be in an unusual location, special procedures may be necessary and BS

5546 and BS 6798 give detailed guidance on this aspect.

The boiler must be mounted on a flat, vertical wall, which must be sufficiently robust to take the weight of the boiler. The boiler may be installed on a combustible wall, subject to the requirements of the Local Authorities and

Building Regulations.

Installation and maintenance manual ecoMAX 646 7

8

3 Mounting

3 Mounting

The Vaillant ecoMAX 646 is delivered pre-mounted in a package unit.

3.1 Scope of delivery and accessories

Scope of delivery

Check that all the parts have been delivered intact (see fig. 3.1 and table 3.1).

8

7

1

2

Please note the following safety instructions below before choosing where to install the appliance:

Caution!

Do not install the appliance in rooms prone to frost. In rooms with aggressive steam or dust, the appliance must be operated independently of the ventilation!

When choosing the place of installation and while operating the appliance, make sure that the combustion air is technically free of chemical substances containing fluorine, chlorine, sulphur etc. Sprays, solvents and cleaning agents, paints, adhesives etc. contain these kinds of substances, which - in the worst case scenario - can lead to corrosion, even in the exhaust system, during ambient air dependent operating of the appliance.

The appliance must be operated independently of the ambient air particularly in hairdressing salons, carpenter‘s shops or paint shops, cleaning companies. Otherwise, a separate installation room is required to guarantee that the combustion air supply is technically free of the above mentioned substances.

6

3

4

5

Fig. 3.1 Scope of delivery

Position Quantity

1

4

5

2

3

6

7

1

1

2

1

1

1

3

Name

Bracket

Appliance

Connector - storage charging circuit

Condensate discharge hose

Bag containing consumables

Installation template

Manuals:

Operating manual

Installation manual

Assembly manual for flue pipe

Table 3.1 Scope of delivery

Installation and maintenance manual ecoMAX 646

3.3 Dimensional drawing and connections

480 fl 80/125

1

2

190

Mounting 3

7

6

Rp1

70

100 100

Rp1

5 fl 20

4

3

R 3/4

7

100

180

450

R 1

144

Fig. 3.2 Connection dimensions

1 Flue connection Ø 80/125 mm

Dimension A with 87° elbow: 253 mm

Dimension A with 87° T-piece: 270 mm

4 Charging circuit return (only in conjunction with cylinder)

6 Charging circuit supply (only in conjunction with cylinder)

Installation and maintenance manual ecoMAX 646 9

3 Mounting

3.4 Required minimum gaps/assembly clearances

Both for the installation/assembly of the appliance and for carrying out maintenance tasks later, you need the minimum gaps and assembly clearances given below:

350

3.6 Removing/Attaching the appliance casing

Removing the casing

To dismount the front casing of the appliance, proceed as follows:

• Unscrew the screw (1) on the bottom of the appliance.

• Press in both holding clips (2) on the bottom of the appliance so that the casing comes loose.

• Pull the casing (3) forwards by its bottom edge and lift the casing up and off (4).

4

2

1

250

Fig. 3.3 Required minimum gaps/assembly clearances

3

Leaving gaps to the sides is not necessary.

Furthermore, it is not necessary to keep a gap between the appliance and components made of combustible constituents, since at the rated heating power of the appliance, the temperature here is never higher than the permitted temperature of 85 °C.

Fig. 3.5 Removing/Attaching the appliance casing

3.5 Mounting the appliance

• Hang the appliance up into the appliance holder (1) from above with the bracket (3).

• Mount the cable connections to the appliance, making sure they are disconnected from the power supply.

Attaching the casing

To mount the casing, proceed as follows:

• Place the casing on the upper appliance holders.

• Push the casing onto the appliance so that the holding clips (2) on the casing click into place.

• Fix the casing by screwing in the screw (1) on the bottom of the appliance.

75

240

75

50

50

85

2

1

23

3

Fig. 3.4 Mounting the appliance

10 Installation and maintenance manual ecoMAX 646

Installation 4

4 Installation

4.2.1 Direct feeding with heating pump located in the interior of the device

When installing, please observe the following points in particular:

- Install the filling device in the return

- Guarantee minimum circulation by means of an overflow valve or hydraulic switch

3

1

2

When recharging:

- Install the storage charging pump

- Install gravity brake in the heating supply and in the storage charging circuit

3

230V~

4.1 Preparing the installation

Safety equipment for an emergency

• From the safety valve‘s blow-out line, a drain pipe with intake guide and siphon must be led to a suitable outlet. The outlet must be visible!

• If plastic pipes are used in the heating system, a suitable maximum thermostat must be mounted on the heating supply (e.g. Vaillant feed thermostat 009 642).

This is necessary in order to protect the heating system from temperature-related damage in the event of a malfunction.

• When using plastic pipes that are not diffusion tight in the heating system, a system separation between the heater and system by means of an external heat exchanger must be performed in order to avoid corrosion occurring in the heater circuit or in the boiler.

4.2 Technical instructions for the heating system

3

53

Fig. 4.1 Example 1: radiator heating, direct feeding, applianceinternal pump

53 overflow valve (on site)

Pump layout; system dimensioning

The system planning is to be done such that in the design point optimally a water volume of:

V = 2000 l/h with T = 20 K flows through the device and system.

The resulting residual delivery head for the system dimensioning is to be taken from fig. 4.2.

Caution!

The following system diagrams are schematic diagrams. They do not replace the full professional diagrams!

The system diagrams do not contain the shutoff devices and safety devices necessary for correct mounting.

Observe the applicable standards and guidelines.

Setting the overflow valve

In order to guarantee the minimum circulating water volume of 1150 l/h through the appliance, install and set the overflow valve.

We recommend you set the overflow valve to 250 mbar with regard to possible noises at thermostat valves. The overflow valve can, however, be set at up to 400 mbar.

Druck in mbar

250

200

150

100

50

0

550

500

450

400

350

300

900

850

800

750

700

650

600

0 200

Restförderhöhe ohne Schwerkraftbremse

Restförderhöhe mit Schwerkraftbremse

(Zubehör, Art.-Nr. 306 715)

Nennpunkt

400 600 800 1000 1200 1400 1600 1800 2000 2200

Volumenstrom in l/h

Fig. 4.2 Resulting characteristic curve (residual delivery head) ecoMAX 646

Installation and maintenance manual ecoMAX 646 11

4 Installation

4.2.2 Hydraulic decoupling with heating pump located on the appliance side

J J

3 3

1

230V~

3

2

3

2

3

3

3

3

2

17a

45

4

4.3 Technical instructions for recharging

Recharging kit (accessory)

Mounting instructions are to be taken from the manual supplied with the recharging kit.

1

2

3

13

3

3

230V~

3

Fig. 4.3 Example 2: radiator heating and floor heating, hydraulic separation, appliance-internal pump

Fig. 4.4 Example 3: use of a cylinder, direct heating circuit

2 heating pump (appliance-internal)

13 weather-based controller VRC 420s

13a mixer module

17a supply temperature sensor

Pump layout in the heater circuit

The appliance pump is set according to table 4.1.

with gravity brake

Pump output

100 %

Table 4.1: pump output without gravity brake

The pump output must be set to the values in the table

(in the DIA system under point d.14).

80 %

Selection of the hydraulic switch

A suitable WH model hydraulic switch (accessory) can be selected with the aid of table 4.2.

A sufficiently large water volume (minimum circulating water volume) is constantly supplied through the boiler via the hydraulic switch in conjunction with the pump built into the boiler.

heating system spread heating system output

10 K 15 K 20 K ecoMAX 646 double cascade triple cascade quadruple cascade

WH 95

WH 160

WH 280

WH 280

WH 40

WH 95

WH 160

WH 160

Table 4.2: Selection of the hydraulic switch, WH model

WH 40

WH 95

WH 160

WH 160

2 heating pump (appliance-internal; accessory)

13 weather-based controller VRC 410

Recharging without accessories

It is imperative to keep to the minimum volume flow of the charging circuit of 1800 l/h.

When dimensioning, pay attention to the pressure losses of the gravity brake, the piping and the cylinder.

The heating circuit‘s gravity brake is to be put in the heating supply; the storage charging circuit‘s gravity brake can be mounted anywhere you like.

Druck in mbar

350

300

250

200

150

100

50

0

650

600

550

500

450

400

900

850

800

750

700

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200

Volumenstrom in l/h

Fig. 4.5 The appliance‘s storage charging circuit without brake and cylinder (the appliance‘s pressure loss characteristic curve)

12 Installation and maintenance manual ecoMAX 646

Installation 4

Note!

When using a cylinder, a gravity brake is to be mounted in the supply.

Caution!

Ensure the gas line is disconnected from the power supply when mounting it so that no leaks are caused.

• Screw in supply (3) and return (4) with the maintenance cocks.

Caution!

The checking of the gas ducts for leaks may only be carried out with a maximum pressure of

50 mbar, since otherwise the gas valve might get damaged.

The appliance must be connected to your gas line via a gas ball cock with a fire protection apparatus.

• Screw the appliance‘s gas supply pipe (1) gas-tight with the (pre-installed) gas ball cock (2). To do this, use the

R3/4 compression fitting supplied with the appliance.

This is suitable for the connection of a R3/4 gas ball cock.

• Inspect the gas connection for leakage.

3

Fig. 4.7 Mounting the heating supply and return

4

Danger!

Only use original Vaillant flue pipes, since these are authorized together with the boiler. Malfunctions can occur if you use other accessories. These may result in damage and injury.

1

2

Fig. 4.6 Gas connection (only surface installation possible)

*

Caution!

Ensure the connecting cables are disconnected from the power supply when mounting them so that no leaks are caused in the heating system.

The appliance is connected to the heating supply and return via maintenance cocks. An installation set for the ecoMAX 646 is available (item no. 306 715).

Caution!

It is imperative that the filling device be mounted in the return; otherwise, the bleeding of the appliance is not guaranteed.

X

Fig. 4.8 Mounting example - vertical roof duct

* In case of x > 1 m an inspection hole has to be provided

Installation and maintenance manual ecoMAX 646 13

4 Installation

Concentric systems made of plastic (diameter - 80/125 mm) are combined with the appliance as flue pipes. The most suitable system depends on the specific installation and application conditions (see also the installation manual 83 44 49 for the flue pipes).

• Mount the flue pipes consulting the installation manual contained in the scope of delivery of this appliance.

Caution!

Supplying power to false plug terminals of the

Pro E system can destroy the electronics.

Only connect the mains supply to the terminals that are marked as being for that purpose.

The condensate generated during combustion is led from the condensate discharge pipe to the waste water connection via a draining funnel.

The rated voltage of the mains must be 230 V; at rated voltages above 253 V and under 190 V, functional impairments are possible.

The mains supply must be connected via a fixed connection and a separator with a contact opening of at least

3 mm (e.g. fuses, circuit breakers).

Caution!

The condensate discharge pipe may not be connected tight to the waste water line.

• Connect the supplied condensate discharge hose (1) to the pre-installed draining funnel (2).

The draining funnel also serves to drain off any heating water that may be escaping at the safety valve.

If the condensate discharge line needs to be extended during installation, only use DIN 1986/EN 12056 compliant drain pipes.

Mounting is to be carried out as instructed in the relevant installation manual. The necessary connections to the boiler‘s electronics (e.g. when using external controllers, external sensors or similar devices) are to be performed as follows:

• Take off the front casing of the appliance and lift the electronics box (1) forward.

• Unclip the back cover (2) of the electronic box from its fixings (3) and lift it up.

• Guide the connecting cables of each of the components to be connected through the cable routes (4) located on the bottom of the appliance to the left.

1

4

2

Fig. 4.9 Condensate discharge

Danger!

Risk of fatal electric shock from touching live connections. Always switch off the power supply to the boiler first. Only once this is done may you carry out the installation.

There is continuous operating voltage at the power supply terminals L and N even when the main switch is switched off.

3

Fig. 4.10 Opening the rear of the switch box

2

1

14 Installation and maintenance manual ecoMAX 646

Installation 4

7 8

RT 24V

9 L N

230V

3 4

RT 230V

5

3

4.8.3 Connecting accessories and external system components

The Vaillant ProE system facilitates a quick and troublefree connection of accessories and external system components to the appliance electronics. Proceed with the wiring up as follows:

• Take off the front casing of the appliance and lift the electronics box forward.

• Unclip the back cover of the switch box (1) from its fixings (2) and lift it up.

• Guide the connecting cables of each of the components to be connected through the PG screw connections (4) located on the bottom of the appliance to the left.

• Then insert the connecting cables (5) into the electronics box and cut them to length.

• Strip the connecting cable by about 2-3 cm and bare the wires.

• Connect the connecting cables to the corresponding

ProE plugs or slots of the electronics.

Fig. 4.11 Example of cable insertion

• Then insert the connecting cables (5) into the electronics box and cut them to length.

• Strip the connecting cable by about 2-3 cm and bare the wires.

• Connect the connecting cables to the corresponding

ProE plugs or slots of the electronics.

Caution!

Do not connect the mains voltage supply to terminals 7, 8, or 9. The electronics could be destroyed by this!

Please note that the jumper on the ProE plug should be removed when connecting a maximum thermostat (feed thermostat) for floor heating.

• Close the rear cover of the electronics box and press it in until you hear it click into place.

• Lift the electronics box up and press it by the two clips on its left and right against the lateral appliance casings until you hear the clips click into place.

• Attach the front casing.

• If no room/clock thermostat is in place, provide a jumper between terminals 3 and 4 if not already present. Remove the jumper if a room/clock thermostat is connected to terminals 3 and 4.

• When connecting a weather-controlled temperature controller or room temperature controller (continuous controlling - terminals 7,8,9), the jumper between terminals 3 and 4 must remain in place.

• Close the rear cover of the electronics box and press it in until you hear it click into place.

• Lift up the electronics box and press it by the two clips on its left and right against the lateral appliance casings until you hear the clips click into place.

• Attach the front casing.

• In order to attain pump mode I (continuous pump) for

VRC-MF-TEC or the multicircuit controller, increase the pump run-out time to 15-20 minutes (diagnosis point d.1, see chapter 6.2).

Installation and maintenance manual ecoMAX 646 15

4 Installation

Fig. 4.12 Connection diagram ecoMAX 646

16

Diagnostics

PWM pump signal

Connection accessory box 306 248 and multi-function module 306 253 (1 of 5) or multi-function module 306247 (2 of 6) edge connector is included with the weather compensator sensor for circulation pump/ sensor for underfloor-heating system outside temperature sensor supply or return sensor

DCF-77 signal hydraulic decoupler sensor

Maximum thermostat for fl oor heating, 20 V

(remove bridge on connection)

Room thermostat 24 V: connections 7, 8 and 9

Caution: Do not connect supply voltage!

Risk of electronics being destroyed!

Mains supply: 230 V/50 Hz

Room thermostat 230 V/50 Hz

(remove bridge on connection)

Connection 230 V/50 Hz fan

Connection heating pump

Connection storage charging pump

Use of other functions via module 1 of 5 (306 253) or module 2 of 6 (306 247)

(diagnosis point d.16 except function)

Installation and maintenance manual ecoMAX 646

Start-up 5

X 2/4 red

X 2/10 white

X 2/15 blue

Forward flow NTC

Return flow NTC Ignition electrode

Water pressure switch Gas fitting

X 2/8 black

X 2/20 black

X 2/9 red (22 VDC)

X 2/24 blue (earth)

X 2/12 blue (earth)

X 2/7 grey (PWM)

X 2/3 black (hall signal)

X 2/17 red (22 VDC)

Plug-in coupling

Fan

230 V connection

Plug-in coupling

Pump

X 2/23 black (earth)

X 2/6 brown (signal)

X 2/24 black (earth)

X 2/2 orange (signal)

BW contact C1/C2

Cylinder NTC connection or upper solar storage tank sensor

(plug colour: white)

24V I

230V

Electronics box

Fig. 4.13 Wiring diagram ecoMAX 646

X 4

1

X 10

1

1

X 7

1

X 6 13 X 2

Coding resistance

Installation and maintenance manual ecoMAX 646

Contact-

Therm

7 8

RT 24V

9 L N

230V

3 4

RT 230V

5 L N

Pump

17

5 Start-up

5 Start-up

Particularly observe the following when putting the boiler into service:

• Open the cover of the exhaust fan before filling the heating circuit/storage charging circuit.

• Start the bleeding program for the heating circuit/storage charging circuit.

Caution!

Softening the heating water when water hardness is 20° dH or more is absolutely necessary.

To do this, you can use the water softening cartridge, item no. 30 13 63. Please observe the instructions supplied with it.

Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449: Part 1 (for small bore and micro bore central heating systems). Pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated 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. Draining taps should be at least 1/2 in.

BSP nominal size and be in accordance with BS 2879.

The boiler is suitable for use with minibore or microbore systems. Copper tubing to BS 2871: Part 1 should be used for water carrying pipework. All capillary joints in all

DHW pipework must be made with lead free solder. Particularly where a new boiler is to be fitted to an existing system, it is good practice that the system is thoroughly cleansed.

Important!

To prevent the formation of deposits and prevent serious damage to the appliance and system, cleansers must be used carefully and must be completely removed by thoroughly flushing the system. Cleansers should only be left in systems for a maximum of 24 hours.

5.1.2 Heating side filling and bleeding

For the heating system to function perfectly, a water pressure/filling pressure of between 1.0 and 2.0 bar is necessary. If the heating system stretches out over several storeys, higher values for the water level of the system at the pressure gauge can be necessary (maximum pressure for safety valve: 3 bar).

Caution!

Only fill the system via the appliance-internal

KFE cock. Otherwise bleeding problems may arise.

• Rinse the heating system thoroughly before filling it proper.

• Open the cap of the appliance-internal exhaust fan (1)

(fig. 5.1).

• Open all thermostat valves in the system.

• Connect the system‘s filling and draining cock to the appliance return via a hose.

• Slowly unscrew the filling cock and tap valve und fill with water until the required system pressure at the pressure gauge (2) has been reached (at least 1 bar).

• Close the tap valve.

• Bleed all radiators.

• Then check the filling pressure of the system again

(and repeat filling procedure if necessary).

• Start the “P.O” bleeding program (see chapter 8.1.5).

This cleansing must take place prior to the fitting of the new boiler and be in accordance with BS 7593. For advice on the application of system cleansers contact:

Sentinel, Betz Dearborn Ltd. Widnes,

Cheshire, WA8 8UD. Tel: 0151 495 1861 — or

Fernox, Alpha Fry Technologies, Tandem House,

Marlow Way, Croydon, CR0 4XS. Tel: 0870 6015000

5.1.1 Treating the heating water

Caution!

Do not enrich the heating water with frost or corrosion protection fluid.

Note!

The bleeding program runs for approx. 6.5 minutes.

Caution!

For the bleeding of the system, the minimum pressure must be 0.8 bar.

If pressure is too low, the gas valve jams when the burner starts up.

• Open the filling cock and tap valve again if necessary.

If you enrich the heating water with frost or corrosion protection fluid, changes can be caused in the seals and noises may arise during the heating operation. Vaillant assumes no liability for this (or for any subsequent resulting damage).

Please inform the user as to how to go about frost protection.

Caution!

If there is still too much air in the system after the bleeding program has finished, the program must be started anew.

18 Installation and maintenance manual ecoMAX 646

Start-up 5

Caution!

After the filling process has finished

The system pressure should be at least 0.2 bar above the back pressure from the expansion tank (ET) Psystem PET + 0.2 bar

• Close the filling unit and remove the filling hose.

• Inspect all connections for leakage.

1

Danger!

If the device is operated with an empty condensate siphon, there is the danger of poisoning through escaping flue gases.

Therefore, it is mandatory to fill the siphon as described below before start-up.

• Screw off the bottom (1) of the condensate siphon

(fig. 5.2).

• Fill the bottom about 3/4 full with water.

• Screw the bottom back on the condensate siphon.

5.2 Checking the gas setting

Caution!

Before starting up the appliance, compare the data on the set gas type on the data badge with the gas on site. Checking the amount of gas is not necessary. The setting takes place with regard to the percentage of CO

2

in the flue gas.

The appliances are set ex works to the values listed in table 5.1. An on site adjustment can be necessary in some supply areas.

The appliance design corresponds to the gas family available on site:

• Check the CO

2

percentage as described in chapter 5.2.3.

Fig. 5.1 Bleeding the appliance

5.1.3 Hot water side filling and bleeding

To fill the storage charging circuit, proceed as described in point 5.1.2.

• Restart the bleeding program (P.0).

The appliance design doesn‘t correspond to the gas family available on site:

• Carry out a gas conversion.

Note!

Please ask Vaillant customer service about the gas conversion of the appliance.

• Check the CO

2

percentage as described in chapter 5.2.3.

1

Appliance type

Appliance design ecoMAX 646

Natural gas H

Designation on the appliance badge II

2H3P

Factory setting to Wobbe index Ws (in kWh/m 3 ), corresponding to 0 °C / 1013 mbar

15.0

Factory setting of the hot water output (in kW) 45

35 Factory setting of the heating output (in kW)

Table 5.1 Overview of factory gas settings

Fig. 5.2 Filling the siphon

Installation and maintenance manual ecoMAX 646 19

5 Start-up

5.2.2 Checking the connection pressure (gas flow ting. pressure)

To check the connection pressure, proceed as follows

(cf. fig. 5.3):

• Take the front casing off the appliance.

• Close the appliance‘s gas stop cock.

• Unscrew the seal plug (1) marked “in” on the gas fit-

• Connect a digital pressure gauge or U-pipe pressure gauge (2).

• Open the appliance‘s gas stop cock.

• Start up the appliance.

• Measure the connection pressure against the atmospheric pressure.

1

• Put the appliance out of operation.

• Close the appliance‘s gas stop cock.

• Remove the pressure gauge and screw the seal plug (1, fig. 5.3) back on.

• Check that the seal plug is fit tight.

• Put the front casing back on.

Do not start up the appliance!

CO

2

content and adjusting it if needed (air ratio setting)

• Take off the appliance casing.

• Activate test program P.1:

• Press “Mains ON” or press the reset key.

• Now press the “+” key until P.0 appears in the display

(approx. 5 s).

• Then press the “+” key once. The display shows P.1.

• The test program P.1 is started by pressing the “i” key.

The appliance then runs for 15 minutes at full power.

• Wait at least 5 minutes until the appliance reaches operating temperature.

• Measure the CO2 content at the flue gas test nozzle

(3) (fig. 5.4). Compare the value measured with the corresponding value in table 5.2.

• If a setting of the flue gas value is necessary, unscrew the screw (4) and move the air intake pipe (5) forward by 90°.

2

Fig. 5.3 Measuring the connection pressure

Caution!

Natural gas:

If the connection pressure lies outside the range from 17 to 25 mbar, you mustn‘t make a setting or start up the appliance.

Liquid gas:

If the connection pressure lies outside the range from 47.5 to 57.5 mbar, you mustn‘t make a setting or start up the appliance.

If the connection pressure lies within the permissible range, proceed as follows:

• Put the appliance out of operation.

• Close the appliance‘s gas stop cock.

• Remove the pressure gauge and screw the seal plug (1) back on.

• Open the appliance‘s gas stop cock.

• Check that the seal plug is fit tight.

• Put the front casing back on and start the appliance up again.

If the connection pressure does not lie within the permissible range and you can‘t correct the error, notify the gas supplier. Proceed as follows:

Do not remove the air intake pipe!

• If necessary, set the corresponding flue gas value

(table 5.2) by turning the screw (6).

Note!

Natural gas:

Adjust only in 1/8 of a full revolution increments and wait about a minute after every adjustment until the value becomes stable.

Liquid gas:

Adjust only in very small increments (approx.

1/16 of a full revolution) and wait about a minute after every adjustment until the value becomes stable.

20 Installation and maintenance manual ecoMAX 646

3

4

5

6

Start-up 5

Settings

CO

2

after 5 minutes full-load operation

Natural gas H tolerance

8.8 +/— 1.0

set for Wobbe index Wo 15

Table 5.2 Factory gas setting

Unit

Vol. % kWh/m 3

After installing the appliance and setting the gas, perform a functional test before commissioning the appliance and handing it over to the user.

• Commission the appliance in accordance with the instructions in the relevant operating manual.

• Check the appliance for gas and water leaks.

• Check the flue system for leaks and that it is fixed properly.

• Check over-ignition and that the flame on the burner is burning evenly.

• Check that the heating and hot water generation are working properly.

• Pass the appliance on to the user.

I

0

Fig. 5.4 Carrying out a CO

2

measurement, carrying out an air ratio setting (gas setting)

Fig. 5.5 Functional test

- Turn to the left (anti-clockwise): higher CO

2

content

- Turn to the right (clockwise): lower CO

2

content

• After the setting procedure, put the air intake pipe back up.

• Check the CO

2

content again.

• If necessary, repeat setting.

• Quit the P.1 test program by pressing the “+” and “i” keys simultaneously. The measuring operation is also quit when no key has been pressed for 15 minutes.

• Screw the screw (4) in.

• Put on the appliance casing.

The Vaillant ecoMAX 646 possesses status codes that display the operating status of the appliance in the DIA system display. A functional test of the hot water operation and heating operation can be carried out using these status codes by pressing the “i” key.

Installation and maintenance manual ecoMAX 646 21

5 Start-up

Recharging

• Switch on the appliance and the connected hot water cylinder.

• Make sure that the cylinder thermostat is requesting heat.

• Press the “i” key.

When the cylinder is correctly charged, the status code

“S.24” appears in the display.

Caution!

The appliance may only be used

• for initial operation

• for testing

• for continuous operation with the chamber cover closed and with the flue system fully mounted and sealed.

5.4.1 Instructing the user about the heating system

• Instruct the user about the methods used for combustion air supply and flue conducting. Be especially sure to point out that these must not be altered.

• Instruct the user on how to check the required water level/filling pressure of the system as well as on methods of refilling and bleeding the heating system when needed.

• Point out to the user the correct (economical) settings for temperatures, controllers and thermostat valves.

• Instruct the user on the need for yearly inspection and maintenance of the system. Recommend making a maintenance contract.

Fig. 5.6 Display during recharging

Heating

• Switch on the appliance.

• Make sure that heat is being requested.

• Press the “i” key.

When the heating is running correctly, the status code

“S.4” appears in the display.

Vaillant provide a full parts and labour warranty for this appliance. The appliance must be installed by a suitably competent person in accordance with the Gas Safety (Installation and Use) Regulations 1998, and the manufacturer’s instructions. In the UK ‘CORGI’ registered in-stallers undertake the work in compliance with safe and satisfactory standards.

All unvented domestic hot water cylinders must be installed by a competent person to the prevailing building regulations at the time of installation. (G3) Terms and conditions apply to the warranty, details of which can be found on the warranty registration card included with this appliance.

Failure to install and commission this appliance in compliance with the manufacturer’s instructions may invalidate the warranty (this does not affect the customer’s statutory rights).

Fig. 5.7 Display during heating mode

The user of the heating system must be instructed about its functions and how to operate it. The following measures in particular are to be carried out here:

• Hand over any instructions intended for the user as well as the appliance documentation.

• Inform the user that the instruction manuals should be kept near the appliance.

Note!

When you have finished the installation, attach the sticker supplied (835593) to the appliance in the user’s language.

22 Installation and maintenance manual ecoMAX 646

Adapting the appliance to the heating system 6

6 Adapting the appliance to the heating system

The appliances are set in the factory to the thermal load shown in table 6.1. If you want to set a different load, proceed as follows:

• Press the “i” and “+” keys simultaneously.

• Then hold down the “i” key for approx. 5 s until the display no longer flashes.

The value is now saved. The standard display appears again in the display (current heating supply temperature, e.g. 45 °C).

• Continue to hold the “+” key down until “d.0” appears in the display.

The display runs from “d.0” through to “d.99” and starts again at “d.0”.

• Quit the setting mode by pressing the “i” and “+” keys simultaneously.

The setting mode is also quit if you do not touch a key for 4 minutes.

• Press the “i” key.

The “=” symbol appears in the display. Then the set partial load is displayed in kW.

Appliance type ecoMAX 646

Setting range in kW

12 - 45

Factory setting in kW

35

• By pressing the “+” or “-” keys you can now increase or decrease the value in 1 kW increments.

The displayed value flashes during the setting procedure. The possible setting ranges are to be found in table 6.1.

Table 6.1 Setting range for partial-load heating

Installation and maintenance manual ecoMAX 646 23

6 Adapting the appliance to the heating system

6.2 Setting the pump run-out time

The pump run-out time for the heating mode is set to

5 minutes in the factory. It can be varied within a range from 1 minute to 60 minutes or be in “continuous” mode.

In order to change the pump run-out time, proceed as follows:

• Pull the front panel of the appliance outwards.

• Switch the appliance main switch to the “l” position.

• Press the “i” and “+” keys simultaneously and hold down the “+” key until “d.1” appears in the display.

• Press the “i” key.

The current pump run-out time in minutes appears in the display.

• By pressing the “+” or “-” keys you can now increase or decrease the value. the heating mode after a control shutdown can be viewed under diagnosis point d.67.

In order to change the lockout time, proceed as follows:

• Pull the front panel of the appliance outwards.

• Switch the appliance main switch to the “l” position.

• Press the “i” and “+” keys simultaneously and hold down the “+” key until the diagnosis code “d.2” appears in the display.

• Press the “i” key.

The symbol “=” now appears in the display and then the current burner lockout time in minutes.

• By pressing the “+” or “-” keys you can now increase or decrease the value in 1 minute increments.

To set the pump mode “continuous”, do not enter a number, rather select the symbol “--” with the “+” or “-” key.

• Hold down the “i” key for about 5 seconds until the display stops flashing.

The displayed value flashes during the setting procedure.

• Hold down the “i” key for about 5 seconds until the display stops flashing.

The value is now saved.

• Quit the setting mode by pressing the “i” and “+” keys simultaneously.

The value is now saved.

• Quit the setting mode by pressing the “i” and “+” keys simultaneously.

The standard display appears again in the display (current heating supply temperature, e.g. 45 °C).

The setting mode is also quit if you do not touch a key for 4 minutes.

The standard display appears again in the display (current heating supply temperature, e.g. 45 °C).

The setting mode is also quit if you do not touch a key for 4 minutes.

6.3 Setting the pump output

6.3.1 Setting the pump output with direct feeding

The operating mode of the pump is factory set to “auto”

(diagnosis point d.14 = 0).

6.3.2 Setting the pump output with hydraulic decoupling

Proceed as described in chapter 4.2.2.

6.4 Setting the burner lockout time

In order to avoid frequent switching on and off of the burner (energy loss), an electronic block on it switching back on is activated for a certain time after every time it has been switched off. The burner lockout time can be adjusted to fit the characteristics of the heating system.

The burner lockout time is only activated for the heating mode. Hot water operation during a burner lockout time in progress does not affect the timer.

The maximum burner lockout time can be set under diagnosis point d.2 between 2 and 60 minutes (factory setting: 20-minutes). The lockout time effective in each case is then automatically calculated from the current set supply temperature and the set maximum burner lockout time.

The timer can be reset or deleted by pressing the appliance main switch. The burner lockout time remaining in

24 Installation and maintenance manual ecoMAX 646

Inspection and maintenance 7

No.

Step

7.1 Inspection and maintenance intervals

Appropriate, regular inspections and maintenance and the exclusive use of original spare parts are the decisive factors in determining whether your Vaillant ecoMAX 646 will run problem-free and have a long service life.

Danger!

Inspections/Maintenance work not carried out can result in material damage and injury to persons.

1 Disconnect the appliance from the mains supply, close the gas supply and maintenance cocks, depressurize the appliance on the water side

(observe the pressure gauge)

2 Dismantle compact thermal module

For this reason, we recommend the signing of an inspection and/or maintenance contract. The inspection is intended to determine the actual condition of an appliance and compare it with the specified condition. This is done by measuring, checking, observing. Maintenance is required in order to eliminate any deviations of the actual condition from the specified condition. This is usually done by cleaning, setting and, if necessary, replacing individual components subject to wear. With regard to the

Vaillant ecoMAX 646, this means it is usually sufficient to conduct an inspection once a year. Inspections can be performed quickly and economically without dismounting any components thanks to the data query in the

DIA system, easy optical inspection and an air ratio measurement. Experience indicates that under normal circumstances it is not necessary to clean the burner and heat exchangers yearly. These maintenance intervals and their extent are determined by a specialist, depending on the ascertained condition of the appliance during the inspection. All inspection and maintenance work should be performed in the order specified in table 7.1.

7.2 Inspection and maintenance instructions

Only genuine Vaillant spare parts may be used for inspections, maintenance and repair work to ensure the perfect long-term working order of all functions of your

Vaillant appliance and to prevent the permitted series condition from being changed. Any spare parts which might be required are listed in the relevant current spare parts catalogues. Information can be obtained from

Vaillant Customer Service Centres.

Note!

If inspection and maintenance work is necessary with the mains switch on, this is indicated in the description of the maintenance work.

Danger!

The supply terminals of the appliance are under voltage even if the mains switch is off.

3 Clean the integral condensation heat exchanger

4 Check whether the burner is dirty

5 Install compact thermal module.

Caution: replace the seals!

6 Check whether the electrical plug connections and other connections are fitted tightly, and make adjustments if necessary

7 Check the primary pressure at the expansion tank, and adjust it if necessary

8 Clean the air barrel

9 Open the maintenance cocks and fill the appliance/system up to about

1.0 - 2.0 bar (depending on the static height of the system); start the bleeding program

10 Check the overall condition of the appliance, remove general dirt from the appliance and the vacuum chamber

11 Check the condensate siphon in the appliance, and clean and fill it if necessary

12 Clean the condensate paths in the appliance

13 Open the gas supply and switch on the appliance

14 Carry out a test operation on the appliance and heating system including water heating, and bleed if necessary

15 Test ignition and burner performance

16 Check whether the appliance is leaking flue gas, water or condensate

17 Check the flue system for leaks and that it is fixed properly, and make adjustments if necessary

18 Check appliance gas setting, and reset and record if necessary

19 Service the hot water cylinder

(if present): rinse the inner tank, check the magnesium protection anode for abrasion, replace after a max. of

5 years

20 Keep a log of the inspection/maintenance carried out

Table 7.1 Maintenance steps

To be carried out during:

Inspection

Maintenance

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Installation and maintenance manual ecoMAX 646 25

7 Inspection and maintenance

Always perform the following steps prior to maintenance work:

• Switch off the mains switch.

• Disconnect the appliance from the mains supply by deenergising the appliance by means of a separator with a contact opening of at least 3-mm (e.-g. fuses or circuit breakers).

• Close the gas shut-off valve.

• Close the heating supply and return and the cold water inlet valve.

• Take the front casing off the appliance.

Caution!

Under no circumstances may the compact thermal module be suspended from the flexible corrugated gas pipe.

• Pull the entire compact thermal module (4) off the integral condensation heat exchanger (1).

1

2

2

2

3

4

5

Always perform the following steps after performing any maintenance work:

• Open the heating supply and return and the cold water inlet valve.

• Refill the appliance, if necessary, on the hot water side up to a pressure of between 1.0 and 2.0 bar and bleed the heating system (see chapter 5.1).

• Open the gas shut-off cock.

• Reconnect the device to the mains supply and switch on the mains switch.

• Check the appliance for gas and water leaks.

• If necessary, refill and re-bleed the heating system.

• Put on the appliance‘s front casing.

6

7

7.2.1 Servicing the compact thermal module

8

Dismantling the compact thermal module

The compact thermal module consists of a speed-controlled fan, combined gas/air fittings, the gas supply

(mixer tube) for the fan of the pre-mixing burner and the pre-mixing burner itself. These four components make up the complete assembly that is the compact thermal module. Proceed as follows to dismount it: (see fig. 7.1)

Danger!

There is danger of being injured or scalded at the compact thermal module and at all components carrying water. Only work on the components once they have cooled down.

The mixer tube (7) between gas control unit and burner may not be opened. It can only be guaranteed that this component is gas-tight after it has been inspected at the factory.

• Cut off the gas supply to the appliance.

• Lower the switch cabinet.

• Undo the fastening screw of the air intake pipe (5) and lift the air intake pipe forward (3); remove the air intake pipe from the intake socket.

• Pull the two plugs of the ignition und grounding lines off the ignition electrode (6).

• Undo the gas supply line (10) on the underside of the gas fitting (fig. 7.2).

• Pull the cables (9) off the fan motor and the cable (8) off the gas fitting.

• Undo the five nuts (2).

9

Fig. 7.1 Dismounting/Mounting the compact thermal module

Mounting the compact thermal module

Danger!

The two silicon seals (1) on the compact thermal module (fig. 7.3) (SP no. 98-1046) must be replaced every time maintenance is carried out.

The burner flange insulation (2) on the compact thermal module (fig. 7.3) (SP no. 21-0734) must not show any signs of damage; if it does, it must also be replaced.

• Put the compact thermal module (4) onto the integral condensation heat exchanger (1) (fig. 7.1).

• Tighten the five nuts (2) evenly and crosswise.

• Put the air intake pipe (3) onto the intake socket and tighten the screw (5).

• Connect the gas supply line (10) with a new seal (SP no. 98-0012) to the gas fitting (fig. 7.3). Use the spanner flat at the flexible gas line to hold the gas fitting.

• Connect the two plugs of the ignition und grounding lines to the ignition electrode (6).

• Connect the cables (9) to the fan motor and the cable

(8) to the gas fitting.

• Open the gas supply to the appliance.

26 Installation and maintenance manual ecoMAX 646

Inspection and maintenance 7

Danger!

Check the gas connection (10) for leaks with leak spray (fig. 7.2).

2

1

3

10

Fig. 7.2 Gas connection

Fig. 7.4 Cleaning the integral condensation heat exchanger

1

1

2

The burner is maintenance-free and needs no cleaning.

The surface should be checked for damage, and the burner replaced if necessary.

• After checking/replacing the burner, install the compact thermo module as described in 7.2.1.

Fig. 7.3 Checking seals and burner flange insulation

7.2.2 Cleaning the integral condensation heat exchanger

7.2.4 Cleaning the condensate siphon

• Screw off the bottom (3) of the condensate siphon

(see fig. 7.5).

• Clean the bottom of the siphon by rinsing it out with water.

• Then fill the bottom about 3/4 full with water.

• Screw the bottom back on the condensate siphon.

Caution!

Protect the lowered electronics box against spray water.

• Dismantle the compact thermo module as described under 7.2.1.

• Clean the heating spiral (1) of the integral condensation heat exchanger (2) using regular vinegar essence

(fig. 7.3). Rinse with water.

• The condensate receptacle can also be cleaned via the opening (3).

• After an action time of approx. 20 minutes, rinse off the dust particles that have come loose with a powerful water jet.

Danger!

If the appliance is operated with an empty condensate siphon, there is the danger of poisoning through escaping flue gases. Therefore, refill the siphon after each cleaning.

7.2.5 Cleaning the condensate paths

To clean the condensate paths, the complete condensate siphon can be taken off by pulling out the clips (1). Then the two condensate discharges on the heat exchanger are accessible.

Dirt accretions in the front condensate discharge area can be removed via the lower cleaning hole (2).

Installation and maintenance manual ecoMAX 646 27

7 Inspection and maintenance

1

2

3

7.5.3 Cleaning the air barrel

Danger!

There is danger of being injured or scalded at all components carrying water. Only carry out work on these components once they have cooled down.

• Dismount the air barrel as shown in fig. 7.6 and rinse it with hot water.

• Remount the air barrel and make sure to use new seals (SP no. 981272).

Fig. 7.5 Cleaning the condensate paths

7.3 Checking the gas setting

Perform a gas setting check as described in chapter 5.2.

7.4 Filling and bleeding the system

Proceed as described in points 5.1.2 and 5.1.3.

7.5 Draining the appliance and the system

1

3

2

• Close the appliance‘s maintenance cocks.

• Open the drain valve in the return.

• Open the air-release valve on the cylinder supply in order for the appliance to be completely drained.

Fig. 7.6 Cleaning the air barrel

7.5.2 Draining the entire system

• Attach a hose to the system‘s drain point.

• Bring the open end of the hose to a suitable discharge point.

• Make sure that the boiler‘s maintenance cocks are open.

• Open the draining cock.

• Open the air-release valves on the radiators. Start with the radiator that is highest up and then continue downward.

• When the water has run out, close the radiators‘ exhausts and the draining cock again.

After the maintenance work has been completed, carry out a functional test (see chapter 5.3).

28 Installation and maintenance manual ecoMAX 646

Troubleshooting 8

8 Troubleshooting

Code Meaning

8.1 Diagnostics

The status codes, which you get via the DIA system‘s display, give you information about the appliance‘s current operating status.

If several operating statuses exist simultaneously, the most important status code is always shown.

The display of the status codes can be viewed as follows:

• Press the “i” key beneath the display.

The status code appears in the display, e.g. S.04 for

“Burner mode - heating”.

The display of the status codes can be ended as follows:

• Press the “i” key beneath the display or

• do not press any key for about 4 minutes. The current heating supply temperature appears in the display again.

Fig. 8.1 Display of status codes

S. 4

S. 5

S. 6

S. 7

S. 8

S. 0

S. 1

S. 2

S. 3

No heat required

Heating pump supply

Heating fan start

Heating ignition

Heating burner on

Heating fan run-out

Heating pump run-out

Remaining lockout time heating

S. 10

S. 11

S. 13

S. 14

S. 15

Hot water request

Hot water fan start

Hot water ignition

Hot water burner on

S. 16

S. 17

Hot water fan run-out

Hot water pump run-out

S. 20 Hot water cycle mode

S. 21 Hot water fan start

S. 23 Hot water ignition

S. 24 Hot water burner on

S.25

S. 26 Hot water fan run-out

S. 27 Hot water pump run-out

S. 28 Hot water lockout time

S. 30 No heat requirement controller (2-point controller)

S. 31 Summer mode

S. 32 Waiting time fan

S. 34 Heating frost protection

S. 36 No heat requirement controller (continuous controller)

S. 37 Waiting time fan

S. 39 Feed thermostat contact open

S. 42 Flue gas flap no feedback

Waiting time lack of water (burner on T VL-RL was > 40 K;

S. 53 burner off T VL-RL was > 45 K

S. 54 Waiting time lack of water

Table 8.1 Status codes

Installation and maintenance manual ecoMAX 646 29

8 Troubleshooting

In the diagnosis mode, you can change certain parameters or display more information (see following table).

• Press the “i” and “+” keys under the display simultaneously.

The display shows “d.0”.

• Scroll to the desired diagnosis number with the “+” or

“-” buttons.

• Press the “i” key.

The display shows the relevant diagnosis information.

• If necessary, use the “+” or “–” keys to change the value (display flashes).

• Save the new value by holding down the “i” key for approx. 5 seconds until the display no longer flashes.

You can end the diagnosis mode as follows:

• Press the “i” and “+” keys simultaneously

or

• do not press any key for about 4 minutes. The current heating supply temperature appears in the display again.

Code Meaning Display value/adjustable value d. 9 d. 10 d. 11 d. 12 d. 13 d. 14 d. 15 d. 16 d. 0 d. 1 d. 2 d. 3 d. 4 d. 5 d. 6 d. 7 d. 8 d. 17 d. 22 d. 23 d. 24 d. 25 d. 33 Fan target value d. 34 Fan actual value d. 40 Supply temperature actual value d. 41 Return temperature actual value d. 42 Solar cylinder temperature actual value d. 44 d. 46 d. 47 d. 50 d. 51 d. 52

Partial-load heating

Pump run-out heating

Max. lockout time heating

With use of solar energy: collector temperature actual value

Cylinder temperature actual value

1 - 60 minutes (factory setting: 20 minutes) actual value in °C actual value in °C; with use of solar energy: actual value of the upper cylinder temperature sensor target value in °C Supply temperature target value

Cylinder temperature target value target value in °C

Cylinder temperature target value for VC appliances target value in °C

Terminal 3-4 adjustable values in kW

1 - 60 minutes or “continuous” (factory setting: 5 minutes)

Terminal 7-8-9 target value

Internal pump

0 = room thermostat open (no heating operation)

1 = room thermostat closed (heating operation) in °C (continuous controller)

1 = on; 0 = off

External pump

Storage charging pump

Circulation pump

Pump speed target value

Pump speed actual value

Pump 2

Control type:

Hot water request:

Operating mode

Air pressure sensor actual value

Hot water enabling via warm restart clock

Ionisation current actual value

External temperature correction value

External temperature actual value

Minimum speed offset

Maximum speed offset

Minimum air pressure offset

1 = on; 0 = off

1 = on; 0 = off

1 = on; 0 = off target value internal pump in %. Possible settings: factory setting auto, 53, 60, 70, 85, 100 % actual value internal pump in %

1 = circulation pump; 2 = external pump;

3 = storage charging pump; 4 = solar pump

0 = supply temperature control; 1 = return temperature control

1 = on; 0 = off summer/winter mode: 1 = on; 0 = off actual value in Pa

1 = yes; 0 = no target value in upm/10 actual value in upm/10 actual value in °C actual value in °C actual value in °C; with use of solar energy: actual value of the lower cylinder temperature sensor actual value/100 in A correction value in K actual value in °C in upm/10 in upm/10 in Pa d. 53 Maximum air pressure offset d. 60 Number of temperature limiting shutdowns d. 61 Safety thermostat shutdown d. 67 Remaining lockout time heating d. 68 No first start number d. 69 No second start number d. 71 Max. supply temperature heating d. 72 d. 73

Pump run-out hot water

Activation difference for solar pump d. 75 Max. charging time hot water cylinder d. 76 Appliance variants d. 77 Partial-load hot water cylinder d. 78 Max. supply temperature hot water when using solar energy: scalding protection temperature d. 80 Operating hours heating d. 81 Operating hours hot water generation d. 82 Burner starts - heating d. 83 Burner starts - hot water mode in Pa number number in minutes number of failed ignitions in the first attempt number of failed ignitions in the second attempt max. target value of the heating supply temperature: adjustable value 40 - 85 °C (factory setting: 75 °C) pump run-out time in seconds after the charging of a hot water cylinder; factory setting: 80 s recommended setting when using solar energy: +7 °C .

maximum charging time for a cylinder without its own controller

1 - 17 limitation of the storage charging output in kW limitation of the storage charging temperature in °C when using solar energy: temperature at which the solar pump is switched off.

in h in h number of hystereses in the heating mode x 100 number of hystereses in the hot water mode x 100

Table 8.2 Diagnosis codes

30 Installation and maintenance manual ecoMAX 646

Troubleshooting 8

The error codes displace all other displays when errors occur. An error that arises is shown in the display as

“F...”, e.g. “F.10” (see table on the next page). If several errors occur simultaneously, the corresponding error codes are displayed alternately for approx. 2 seconds each.

The last 10 errors are saved in the appliance error memory.

• Press the “i” and “–” keys simultaneously.

• You can scroll back through the error memory by pressing the “+” key.

You can exit the error memory display as follows:

• Press the “i” key beneath the display

or

• do not press any key for about 4 minutes.

The current heating supply temperature appears in the display again.

Code

F. 0

Meaning Cause

F. 1

F. 10

F. 11

F. 13

F. 20

F. 22

F. 23

F. 24

F. 25

F. 27

F. 28

F. 29

F. 32

F. 37

F. 42

F. 43

F. 60

F. 61

F. 62

F. 63

F. 64

Interruption supply sensor

Interruption return sensor

Short circuit supply sensor

NTC-connector not plugged in or loose, NTC defective, multi-plug on the electronics not plugged in properly

NTC-connector not plugged in or loose, NTC defective, multi-plug on the electronics not plugged in properly

NTC defective, short-circuit to ground/short circuit in the cable harness

Short circuit return sensor

Short circuit cylinder sensor

NTC defective, short-circuit to ground/short circuit in the cable harness

NTC defective, short-circuit to ground/short circuit in the cable harness, inside of the plug damp

Water safety thermostat

Dry burning (no water in the appliance) supply or return NTC defective (intermittent contact), supply temperature too high, earth connection of the cable harness to the appliance not correct, failed discharge to the electrode via ignition cable, ignition plug or ignition electrode no water in the primary heat exchanger during commissioning,

RESET activated while the appliance is hot, water pressure switch has been triggered

No water in the appliance, water shortage, temperature spread too large, system not bled correcly pump jammed, reduced output of the pump, air in the appliance, system pressure too low, supply and return NTC mixed up, appliance not filled via appliance-internal KFE cock

(fill only via return!), start bleeding program

Water shortage

Temperature rise too quick

System not bled correcly

Flue gas safety thermostat flue gas temperature too high

System pressure too low

Flame simulation (flame signal despite gas valve being switched off)

No ignition when starting

No reignition pump jammed, reduced output of the pump, air in the appliance, system pressure too low, supply and return NTC mixed up, start bleeding program, appliance not filled via return plug connector option flue gas safety thermostat interrupted water pressure switch has been triggered gas solenoid valve leaking, electronics (flame detector defective, dampness on the electronics) no or too little gas, ignition system (ignition transformer, ignition cable, ignition plug) defective, interruption of the ionisation current (cable, electrode), false gas setting, faulty earthing of the appliance, electronics defective gas supply temporarily interrupted, flue gas recirculation, faulty earthing of the appliance

Speed deviation fan

(too large when starting)

Speed deviation fan

(too large or small during operation) fan jammed, plug to fan not plugged in correctly, error in the cable harness, electronics defective pressure sensor not fitted or defective (however, not short circuit or interruption)

Short circuit coding resistance

Interruption coding resistance

Gas valve control “+” faulty

Gas valve control “-” faulty

Gas valve shut-off faulty

EEPROM faulty

Electronics/sensor fault no valid value for appliance variant no valid value for appliance variant short circuit/short-circuit to ground in the cable harness to the gas valves, gas fitting defective (short-circuit to ground of the coils), electronics defective short circuit/short-circuit to ground in the cable harness to the gas valves, gas fitting defective (short-circuit to ground of the coils), electronics defective gas fitting leaking, electronics defective electronics defective short circuit supply or return NTC, electronics defective

F. 65

F. 67

Electronics temperature too high electronics too hot due to external influence, electronics defective

Electronics error flame (implausible flame signal) electronics defective fan (hall sensor) defective, error in the cable harness, electronics defective Emergency run “speed”

Special message: no speed signal from the fan

Table 8.3 Error codes

Installation and maintenance manual ecoMAX 646 31

8 Troubleshooting

9 Vaillant service

10 Recycling and disposal

Special functions can be triggered in the appliances by activating various test programs. These programs are given in detail in the following table 8.5.

• The test programs P.0 to P.6 are started when “Power

ON” is turned on and the “+” key is pressed for 5 s.

To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement.

Please contact Vaillant Service Solutions (0870 6060 777) for further details.

The display shows “P.1”.

• Press the “+” key to start counting the test number upwards.

• By pressing the “i” key the appliance is now put unto operation and the test program started.

• Press “i” and “+” simultaneously to end the test programs. You can also end the test programs by not pressing any key for 15 minutes.

Display Meaning

Recycling and disposal have already been taken into account during the development of all Vaillant products.

Vaillant‘s standards lay down strict requirements.

When selecting materials, the recyclability, dismountability and separability of materials and components are taken into account, just as environmental hazards and health risks during recycling and the disposal of unavoidable remains of unusable residue are.

P. 0

P. 1

P. 2

Bleeding test program

1x "i" key: start bleeding the heating pump

(display: HP)

2x "i" key: start bleeding the charging pump

(display: LP)

3x "i" key: end bleeding program

Note: the bleeding program runs for approx. 6.5 mins.

Test program whereby the appliance is operated at full load after successful ignition

Test program whereby the appliance is operated with minimum gas volume after successful ignition

P. 5 Test program for safety thermostat test; appliance heats up by bypassing a control shutdown until the safety thermostat shutdown temperature of 97 °C is reached

Table 8.5 Test programs

10.1 Appliance

Your Vaillant ecoMAX 646 consists 92 % of metallic materials which can be melted down again at iron and steel works and therefore can be recycled practically any number of times. The plastic materials used are labelled and, in this way, are already prepared for sorting and fractionation for subsequent recycling.

10.2 Packaging

Vaillant has reduced the transport packaging of the appliances to a minimum. The strict selection of the packaging materials is based on their recyclability. The highquality cardboard articles are secondary raw materials which have been in demand in the cardboard and paper industry for a long time.

EPS (polystyrene) ® is used to protect the products during transport. EPS is 100 % recyclable and CFC-free.

Even the films and tightening bands are made of recyclable plastic.

32 Installation and maintenance manual ecoMAX 646

11 Technical data

ecoMAX nominal heat output range P (heating 40/30 °C) nominal heat output range P (heating 50/30 °C) nominal heat output range P (heating 60/40 °C) nominal heat output range P (heating 80/60 °C) storage charging output Pw max. thermal load Q during heating operation max. thermal load Q during recharging min. thermal load

NOx class connection pressure (gas flow pressure) natural gas, pü connection pressure (gas flow pressure) propane, pü flue gas mass flow min./max.

flue gas temperature min./max.

rated water volume (when T = 20 K) residual delivery head of the pump (without gravity brake) residual delivery head of the pump (with gravity brake) max. supply temperature approx.

permissible operating overpressure on the heating side (PMS) min. required total overpressure on the heating side condensate volume (pH value: 3.0-4.0) mounting weight height width depth electrical connection electrical power consumption min./max. (with integrated pump) type of protection

Technical data 11

Unit l/h kg mm mm mbar

°C bar bar

W

— mm

V/Hz kW

— mbar mbar g/s

°C l/h mbar kW kW kW kW kW kW kW

646

4,5

45

800

480

190

85

3.0

0.8

450

230/50

138/180

IP X4 D

12.5

5

20

50

5.7/20.5

40/70

1935

280

13.3 - 47.7

12.9 - 46.4

12.5 - 45.0

12.3 - 44.1

44.1

45.0

45.0

Installation and maintenance manual ecoMAX 646 33

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