Vaillant ecoMAX 646 Service Manual

TURBOmax VUW 242 EG.C. No 47-044-25TURBOmax VUW 282 EG.C. No 47-044-26Wall hung room sealed fan assistedcombination boilersINSTRUCTIONS FOR INSTALLATI

103.5 Air supplyDetailed recommendations for airsupply are given in BS 5440: Part 2. It is not necessary to have an air ventin the room or internal sp

11fig. 6GW 400/03.7.2 Filling and make upThe system should be filled with watervia a separate filling point fitted at aconvenient position on the heat

12Safety valve setting (bar) 3.0Initial system pressure (bar) 1.0 1.5Total water content of system VESSEL VOLUME (L)litres25 2.7 3.950 5.4 7.8100 10.9

4. Boiler installationsequence4.1 GeneralThe boiler should be mounted on aflat and vertical area of wall ofsufficient area for the boiler plus therequ

Standard Accessories Art. No.1. Air/flue duct and terminal accessory 300 807Optional Accessories Art. No.1. Vertical air / flue duct (including termin

154.3.2 Using the boiler template(fig. 12)4.3.2.1 Once a suitable location hasbeen chosen, fix the paper installationtemplate on the wall ensuring tha

4.4 Installing the flue systemAt this stage install the flue system(refer to separate installationinstructions supplied). 4.5 Mounting the boiler4.5.1

4.5.3.4 Gas supply The boiler is supplied with a 20 x 15mm gas service valve (10, fig. 14). Fitthe 20mm compression fitting to theboiler gas inlet (11

Loosen screws on the 95 mm diameterx 55mm wide clamp (6, fig. 21) andpush over the air duct.Remove screws and sealing washeron the 95 mm diameter x 25

Drill two holes 3 mm diameterthrough the air duct clamp (2. Fig 24)ensuring that the drill does not pene-trate the flue duct. Screw the clamp tothe bo

2Page 1. Introduction 32. Boiler Specification 42.1 Technical Data 42.2 Dimensions 52.3 Boiler connections 52.4 Function diagram 63. General R

2043NLNL 44.8 Controls4.8.1 External electrical controlsThe boiler terminals 3,4 and 5 are forconnecting external controls such as atime switch and/or

214.8.3 Thermostatic radiator valvesThe boiler has a built-in automaticbypass valve making it ideal for use insystems with thermostatic radiatorvalves

22fig. 31GW 610/05. Commissioning5.1 Preliminary electrical checksCheck the electrical installation bycarrying out short circuit, earthcontinuity and

23fig. 32GW 634/05.4 Filling the heating systemThe boiler primary circuit and theheating system should be filled usinga filling method as described in

24fig. 33GW 612/05.6 Initial lighting •Check that the boiler combustionchamber (5, fig. 33) is correctlyfitted.•Ensure the cold water shut-off valve(4

VUW 242 VUW 282Maximum Burner 10.0 mb 10.6 mbPressure (DHW) (-–+1.0 mb) (-–+1.0 mb)Maximum Gas 2.79 m3/h 3.26 m3/hRate(98.5 ft3/h) (115.1 ft3/h)25fig.

Output to Range rating mbarcentral Heatingmbar VUW 242 VUW 28228.0 (95,560) - 10,624.0 (81,900) 10,0 8,021.0 (71,700) 8,0 6,318.0 (61,500) 6,1 4,815.0

•The gas valve will open and spar-king will commence at the burner.The ignition indicator will illuminate.•As soon as the burner has ignitedand the fl

285.11 Checking flamesupervision deviceOperate the boiler and turn off thegas supply at the boiler gas servicevalve. The boiler should attempt to re-l

5.14 Hand over to userSet the maximum radiator temperaturecontrol (3, fig. 44) to the desiredsetting.The following settings may be used asa guide:Spri

331. IntroductionNote: This boiler must be installedand serviced by a competent personin accordance with the Gas Safety(Installation and Use) Regulati

306.2 Routine maintenance6.2.1 Remove front caseRemove bottom hinge screw (1, fig. 46) and pull lower door panelforward and down to release it fromthe

31fig. 49GW 604/0fig. 48GW 639/06.2.5 Inspect burnerWith the combustion chamber frontcover and heat exchanger front panelremoved it is possible to ins

32fig. 50GW 619/07. Parts replacementIMPORTANT:Before starting any maintenancework:•Isolate the mains electricity supplyby disconnecting the plug at t

337.1.3 Removal of front casing7.1.3.1 Door (fig. 52)•Remove bottom hinge screw (1)and pull the bottom door panel forwards and down to release itfrom

347.2 Replacement of fan (fig. 55)•Isolate the boiler from the electricalsupply.•Remove front casing as in section7.1.3, and remove combustionchamber

357.4 Replacement of burner•Isolate the boiler from the electricalsupply.•Remove front casing as in section7.1.3.•Remove combustion chamber coveras in

36fig. 59GW 643/07.6 Replacement of NTCtemperature sensorNote: The NTC temperature sensor isan extremely reliable component andas such is unlikely to

377.7.1 Replacement of main solenoidvalve.•Isolate the boiler from the electricalsupply.•Remove front casing as in section7.1.3 •Lower front control p

387.9 Replacement of CHexpansion vessel In the unlikely event of a failure of theCH expansion vessel follow procedure7.9.1 or 7.9.2 depending upon the

397.10 Replacement of transformer•Isolate boiler from the electricitysupply.•Remove front casing as in section7.1.3•Lower front control panel as insec

TURBOmax VUW 242 E VUW 282 E unitsMaximum CH heat input 29.3 34.2 kW(100,000) (116,600) (Btu/h)CH heat output range 9.6-24.0 11.2-28.0 kW(32,800-81,90

40fig. 69GW 607/0fig. 70GW 646/0fig. 71GW 647/07.13 Replacement of automaticair release•Turn off boiler as in section 7.1.1.•Remove front casing as in

417.15.1 Replacement of water sectiondiaphragm (fig. 72).•Turn off boiler as in Section 7.1.1. •Remove bottom cover as in section7.1.3.3.•Open hot wa

42fig. 74GW 650/17.18 Replacement of DHWmicroswitch.•Isolate appliance from electricitysupply.•Remove front casing as in section7.1.3.•Lower front con

fig. 76GW 617/0437.20 Removal of printed circuitboards (PCBs)Before commencing work on PCBreplacements carry out the following:-•Diagnose which board

448. Fault finding8.1 IntroductionThe TURBOmax has built in diagnosticindicator lights (fig. 77) to assist youwith fault finding in the unlikely event

45Sheet A Check electrical supply and appliance fusesEnsure boiler main on/off controlis set

46Sheet B Check main on/off control, overheat Thermostat and anti-surge fuseDoes green power

47Sheet C Check Central Heating control and external controlsDoes yellow central heating dem

48Sheet D Check operation of pumpDoes pump run?Is red burner lockoutindicator ( ) glowing?

49Sheet E Check fan/flue gas systemDoes yellow fan operation indicator ( ) glow?Does yell

55GW 547/0fig. 12.3 Boiler connections1 Compression union (flow ofheating system)2 Service valve (flow of heatingsystem)3 Domestic hot water connectio

50Sheet F Check operation of differential pressure switchDoes sparking startat burner?Does re

51Sheet G Check ignition system and gas sectionDoes burner light?Does red lockout indicator (

52Sheet H Check operation of burner and modulationIs flame extinguishedafter 10s, and redlock

53Sheet J Check D.H.W. OperationDraw hot water athigh rateDoes yellow hot water demandindicat

549 Electrical diagrams9.1 Functional Flow diagram: VUW 242 E / 282 EGW 651/0fig. 78S

559.2 Wiring diagram: VUW 242 E / 282 Efig. 79FlamesensingelectrodeIgnitionelectrode

569.3 Schematic appliance circuit diagram: VUW 242 E / 282 EGW 652/0fig. 80

5710. Short parts listKey No. Description Part No. GC No.01 Fan 19 016202 Air pressure switch 05 055703 Main heat exchanger VUW 242 06 495104 Main hea

58fig. 88GW 684/0fig. 90GW 686/0fig. 92GW 682/1fig. 87GW 683/0fig. 89GW 693/0fig. 91GW 691/0fig. 93GW 689/0fig. 94GW 690/0fig. 95GW 692/0fig. 96GW 685

59Technical DataL.P.G. Appliances:VUW 242 EBVUW 282 EBThe appliance delivered is designedfor use with LPG.Please read the instructions forinstallation

66GW 573/1fig. 32.4 Function diagram1 Air duct2 Air pressure switch3 Combustion chamber4 Temperature sensor (NTC)5 Ignition electrodes6 Modulating bur

83 20 16 GB01HEATING, CONTROLS, HOT WATER0796 VPrinted in Germany - Imprimé en AllemagnePrinted on 100 % recycled paperSubject to alterationWe do not

73. General requirements3.1 Related documentsThe installation of the boiler must bein accordance with the relevantrequirements of Gas Safety (Installa

83.3 Gas supplyThe gas supplier should ensure theavailability of an adequate supply ofgas.A gas meter may only be connectedto the service pipe by the

3.4.1 Flue Termination1. The terminal must be positionedsuch that the combustion products candisperse freely at all times.2. In certain weather condit