Vaillant ecoMAX pro SERIES Operating manual

To be left with the user
Instructions for Use, Installation
and Servicing
ecoMAX pro
Wall hung condensing
boilers for traditional open vented
systems
GB
18 E
28 E

Instructions for Use, Installation and Servicing ecoMAX pro2
Table of Contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Contents included with ecoMAX pro boiler. . . . . . . . . . . . . 3
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety instructions and symbols . . . . . . . . . . . . . . . . . . . . . 3
2.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Gas Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Gas Safety (Installation and Use) Regulations. . . . . . . . . . . 4
2.4 Gas Testing and Certification. . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Control of Substances Hazardous to Health . . . . . . . . . . . . 4
2.6.1 Insulation Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.8 Manual Handling Guidance . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.9 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.10 Protection Against Freezing. . . . . . . . . . . . . . . . . . . . . . . . . 5
2.11 Boilers Installed in a Compartment or Cupboard . . . . . . . . 5
2.12 Boiler Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.13 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.14 Pluming from flue terminal . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.16 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.17 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Operating the Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Sealed Central Heating Systems only . . . . . . . . . . . . . . . . . 7
3.2 All Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 User Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 To Turn the Boiler Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Sheet Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Statutory Requirements and certification . . . . . . . . . . . . . . . 8
4.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dimensions and Data labels . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Heating System Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Boiler Location and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Timber Frame Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.4 Room Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.5 Compartment Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Draining Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Safety Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4 Bypass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.5 Inhibitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.6 Open (Vented) Water System. . . . . . . . . . . . . . . . . . . . . . . . 14
6.7 Domestic Hot Water Cylinder . . . . . . . . . . . . . . . . . . . . . . . 14
6.8 Domestic Hot Water System - unvented . . . . . . . . . . . . . . . 14
6.9 Sealed water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.9.1 Safety Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.9.2 Expansion Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.9.3 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
6.9.4 Domestic Hot Water Cylinder . . . . . . . . . . . . . . . . . . . . . . . 15
6.9.5 Water Make up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.9.6 Filling a Sealed Water System. . . . . . . . . . . . . . . . . . . . . . . 15
7 Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 Flue Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Internal Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.1 Unpacking of Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2 Rear flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.3 Other flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.1 Fitting the boiler hanging bracket . . . . . . . . . . . . . . . . . . . . 19
9.2 Boiler Fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10 Gas, Water and Condensate Connections . . . . . . . . . . . . . . . . . . 20
10.1 Gas Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10.2 Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10.3 Condensate Drain Connection. . . . . . . . . . . . . . . . . . . . . . . 20
11 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.1 Appliance, pump and external controls . . . . . . . . . . . . . . . . 21
11.2 Electrical connections – testing. . . . . . . . . . . . . . . . . . . . . . 21
12 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12.1 Preliminaries - All Systems. . . . . . . . . . . . . . . . . . . . . . . . . 22
12.2 Sealed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12.4 Initial Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.5 Testing - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.6 Testing - Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.7 User Controls and Options . . . . . . . . . . . . . . . . . . . . . . . . . 24
12.8 Temperature Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12.9 Pump Exercise Programme . . . . . . . . . . . . . . . . . . . . . . . . . 24
12.10 Hand over to user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
13 Natural Gas to LPG conversion (ecoMAX pro 28E only) . . . . . . . 25
14 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
14.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14.3 Functional Check of Boiler Operation . . . . . . . . . . . . . . . . . 28
14.4 Spark Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
14.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
14.6 Combustion Chamber and Heat Exchanger. . . . . . . . . . . . . 30
14.7 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
14.8 Inner Casing Panel Seal Check . . . . . . . . . . . . . . . . . . . . . . 31
15 Combustion analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
16 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
16.1 Status Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
16.2 Fault Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
16.3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
16.4 Fault Finding Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 36
17 Short Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
18 Benchmark gas boiler commissioning checklist . . . . . . . . . . . . . 38

Instructions for Use, Installation and Servicing ecoMAX pro 3
1.1 Contents included with ecoMAX pro boiler
Ensure that all contents are included before commencing
installation.
Item Quantity Description
1 1 Boiler
2 1 Hanging bracket
3 1 Flue connection adaptor
4 1 Instruction booklet
5 2 Guarantee card and envelope and log book
6 1 Template
7 1 Screws/wallplugs
8 1 Gas service valve and compression couplers
9 1 Natural Gas to LPG conversion
data badge over sticker
Vaillant Ltd. support the Benchmark initiative.
At the rear of this literature you will find a
Benchmark gas boiler commissioning checklist. It is
very important that this is completed correctly at the
time of installation, commissioning and hand over to
the user.
List of Contents 2 Introduction
Fig 1.1
Items supplied with unit
(ecoMAX pro)
12621
Safety instructions and symbols
Please observe the safety instructions in this manual for
the installation of the appliance!
Symbols used in the manual are explained below:
DANGER!
Immediate danger to life and limb!
CAUTION!
Potentially dangerous situation for the product
and environment!
NOTE:
Useful information and instructions.
• Symbol for necessary task.
- List for functional descriptions and general list.

Instructions for Use, Installation and Servicing ecoMAX pro4
2.1 General Information
Thank you for choosing a Vaillant boiler. The information
given in this booklet will enable you to obtain the best
performance from your boiler.
The Benchmark logbook should be completed by the
installer and/or commissioning engineer and handed to
the user.
NOTE:
This boiler must be installed and serviced by
a competent person in accordance with the
Gas Safety (Installation and Use) Regulations
1998. In the UK 'CORGI' registered installers
undertake the work to a safe and satisfactory
standard.
This boiler is designed to provide central heating from a
fully pumped open-vented or sealed water system with a
fully indirect cylinder.
The central heating water temperature can be adjusted
on the boiler.
Once the controls are set the boiler operates
automatically.
A frost protection programme is also included.
Please read these instructions and follow them carefully
for the correct and economical use of your boiler.
2.2 Gas Category
The boiler is supplied factory set for use on Natural Gas
(G20). The ecoMAX pro 28E, only, can be field adjusted
for use on LPG (propane G31), see page 22-23 for
instructions or contact Vaillant Service, 0870 6060 777.
2.3 Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law
that ALL gas appliances are installed by a competent
person in accordance with the current issue of the above
regulations.
2.4 Gas Testing and Certification
The boiler is tested and certificated for safety and
performance. It is, therefore, important that no alteration
is made to the boiler.
2.5 CE Mark
This boiler meets the requirements of Statutory
Instrument, No. 3083 The Boiler (Efficiency) Regulations,
and therefore is deemed to meet the requirements of
Directive 92/42/EEC on the efficiency requirements for
new hot water boilers fired with liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by:
Notified body 0087.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the
laws of the Member States relating to appliances burning
gaseous fuels.
2. Directive 73/23/EEC on the harmonisation of the Laws
of the Member States relating to electrical equipment
designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the
Laws of the Member States relating to electromagnetic
compatibility.
2.6 Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act
1974, we are required to provide information on
substances hazardous to health.
The adhesives and sealants used in this appliance are
cured and give no known hazard in this state.
2.6.1 Insulation Pads
These can cause irritation to skin, eyes and the
respiratory tract.
If you have a history of skin complaint you may be
susceptible to irritation. High dust levels are usual only if
the material is broken.
Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before
eating, drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to
the skin seek medical attention.
2.7 Spare Parts
Only original Vaillant spare parts may be used.
2.8 Manual Handling Guidance
During the appliance installation and the replacement of
the heat exchanger it will be necessary to employ
caution and assistance whilst lifting as the appliance or
component exceeds the recommended weight for a one
man lift.
In certain situations it may be required to use a
mechanical handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.
2.9 Warnings
Gas Leak or Fault
If a gas leak or fault exists or is suspected, turn off the
gas emergency control valve immediately. Eliminate all
sources of ignition, i.e. smoking, blowlamps, hot air guns
etc. Do not operate electrical lights or switches either on
or off. Open all doors and windows, ventilate the area.
Clearances
If fixtures are positioned close to the boiler, space must
be left as shown in fig 5.1. Enough space must also be
left in front of the boiler to allow for servicing.
2 Introduction

Instructions for Use, Installation and Servicing ecoMAX pro 5
Sheet Metal Parts
This boiler contains metal parts (components) and care
should be taken when handling and cleaning, with
particular regard to edges.
Sealed Components
Under no circumstances must the User interfere with any
sealed component as this could result in a
potentially dangerous situation arising.
Electrical Supply Failure
This boiler must be earthed.
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the
electrical supply is restored.
Reset any external controls to resume normal operation
of the central heating.
If the boiler does not resume normal operation turn the
mains reset switch off and on. If the boiler does not
resume normal operation after this the overheat
thermostat may have operated. The overheat
thermostat would only operate under abnormal
conditions and, under these circumstances; it would be
advisable to consult your installation / servicing
company.
2.10 Protection Against Freezing
The boiler has a built in frost protection programme as
long as the electricity and gas are left switched on.
This device operates the burner and system pump when
the temperature inside the boiler falls to 3°C.
Any other exposed areas of the system should be
protected by a separate frost thermostat.
If the mains electricity and gas are to be turned off for
any long periods during severe weather, it is
recommended that the whole system, including the
boiler, should be drained to avoid the risk of freezing.
Make sure that, if fitted, the immersion heater in the
cylinder is switched off.
If you have a sealed water system contact your
installation/ servicing company as draining, refilling and
pressurising MUST be carried out by a competent
person.
As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the
condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe. The
boiler should then restart. Contact your installation/
servicing company if the fault persists.
2.11 Boilers Installed in a Compartment or Cupboard
If the boiler is fitted into a compartment or cupboard it
does not require ventilation openings.
Do not use the compartment or cupboard for storage.
Important information 2
2.12 Boiler Casing
Do not remove or adjust the casing in any way, as
incorrect-fitting may result in incorrect operation or
failure to operate at all.
2.13 Condensate Drain
The condensate drain, see section 10.3, must not be
modified or blocked.
2.14 Pluming from flue terminal
All condensing boilers produce a plume of water vapour
from the flue terminal. This is due to the high efficiency
and hence low flue gas temperature. This may increase
in wet, damp weather but this is completely normal and
indicates that the boiler is operating correctly.
2.15 Cleaning
This appliance contains metal parts and care should be
taken when handling and cleaning with particular regard
to edges.
The boiler casing can be cleaned using a mild liquid
detergent with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as
you may damage the paint work.
2.16 Maintenance and Servicing
For the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced
at regular intervals. The frequency of servicing will
depend upon the installation conditions and usage, but in
general, once a year should be enough.
If this appliance is installed in a rented property there is
a duty of care imposed on the owner of the property by
the current issue of the Gas Safety (Installation and Use)
Regulations, Section 35.
Servicing/maintenance should be carried out by a
competent person in accordance with the rules in force in
the countries of destination.
To obtain service, please call your installer or Vaillant
Service Solutions (0870 6060 777).
Please be advised that the installation engineer on
completion of commissioning and servicing should
complete the ‘Benchmark’ logbook.
All CORGI Registered Installers carry a CORGI ID card,
and have a registration number. Both should be recorded
in your boiler Logbook. You can check your installer is
CORGI registered by calling CORGI direct on: - 01256
372300.

Instructions for Use, Installation and Servicing ecoMAX pro6
2 Introduction
2.17 Guarantee
Vaillant provide a full parts and labour warranty for your
appliance.
The appliance must be installed by a suitably competent
person in accordance with the gas safety (installation
and Use) Regulations 1998, and the manufacture's
instructions. In the UK ‘CORGI’ registered installers
undertake the work in compliance with safe and
satisfactory standards.
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 commis ion this appliance in
compliance with the manufacture's instructions may
invalidate the warranty (this does not affect your statutory
rights).

Instructions for Use, Installation and Servicing ecoMAX pro 7
3 Operating the boiler
Fig 3.1
12622
3.1 Sealed Central Heating Systems only
CAUTION: A sealed water system must be filled and
pressurised by a competent person.
Only light the boiler when you are sure that the system
and boiler have been filled and pressurised.
The pressure should read at least 0.7 bar, when the
system is cold. If the needle displays a value below this,
follow the instructions left by your installer to refill the
system. Alternatively your installer should be called to
refill the system.
3.2 All Systems
Check that the electrical supply to the boiler is ON at the
external isolator.
Set any remote heating system controls as required.
3.3 User Controls
Slide the On / Off control down to the I position to turn on
the boiler. The operating indicator will illuminate (green)
to show that the boiler is on.
The temperature of the central heating water can be
adjusted by pushing the mode button ( ) until the
radiator symbol is displayed. Pushing the + or - buttons
will then set the water temperature as desired. (Typical
setting temperatures for a normal radiator heating system
will be in the range of 60 °C to 80 °C. Note that set
temperatures below 60 °C will not sufficiently heat any
hot water cylinder). To return to the normal mode push
the mode button ( ) until the display shows the current
temperature of water in the boiler.
When the boiler is operating the flame symbol will be
shown in the display. The bar symbol is also shown and
this indicates the modulating output of the boiler. The
boiler will automatically modulate to the output needed
by the heating system - the more bars that are displayed,
the higher the output.
The ecoMAX pro is a fan flue appliance and the
operation of the fan may be heard when the boiler
is running and for a short period after the boiler has
stopped. Should a fault condition occur the operating
indicator will flash red and will be accompanied by
an "F" symbol in the display. To reset the boiler slide
the On / Off control to the Off (O) position and after 5
seconds back to the On (I) position. The boiler should
now operate. If the fault persists contact your installer /
service provider. The ecoMAX pro has a Holiday / frost
mode. If you are going on holiday and do not want the
boiler to be operated by the external heating controls
press the mode button ( ) until the MODE indicator
flashes in the left hand edge of the display. Then press
the + or - button until the arrow indicator points to the
holiday symbol ( ). The boiler will now only operate if
necessary for frost protection of the boiler itself as well
as running a daily pump exercise programme to prevent
sticking. It will not be turned on and off by the external
heating controls. If a system frost protection thermostat
has been fitted this will remain active.
3.4 To Turn the Boiler Off
Normally the boiler will be turned off by the heating
system controls. The mains On / Off control may be used
to switch off the boiler, however it is preferable to leave
the electrical supply on whenever possible to permit
operation of the built-in frost protection and daily pump
exercise programme.

Instructions for Use, Installation and Servicing ecoMAX pro8
IMPORTANT NOTICE:
The boiler is supplied in one pack and the flue is
supplied separately.
The boiler is factory set for use on Natural Gas (G20).
The ecoMAX pro 28E, only, can be field adjusted for use
on LPG (propane G31).
Where no British Standards exists, materials and
equipment should be fit for their purpose and of suitable
quality and workmanship.
Refer to Manual Handling Operations, 1992 regulations.
The installation of this boiler must be carried out by a
competent person in accordance the rules in force in the
countries of destination.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
4.1 Sheet Metal Parts
CAUTION!
When installing the appliance, care should be
taken to avoid any possibility of personal injury
when handling sheet metal parts.
4.2 Statutory Requirements
The appliance is suitable only for installation in GB and
IE and should be installed in accordance with the rules in
force. In GB the installation of the boiler must be carried
out by a competent person as described in the following
regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The
Building Regulations, The Building Regulations
(Scotland),The Building Regulations (Northern Ireland).
The Water Fittings Regulations or Water bye laws in
Scotland. The Health and Safety at Work Act, Control of
Substances Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference
should be made to the relevant British Standard Code of
Practice. In IE, the installation must be carried out by a
competent person and installed in accordance with the
current edition of I.S.813 “Domestic Gas Installations”,
the current Building Regulations and reference should be
made to the current ETCI rules for Electrical Installation.
In GB the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2,
BS7593, BS7671.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
Note: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK)
and the current issue of the following:
1) Central heating system specification (CheSS)
2) Controls for domestic central heating system and hot
water. BRECSU.
Certification
This boiler certificated to the current issue of EN 483 for
performance and safety.
It is important that no alteration is made to the boiler,
without permission, in writing, from Vaillant.
Any alteration that is not approved by Vaillant, could
invalidate the warranty and could also infringe the
current issue of the Statutory Requirements.
4.3 Gas Supply
The gas installation must be in accordance with the
current issue of BS6891. In IE this is the current edition
of IS813.
The supply from the governed meter must be of
adequate size to provide a steady inlet working pressure
of 20mbar (8in wg) G20 and at the boiler.
On completion, test the gas installation for soundness
using the pressure drop method and suitable leak
detection fluid, purge in accordance with the above
standard.
4.4 Technical Data
All dimensions are given in millimetres (except as noted).
See Fig. 4.1.
The data label is positioned on the combustion chamber
cover see fig. 4.2.
The data label includes the product Gas Council number;
18E - 41 044 30
28E - 41 044 31
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is:
All ecoMAX pro: Class ‘A’.
The value is used in the UK Government’s Standard
Assessment Procedure (SAP) for energy rating of
dwellings. The test data from which it has been
calculated has been certified by B.S.I.
4 General information

Instructions for Use, Installation and Servicing ecoMAX pro 9
4 General information
ecoMAX pro ecoMAX pro
18 E 28 E Units
Maximum CH heat input (net) 18.9 28.6 kW
CH heat output (80/60 °C) 5.0 - 18.3 5.3 - 28.2 kW
CH heat output (50/30 °C) 5.3 - 20.0 5.7 - 30.6 kW
SEDBUK Band A A
SAP Seasonal Efficiency 90.4 90.6 %
NOx Class 5 5
Electrical rating IP40 IP40
Inlet gas working pressure
required (natural gas) 20 20 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 37.8 MJ/m3
Maximum gas rate 2.00 3.02 M3/h
Minimum gas rate 0.53 0.56 M3/h
Burner % CO2 (Case on) 9.0 +/-0.2 9.0 +/-0.2 %
Gas connection 15 mm Compression 15 mm Compression
Water connections 22 mm Compression 22 mm Compression
Condensate drain (internal diameter min.) 19 19 mm
Internal fuse ratings Fan supply PCB 3.15 AT Fan supply PCB 3.15 AT A
Main PCB 125 mAT Main PCB 125 mAT A
Maximum CH system pressure 3 3 bar
Weight 31 33 kg
Electrical supply 230/~50 230/~50 V~/Hz
External fuse 3 3 A
Power input 60 60 W
Case height 600 600 mm
Case width 375 375 mm
Case depth 334 334 mm
Boiler specification

Instructions for Use, Installation and Servicing ecoMAX pro10
Fig 4.1
12729
12740
Fig 4.2
4 General information

Instructions for Use, Installation and Servicing ecoMAX pro 11
4.5 Electrical Supply
The boiler must be earthed.
All system components shall be of an approved type and
all wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and
in accordance with the relevant standards.
In GB this is BS 7671.
In IE this is the current edition of I.S.813 “Domestic Gas
Installations”.
The boiler must be connected to a permanent 230V ac,
50Hz supply.
Connection of the whole electrical system of the boiler,
including any heating controls, to the electrical supply
must be through one common isolator and must be fused
3 Amp maximum.
Isolation should be by a double pole switched fused
spur box, with a minimum gap of 3mm for both poles.
The fused spur box should be readily accessible and
preferably adjacent to the appliance. It should be
identified as to its use.
Alternatively connection can be made through an
unswitched shuttered socket and 3A fused 3-pin plug
both to the current issue of BS 1363 may be used,
provided they are not used in a room containing a bath
or shower.
The colours of three core flexible cable are, blue -
neutral, brown - live, green and yellow - earth.
4.6 Condensate Drain
A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the
internal household draining system. If this is not
practical, discharge can be made externally into the
household drainage system or a purpose designed soak
away, see Section 10.3 for more details.
4.7 Heating System Controls
It is recommended that a programmer and room
thermostat control the boiler.
Thermostatic radiator valves may be installed, however
they must not be fitted in a room where the room
thermostat is located.
NOTE:
All systems must have at least one radiator not
fitted with a thermostatic valve.
NOTE:
For further information, see the current issue of
the Building Regulations, approved document
L1, and the following current issues of:
1) Central heating system specification (CheSS)
and
2) Controls for domestic central heating
system and hot water. BRECSU.
4 General information

Instructions for Use, Installation and Servicing ecoMAX pro12
5.1 Boiler Location
NOTE:
This boiler is not suitable for outdoor
installation.
This boiler may be installed in any room,
although particular attention is drawn to the
installation of a boiler in a room containing a
bath or shower where reference must be made
to the relevant requirements.
This boiler is suitable for installation in
bathroom zones 2 and 3.
In GB this is the current I.E.E. WIRING REGULATIONS
and BUILDING REGULATIONS. In IE reference should
be made to the current edition of I.S.813 “Domestic Gas
Installations” and the current ETCI rules. The boiler must
be mounted on a flat wall, which is sufficiently robust to
take its total weight, see boiler specification page 9.
5.2 Clearances
The boiler should be positioned so that at least the
minimum operational and servicing clearances are
provided, see fig 5.1.
Additional clearances may be beneficial around the boiler
for installation and servicing.
For flue installations where external access is not
practicable, consideration should be given for the
space required to insert the flue internally, which may
necessitate clearance larger than those specified in fig
5.1.
5.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it
should be fitted in accordance with the Institute of Gas
Engineers document IGE/UP/7/1998. If in doubt seek
advice from the local gas undertaking or Vaillant.
5.4 Room Ventilation
The boiler is room sealed, so when it is installed in a
room or space, a permanent air vent is not required.
5.5 Compartment Ventilation
Due to the high efficiency and hence low casing
temperature of this boiler, cupboard or compartment
ventilation is not necessary. Leave existing air vents.
5 Boiler location and ventilation
Fig 5.1
12629

Instructions for Use, Installation and Servicing ecoMAX pro 13
6.1 Draining Tap
A draining tap must be provided at all the lowest points
of the system, which will allow the entire system and hot
water system to be drained.
Draining taps shall be to the current issue of BS 2879.
6.2 Safety Valve
A safety valve need not be fitted to an open-vented
system. See also section 6.9.1.
6.3 Pump
The pump should be fitted on the flow pipe from the
boiler and have isolating valves each side.
A variable duty pump should be set to give a
temperature difference of no greater than 20°C
between the flow and return, with the thermostat set at
“MAX”, which is about 80°C, to give a flow rate as shown
in table 2.
See chart for pressure loss of the boiler, fig 6.1 or 6.2.
High resistance micro bore systems may require a higher
duty pump.
6.4 Bypass
A system bypass will be required fitted at least 1.5
metres away from the boiler, refer to the current issue of
central heating system specifications (CHeSS).
Fig 6.1
12625
Fig 6.2
12626
6 Water system
Model Minimum flow rate
ecoMAX pro 18 E 773.8 litres/hr
ecoMAX pro 28 E 1289 litres/hr
This is equal to 20°C differential at
maximum heat input.
TABLE 2

Instructions for Use, Installation and Servicing ecoMAX pro14
6.5 Inhibitor
In the case of an existing installation, it is ESSENTIAL
that prior to installing the new boiler the system is
thoroughly flushed. For optimum performance after
installation of a new system, the boiler and its associated
central heating system should also be flushed. Flushing
should be carried out in accordance with BS7593: 1992
using a cleanser such as Sentinel X300 or X400, or
Fernox Superfloc.
For long-term corrosion protection, after flushing, an
inhibitor suitable for stainless steel heat exchangers
should be used, refer to the current issue of BS 5449
and BS 7593 on the use of inhibitors in central heating
systems. Examples are Sentinel X100 and Fernox.
IMPORTANT: It is ESSENTIAL that the cleanser is fully
removed from the system after flushing and before
adding inhibitor. Take care to ensure that all low points in
the system are fully drained.
For all systems follow the manufacture’s instructions, but
where new radiators are fitted do not leave the cleanser
in the system for longer than 24 hours.
For optimum performance the boiler and its associated
central heating system should be flushed in accordance
with BS7593: 1992 using a cleanser.
For advice on the application of system cleansers and
inhibitors contact either;
Fernox, Alpha-Fry Technologies
Tandem House
Marlow Way
Beddington Farm Road
Croydon CR0 4XS
Tel: [phone]
Fernox technical help line
01799 550811
or:
Sentinel, GE Betz
Widnes
Cheshire, WA8 8UD
Tel: [phone].
6.6 Open (Vented) Water System
The boiler must be supplied from an unrestricted water
supply taken from a feed and expansion cistern situated
at a maximum height of 27 metres (90ft) above the
boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump, cold
feed and open vent are as shown in fig 6.3.
6.7 Domestic Hot Water Cylinder
CAUTION!
Single feed indirect cylinders are not suitable.
The domestic hot water cylinder must be of the
double feed fully indirect coil type.
Fig 6.3
12627
6 Water system
6.8 Domestic Hot Water System - unvented
General - All domestic hot water circuits, connections,
fittings must be in accordance with the relevant
standards and water supply regulations.
For GB: Guidance G17 to G24 and recommendation R17
to R24 of the Water Regulations Guide.
For IE: The current edition of I.S.813 “Domestic Gas
Installations”. Where a storage system will not have a
vent to atmosphere the installation must comply with the
building regulations and local Water Company bylaws,
see also the current issue of BS5546 and BS6700.
If fitting to an existing system the local authority should
be informed.
NOTE:
ecoMAX pro boilers are not suitable for use
with Vaillant VANTAGE unvented cylinders and
MUST not be used in connection with these
cylinders.
6.9 Sealed water Systems
The installation must comply with the appropriate
requirements of the current issue of BS4814, BS5449,
BS6759, BS6798 and BS7074 Part 1 and 2. For IE your
attention is drawn to the current edition of IS 813.
See fig 6.4 for a suggested layout.

Instructions for Use, Installation and Servicing ecoMAX pro 15
6.9.3 Pressure Gauge
A pressure gauge with a set pointer and covering at least
0 to 4 bar (0 to 60 lb/in2) shall be fitted permanently to
the system in a position where it can be seen when
filling the system.
6.9.4 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT
SUITABLE. The domestic hot water cylinder must be of
the double feed fully indirect coil type. It must be suitable
for
working at a gauge pressure of 0.35 bar above the safety
valve setting.
6.9.5 Water Make up
Provision should be made for replacing water loss from
the system using a make up bottle mounted in a position
higher than the top point of the system, connected
through a non-return valve to the return side of either the
heating circuit or the hot water cylinder.
Alternatively, provision for make up water should be
made using a proprietary filling loop.
6.9.6 Filling a Sealed Water System
Provision for filling the system at low level must be made.
This can be achieved by the use of a proprietary filling
loop.
6.9.1 Safety Valve
A safety valve must be fitted to a sealed system.
It shall be preset, non-adjustable with a lift pressure of
3-bar, incorporating seating of a resilient material, a test
device and a connection for drain.
The safety valve discharge pipe must be routed to
outside the building, must not discharge above an
entrance or window or any type of public access area, be
clear of any electrical fittings and positioned so that any
discharge can be seen.
6.9.2 Expansion Vessel
A diaphragm type expansion vessel, conforming to the
current issue of BS4814 (see also BS7074 Part 1 and 2).
For IE the current edition of IS 813, must be connected
at a point close to the inlet side of the circulating pump,
see the diagrammatic layout, Fig. 6.4. unless laid down
differently by the manufacturer.
The expansion vessel volume depends on the total water
system volume and the initial system design pressure.
For any system an accurate calculation of vessel size is
given in the current issue of BS5449 and BS7074 Part 1.
Example: For an initial design pressure of 0.7 bar, the
minimum total vessel volume required is 0.063 x Total
System Volume.
NOTE:
A higher initial design pressure requires a larger
volume expansion vessel.
The charge pressure must not be less than the
static head of the system, that is, the height of the
highest point of the system above the expansion vessel.
6 Water system
Fig 6.4
12999

Instructions for Use, Installation and Servicing ecoMAX pro16
7 Flue
7.2 Flue termination
The following details refer to both flue systems.
a. The terminal must be positioned such that the
products of combustion can disperse freely at all times.
b. In certain weather conditions a plume of water vapour
may be visible from the flue terminal. Positions where
this could be a nuisance should be avoided.
c. If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people have
access then a suitable terminal guard must be provided
and fitted (A suitable guard is manufactured by:
Tower Flue Components, Morley Road, Tonbridge, Kent,
TN9 1RA. Size: 280mm x 280mm x 270mm) reference
code K6.
NOTE:
Vertical flues must not terminate within 600-mm
of an openable window, air vent or any other
ventilation opening.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
7.3 Internal Flue Installation
The flue can be installed from inside the building when
access to the outside wall face is not practicable.
DANGER!
Vaillant appliances are certified only for use
with genuine Vaillant flue pipes. Only use
genuine Vaillant flue pipes. Malfunctions can
occur if you use other accessories. These may
result in damage and injury. You will find a list
of genuine flue pipes in the Vaillant installation
manual for flue pipes.
The CE mark is valid only if the appliance is
operated with Vaillant flue pipes.
7.1 Flue Options
There are various flue systems to choose from, as follows:
• Standard horizontal air/flue duct
with elbow and terminal. Is suitable for installations up
to 800 mm measured from the centre of the boiler flue
outlet to the outside face of the wall.
Flue extensions are available to extend this length up to
10M. Both 90° bends and 45° elbows are also available
to increase siting flexibility.
• Vertical air/flue duct and terminal
• Air/flue duct extension (470 mm)
• Air/flue duct extension (970 mm)
• Air/flue duct extension (1970 mm)
• Telescopic air/flue duct extension
(440 mm - 690 mm)
• 87° elbow
• Two 45° bends
Additional accessories are available
• Variable termination kit
Refer to flue system installation instructions.
Telescopic Air/Flue Duct, for full details.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at least
3° to allow condensate to run out via the drain.

Instructions for Use, Installation and Servicing ecoMAX pro 17
7 Flue
1) In addition, the terminal should not be nearer
than 150mm to an opening in the building fabric
formed for the purpose of accommodating a built-in
element such as a window.
2) Dimension B,C and D; These clearances may
be reduced to 25 mm without affecting the
performance of the boiler. In order to ensure that
the condensate plume does not affect adjacent
surfaces the terminal should be extended as shown
in Fig 7.4.
3) Dimension F; This clearance may be reduced
to 25 mm without affecting the performance of
the boiler. However, in order to ensure that the
condensate plume does not affect adjacent surfaces
a clearance of 300 mm is preferred.
4) BS 5440-1 It is recommended that a fanned flue
terminal should be positioned as follows:
a) at least 2m from an opening in a building directly
opposite, and
b) so that the products of combustion are not
directly directed to discharge across a boundary.
For IE, recommendations are given in the current
edition of IS 813.
Fig 7.2
12677
A
BCD
A
G
H, I
FJ
BFM
L
L
K
K
G
G
FF
E
A
A
Fig 7.1
12676
TERMINAL POSITION mm
A1) Directly below an opening, above an opening
or horizontal to an opening i.e. air brick,
opening window or other, etc 300
B Below gutters, soil pipes or drain pipes 752)
C Below eaves 2002)
D Below balconies 2002)
E From vertical drain pipes and soil pipes 25
F From internal or external corners 3003)
G Above ground, roof or balcony 300
H From a surface facing a terminal 6004)
I From a terminal facing a terminal 1200
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent wall for vertical Flue 500

Instructions for Use, Installation and Servicing ecoMAX pro18
8.1 Unpacking of Boiler
Stand the boiler carton upright.
Cut and remove the securing straps and lift off the carton
sleeve. Place aside the flue adaptor and connections
pack until required.
NOTE:
Care should be taken not to scratch the white
surface of the boiler casing.
Carefully lay the boiler on its back, remove the two front
casing panel securing screws and lift off the panel from
two retaining lugs, see fig 8.1.
Remove the two inner casing panel securing screws at
the bottom front of the panel, then lift off the two retaining
lugs, see fig 8.2.
8.2 Rear flue exit
Refer to flue system installation instructions for full details.
8.3 Other flue options
Flue instructions for other flue systems such as vertical
RSF flues, flues run to the side of the boiler and the use
of additional bends etc. are detailed in the flue
installation instructions.
Fig 8.1
12678
Fig 8.2
12688
8 Installation preparation

Instructions for Use, Installation and Servicing ecoMAX pro 19
9.1 Fitting the boiler hanging bracket
If previously removed, reposition the wall template over
the flue hole and mark the position of the fixing holes for
the hanging bracket, see fig 9.1.
Mark and drill the fixing holes and secure the hanging
bracket. Fix the hanging bracket to the wall using the
screws supplied. Ensure the uppermost set of screw
positions are used (it may be necessary to use additional
or alternative fixings to ensure adequate support).
NOTE:
If the boiler is to be fitted in a timber framed
building ensure that the bracket is secured to a
substantial part of the timber frame capable of
taking the weight of the boiler.
9.2 Boiler Fixing
Lift the boiler into position in the following manner:
Lean the top of the boiler slightly to the wall and
position just above the hanging bracket. Allow the boiler
to slowly move downwards until engaged in the hanging
bracket.
Fig 9.1
12690
9 Boiler fixing

Instructions for Use, Installation and Servicing ecoMAX pro20
COUPLING
10 Gas, Water and Condensate connections
10.1 Gas Connection
Before connection check the supply of local gas.
The gas supply can be connected from below, or through
the wall at the rear of the boiler. See fig 10.1. and refer to
section 4.3.
The whole of the gas installation, including the meter,
should be inspected, tested for soundness and purged
in accordance with the current issue of BS6891 and
in IE the current edition of I.S.813 “Domestic Gas
Installations”.
10.2 Water Connections
Provision is made for the water connections to be made
from above the boiler, see fig 10.2 (using the two 22mm
compression couplers supplied). The position is shown
on the wall template.
Flush out the domestic hot water and the heating
systems before connecting to the boiler.
10.3 Condensate Drain Connection, refer to fig.10.1.
The condensate drian connection is at the underside rear
of the boiler.
The condense drain is suitable for use with
standard "Push fit" overflow pipe and couplings DO NOT
use adhesive when connecting to the spigot (1) The
condense drain pipe (2) should be non corrosive plastic.
The drain pipe should have a continuous fall of a least
(45mm per metre) away from the boiler. Condensate
should, if possible be discharged into the household
internal drainage system.
(a) Preferably the drain pipe should run and terminate
internally to the house soil and vent stack at least 450mm
above the invert of the stack. A trap giving a water seal
of at least 75mm should be incorporated into the pipe
run, and there must be an air break in the discharge pipe
upstream of the trap. This should be designed so that the
condensate cannot be discharged into the house if the
condensate drain pipe becomes blocked.
(b) Connecting into the internal discharge branch
(e.g. sink waste or washing machine) with an external
termination, the condensate drain pipe should have a
minimum diameter of 22mm with no length restriction
and should incorporate a trap with a 75mm (3) seal.
The connection should preferably made down stream
of the sink waste trap, if the connection is only possible
up stream, then an air break is needed between the two
taps. This is normally provided by the sink waste.
(c) Termination in a gully (5) below grid level (6) and
above the water level. The external pipe length should be
kept as short as possible to minimise the risk of freezing
and should not be more than 3 metres.
(d) At a condensate absorption point (soakaway) (7). The
external pipe length should not be more than 3 metres.
Refer to the latest issue of BS 6798 Specification
Fig 10.2
12692
22mm compression is the
recommended fixing
for servicing.
(not supplied)
Fig 10.1
13081
for installation of gas fired boilers of rate input not
exceeding 70kW net for further information.
Before operating the boiler the condensate trap must be
filled with water.