Vaillant 065 008 Guide

Integral condensing heat exchanger
Primaire warmtewisselaar
Article number: 065 008 (28 kW), 065 007 (23 kW)
Artikelnummer 06-4991 (28 kW), 06-4993 (23 kW)
INSTRUCTIONS FOR INSTALLATION
MONTAGEVOORSCHRIFT

2
Fig. 1.1
Legend to fig. 1.1
1 heat exchanger
2 sealing profile
3 flow pipe
4 bow
5 return pipe
6 clamp
7 oval head screw
8 hexagon nut
9 rectangular sealing ring
10 spring
11 ignition plug
12 NTC lead extension wire
GW 878/1

3
Please read these instructions for
installation thoroughly before
working on the appliance. These
instructions contain important notes on
the replacement of the spare part.
Please refer also to the instructions for
installation and servicing, supplied
with the boiler.
We do not accept any responsibility
for damage caused by the non-
observance of these instructions for
installation.
Contents Page
1 Equipment 3
2 Defined application 3
3 Precautions 3
4 Preliminary measures 4
5 Pre-assembly of the
new integral condensing
heat exchanger 5
6 Removal of the old
heat exchanger 6
7 Installation of the new
integral heat exchanger 13
8 Commissioning 15
1 Equipment
The spare parts kits for the heat
exchanger, art. no. 065 008 (28 kW)
and 065 007 (23 kW) contain the
following components:
1 heat exchanger
2 sealing profile (2)
3 flow pipe
4 bow
5 return pipe
6 clamp
7 oval head screw (2)
8 hexagon nut (4)
9 rectangular sealing ring (2)
10 spring
11 ignition plug
12 NTC extension lead
(pre-asssembled)
2 Defined application
The existing heat exchanger may only
be replaced by the Vaillant integral
condensing heat exchanger in the
following appliances:
•Art.-Nr. 065 007 (23 kW) for:
VUW 236, VU 186
•Art.-Nr. 065 008 (28 kW) for:
VUW 286, VU 226
Only original Vaillant spare parts must
be used.
The valid spare part catalogue indica-
tes the necessary spare parts. Informa-
tion on this subject can be obtained
from the Vaillant sales department.
3 Precautions
The replacement of the heat exchan-
ger, must only be carried out by a
competent installer who is also respon-
sible for the correct installation and
recommissioning.
In the UK ”CORGI”registered instal-
lers undertake the work to a safe and
satisfactory standard.
Furthermore, the rules and regulations
mentioned in the instructions for instal-
lation and servicing must be observed.

4
Fig. 4.1
4 Preliminary measures
•Completely remove the front panels
according to the instructions for
installation and servicing supplied
with the boiler.
•Remove the combustion chamber
front cover.
•Turn off appliance by switching off
main switch.
•Pull off air orifice (1); see fig. 4.1.
High flow temperatures may cause
burns and scalds.
Check flow temperature and cool
appliance, if necessary.
Cooling the appliance
•Turn on appliance by switching on
main switch.
•Ensure heat demand,
For VUW, open a hot water tap.
For VU, turn on all external controls.
The appliance remains in the start
mode. There is, however, no igniti-
on and no gas supply. The pump
and the fan are in operation and
cool the appliance. The ignition
cycle is stopped by the control after
3 minutes. (Fault signalling F 30).
During this period the boiler should
be sufficiently cooled.
•Check appliance temperature,
repeat above procedure if required.
•Turn off appliance by switching off
main switch.
•Isolate the boiler from the electrical
supply by disconnecting the plug at
the socket outlet (if there is an isola-
ting switch only, then remove the
fuse from the switch).
GW 879/0

5
Fig. 5.1
5 Pre-assembly of the
new integral conden-
sing heat exchanger
•Remove transport plugs from the
flow and return connections of the
new integral condensing heat
exchanger.
Keep transport plugs as they are
necessary for the return of the old
heat exchanger.
•Insert return pipe (1) in the return
connection of the heat exchanger.
Lock with spring (2).
Fix return pipe with clamp (3) and
screw (4) to the heat exchanger.
•The flow pipe is mounted later on
when the heat exchanger has been
installed.
GW 880/0

6 Removal of the old
primary heat
exchanger
Preliminary measures
•Release control box and tilt for-
wards.
•Check automatic air vent adjacent
to pump, open it if closed.
•Turn off central heating service
values (flow and return).
•Attach a length of rubber tube to
draining points and drain the water
from the boiler into a suitable con-
tainer by undoing the drain points
one turn (drain points located abo-
ve flow and return service valves).
Removal
Pull off the following plug-in connec-
tions –start at the fan and proceed
anti-clockwise:
•control (1) and supply connection
(2) at the fan
•Plug (3) of the supervision electrode
•AMP-plug (4) at the NTC-sensor of
the heat exchanger on the left
•Two AMP-plugs (5, 6) at the NTC-
sensors of the flow pipe
•Ignition plug (7) and earth cable (8)
at the ignition electrode
•Unscrew ignition plug (7) from HT
lead by turning it to the left; release
plastic cable tie of cable (11).
•Screw new ignition plug included in
the replacement set to the HT lead.
The small opening of the black insula-
tion socket of the ignition plug causes
a slight mechanical resistance when
the plug is screwed down. Screw into
HT lead to the limit stop.
•Release NTC earth (9) at the flow
pipe. Keep screw (10) for later use!
6
NOTE Abb. 6.1
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7
Fig. 6.2
Fig. 6.3
•Undo union on the flow pipe (1) at
the T-piece (see fig. 6.2). Remove
sealing washer and brass restrictor.
The restrictor should be discarded
as it is no longer required.
The lower front panel (2) of the
appliance can be used to collect
any water.
Up to 0.5 l water will be released.
(fig. 6.3)
•Remove spring (1) which secures
the flow pipe (2) at the heat
exchanger.
•Detach flow pipe.
GW 882/0
GW 883/0

(fig. 6.4)
•Remove spring (1) of the return
pipe (2) at the heat exchanger.
Do not remove the spring (3) neces-
sary for securing the connecting
pipe to the combustion chamber!
If the connecting pipe is released from
the combustion chamber, it will be
necessary to remove the complete
appliance from the wall.
8
Fig. 6.4
Fig. 6.5
NOTE
!
•Remove return pipe (1) and plug it
into a different socket for better
draining as shown in Fig. 6.5.
The lower front panel (2) of the
appliance can be used as collec-
ting pan.
Up to 0,5 l water will be released.
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9
Fig. 6.6
Fig. 6.7
•Pull lock (1, fig. 6.6) forwards by
using a screw driver or similar. The
flue gas duct is released from the
flue collector box/condensation
sump.
(fig. 6.7)
•Pull forward captive spring (1) at
the condensation trap.
•Press condensation trap down-
wards.
Note: Some appliances are equipped
with a condensation water pipe with
bayonet fixing. This can be disconnec-
ted by pulling the handle forwards.
GW 886/0
GW 899/0

•Lift leaf springs (1 and 2, fig. 6.9)
at the burner and pull forwards to
remove –see fig. 6.8 –.
•Keep leaf springs for further use.
Only release spring as shown in
fig. 6.8.
10
Fig. 6.9
Fig. 6.8
NOTE
GW 888/0
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•Slightly lower flue collector
box/condensation sump (1, fig.
6.11) at the front and pull out.
•Replace the sealing profile at the
flue collector box with the new one
supplied with the spare part set.
•The sealing profile is placed in the
groove of the flue collector box,
with the rounded edge protruding.
Do not lubricate the sealing profile!
(fig. 6.10)
•Slightly lift burner and fan (1) at the
front and pull out.
•Replace the sealing profile on the
burner with the new one supplied
with the spare part set (2, fig. 1.1).
•The sealing profile is placed in the
groove of the burner cap, with the
rounded edge protruding.
Do not lubricate the sealing profile!
11
Fig. 6.10
Fig. 6.11
NOTE
NOTE
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12
Fig. 6.12
•Remove the four retention nuts (1,
fig. 6.12) of the heat exchanger
and remove heat exchanger (2, fig.
6.12).
•Drain detached heat exchanger by
tilting it several times.
•Close flow and return openings
with the transport plugs. Supplied
with new heat exchanger.
•Place heat exchanger in the spare
part cardboard box.
•Return removed heat exchanger to
Vaillant.
GW 902/0

13
Fig. 7.1
Fig. 7.2
7 Installation of the
new integral conden-
sing heat exchanger
(fig. 7.1)
•Place the new heat exchanger on
the upper stud bolts (1) for suspen-
sion.
Then place the heat exchanger on
the lower stud bolts (2) and simul-
taneously insert the return pipe (3)
in the connection (4).
•Loosely screw down heat exchan-
ger with the new nuts.
•Do not yet tighten the nuts!
•Do not use the old nuts.
(fig. 7.2)
•Push earth cable (1) of the NTC-
sensor through the packing (4) of
the new flow pipe (2) from the top
to the bottom.
•Insert flow pipe (2) from above
through the opening of the combu-
stion chamber and then into the
flow connection of the heat exchan-
ger. Secure with bow (3). Ensure
that the bow (3) is fully seated.
•Screw down flow pipe (2) at the
T-piece (6) with the new sealing (5).
The old brass restrictor must not be
used.
•Place packing (4) in the opening of
the combustion chamber.
•Fix the earth cable of the NTC-
sensor (1) with the existing slotted
screw (7) to the lower screw hole of
the T-piece (6).
GW 903/0
GW 894/0

(fig. 7.4)
•Close boiler drain valves (located
above boiler flow and return servi-
ce valves).
•Open flow and return service val-
ves at the appliance. Fill appliance
to 2 bar, (refer to section 5 of the
installation and servicing instruc-
tions supplied with the boiler).
•Test joints for soundness.
Carry out visual check.
•Check that the cap on the automa-
tic air vent is open 1 to 2 turns.
•Re-connect the following plug-in
connections (see fig. 6.1, page 6):
plug at the supervision electrode
(3), two black AMP-plugs at the
NTC-sensor of the flow pipe (5, 6),
ignition plug and earth cable at the
ignition electrode (7, 8).
•Connect extension lead for the
NTC-sensor (at the heat exchanger
on the right) with the red AMP-plug.
(formerly connected to old heat
exchanger NTC positioned on left
hand side, see 1, fig. 7.4). Locate
this connecting lead into the rear
leaf spring (2) below the heat
exchanger (see fig. 7.4).
A lead loosely laid in the combustion
chamber can be damaged by the
spring of the condensation sump.
14
Fig. 7.3
Fig.7.4
NOTE
(fig. 7.3)
•Align heat exchanger.
The locating lugs must fit into the
hole (1) and the slot (2) of the
upper brackets.
•Tighten the four retention nuts (3).
Start with the retention nut on the
upper right and proceed anti-clock-
wise.
GW 895/0
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GW 904/1
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Fig. 7.5
Mount the following parts in reverse
order to the removal:
(fig. 7.5)
•Flue collector box/condensation
sump (1)
•Burner with fan (2)
•leaf springs (3)
•Position air orifice (4)
•Replace lock of flue gas duct and
flue collector box at the rear and
fully engage (audible click) (5)
Note: The lock is stiff and must proba-
bly be pressed with a tool, e.g. the
butt of a hammer.
•Position condensation water pipe at
the flue collector box and replace
supporting spring. Ensure that a
correct seat of the sealing profile
is obtained (6)
•Connect control and supply
connection to the fan (7)
•Secure the spacing clip to the
flow pipe and insert the
HT lead (8)
•Secure the spacing clip to the
diverter valve connection tube
and insert the HT lead (9)
8 Commissioning
•Tilt control box upwards and secure
in position using locating screw.
•Close combustion chamber.
•Switch on appliance, re-commission
and check functioning of applian-
ce, (refer to section 5 of the instruc-
tions for installation and servicing
supplied with the boiler).
•Mount casing. Ensure all electrical
leads are correctly located.

16
Fig. 1.1
Legenda bij fig. 1.1
1 Warmtewisselaar
2 Afdichtingsprofielen
3 Aanvoerleiding
4 Borgveer
5 Retourleiding
6 Beugel
7 Zeskantschroef
8 Borgmoer
9 Pakkingring
10 Borgveer
11 Ontsteekelektrodestekker
12 NTC-kabel
GW 878/1

17
Lees s.v.p. dit montagevoorschrift
zorgvuldig door. Het bevat belang-
rijke aanwijzingen voor het vervangen
van onderdelen. Raadpleeg in dit ver-
band ook de bijbehorende installatie-
en bedieningsvoorschriften van het
toestel.
Vaillant is niet aansprakelijk voor
schade die voortvloeit door het niet in
acht nemen van de aanwijzingen uit
dit montagevoorschrift.
Inhoud blz.
1 Pakket 17
2 Toepassing 17
3 Veiligheidsvoorschriften 17
4 Voorbereiding 18
5 Voormontage van de
nieuwe primaire
warmtewisselaar 19
6 Demontage van de
oude warmtewisselaar 20
7 Montage van de
nieuwe primaire
warmtewisselaar 27
8 In bedrijfstellen 29
1 Pakket
Het pakket van de primaire warmte-
wisselaar
art. nr. 06-4991 (28 kW) en
art. nr. 06-4993 (23 kW) bevat de
volgende onderdelen:
1 Warmtewisselaar
2 Afdichtingsprofielen (2x)
3 Aanvoerleiding
4 Borgveer
5 Retourleiding
6 Beugel
7 Zeskantschroef (2x)
8 Borgmoer (4x)
9 Pakkingring (2x)
10 Borgveer
11 Ontsteekelektrodestekker
12 NTC-kabel (voorgemonteerd)
2 Toepassing
De Vaillant integrale condensatie-
warmtewisselaar art. nr. 065 007
(23 kW) en 065 008 (28 kW) mag
alleen ter vervanging van een oude
warmtewisselaar gemonteerd worden
in de volgende apparaten:
•Art.-Nr. 065 007 (23 kW)
VUW 18-22/6, VU 18/6
•Art.-Nr. 065 008 (28 kW)
VUW 23-28/6, VU 23/6
Licht bij schade aan een onderdeel
s.v.p. per omgaande de leverancier
in.
Indien extra onderdelen nodig zijn,
mogen uitsluitend de Vaillant onderde-
len gebruikt worden.
De eventueel extra benodigde onder-
delen staan vermeld in de onderdelen-
catalogus. Inlichtingen hierover zijn
verkrijgbaar bij de verkooppunten van
Vaillant.
3 Veiligheidsvoor-
schriften
Het vervangen van de primaire warm-
tewisselaar mag alleen door een
erkende installateur uitgevoerd wor-
den.
Deze is verantwoordelijk voor het cor-
rect uitvoeren van de werkzaamheden
en de hernieuwde ingebruikname.
Verder dienen de bijbehorende instal-
latie- en bedieningsvoorschriften,
regels, normen en richtlijnen in acht
genomen te worden.

18
Fig. 4.1
4 Voorbereiding
Let op!
Hoge aanvoertemperaturen kunnen
verbrandingen en brandwonden vero-
orzaken. Controleer de aanvoertem-
peratuur en indien noodzakelijk het
toestel afkoelen.
Afkoelen van het toestel
•Maak het toestel spanningsloos
door de stekker uit de wandcontact-
doos te nemen.
•Demonteer de front- en zijpanelen
volgens de installatievoorschriften.
•Verwijder de deksel van de onder-
drukkamer.
•Schuif de luchtmeetring (1) naar
rechts. Zie fig. 4.1.
•Neem het toestel in bedrijf door de
stekker in de wandcontactdoos te
steken.
•Vraag warmte door de temperatu-
urinstelling op kamerthermostaat in
de hoogste stand te draaien.
Opmerking!
Het toestel blijft nu in de startfase,
dat wil zeggen geen gasvrijgave
en geen ontsteking. Pomp en venti-
lator komen in bedrijf en koelen het
toestel. De startpoging wordt na
drie minuten afgebroken. De fout-
melding F 30 verschijnt op het dis-
play.
•Druk op de resettoets.
•Controleer de aanvoertemperatuur
van het toestel (display en hand-
test).
•Maak het toestel spanningsloos als
de aanvoertemperatuur voldoende
gedaald is door stekker uit de
wandcontactdoos te nemen.
GW 879/0

19
Fig. 5.1
5 Voormontage van de
nieuwe primaire
warmtewisselaar
•Verwijder de transportstoppen van
de aanvoer- en retouraansluiting
van de nieuwe primaire warmtewis-
selaar.
Opmerking!
Transportstoppen bewaren. Deze
zijn nodig voor het terugzenden
van de oude warmtewisselaar.
•Steek de retourleiding (1) op de
retouraansluiting van de primaire
warmtewisselaar.
•Borg met de borgveer (2) de aans-
luiting.
•Bevestig de retourleiding (1) met de
beugel (3) en zeskantschroef (4)
aan de primaire warmtewisselaar.
•Monteer de aanvoerleiding later als
de primaire warmtewisselaar is
ingebouwd.
GW 880/0

6 Demontage van de
oude warmtewisselaar
Voorbereiding
•Maak de schakelkast los en klap
deze naar voren.
•Controleer of de automatische ont-
luchter op de pomp geopend is.
•Sluit indien gemonteeed de servi-
ceafsluiters voor aanvoer en retour.
•Open de aftapventielen.
Demontage
Maak de volgende stekkerverbindin-
gen los. Begin bij de ventilator en
werk tegen de wijzers van de klok in.
Zie Fig. 6.1.
•Besturings- (1) en voedingskabel (2)
van de ventilator.
•Stekker (3) van de bewakingselek-
trode.
•AMP-stekker (4) van de NCT-voeler
aan de zijkant van de primaire
warmtewisselaar.
•Twee AMP-stekkers (5 en 6) van de
NCT-voelers aan de aanvoerlei-
ding.
•Ontsteekstekker (7) en massadraad
(8) van de ontsteekelektrode.
•Ontsteekstekker van de hoogspan-
ningskabel afschroeven (naar links
draaien) en de kunststof kabelbin-
der (11) losmaken van de hoog-
spanningskabel.
•Nieuwe ontsteekstekker uit de
ombouwset op de hoogspsannings-
kabel schroeven.
Opmerking!
De kleine opening van de ontsteek-
stekker veroorzaakt bij het indraaien
van de hoogspanningskabel een
geringe mechanische weerstand.
Hoogspanningskabel tot aan de aans-
lag indraaien.
•Maak de NTC massakabel (9) los
van de aanvoerleiding. Bewaar de
schroef (10) voor de montage later.
20
Abb. 6.1
GW 881/0