834702_33GB_012005.qxd 09.03.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 2 Table of Contents Page 1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Contents included with boiler . . . . . . . . . . . . . . 1.2 Installation accessories . . . . . . . . . . . . . . . . . . . 3 3 3 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 General Information . . . . . . . . . . . . . . . . . . . . . 2.2 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Showers . . .
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 3 List of Contents 1 1 List of Contents 1.2 Installation accessories 1.1 Contents included with boiler Ensure that all contents are included before commencing installation. DO NOT remove the boiler from the polystrene base at this stage. Cold water supply pressure If the cold water inlet pressure exceeds 6.0 bar an approved pressure reducer must be installed in the cold water inlet to the boiler, the setting of the reducer should be 4.0 bar.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 4 2 Introduction 2 Introduction 2.1 General Information 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. aquaPLUS boiler The aquaPLUS is a fully automatic, wall mounted, room sealed combination boiler for central heating and domestic hot water.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 5 Boiler Specification 3 3 Boiler Specification 3.1 Technical data aquaPLUS VUI 362-7 Units Maximum CH heat input (net) CH heat output range (80/60 °C) Maximum DHW heat input (net) DHW heat output DHW flow rate ∆T = 35 °C rise (continously) DHW flow rate at factory set temperature rise (∆T = 42 °C) Mains water pressure required for max. flow rate Minimum water flow rate Mains water pressure required for min.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 6 3 Boiler Specification 3.2 Boiler connections 3.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 7 Boiler Specification 3 1 30 2 3 4 29 28 5 6 27 7 8 26 25 9 24 10 23 11 22 21 12 13 20 19 14 18 15 17 16 Fig. 3.
34702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 8 4 General Requirements 4 General Requirements 4.1 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. 4.2 Related Documents 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.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 9 General Requirements 4 4.5 Flue system 4.5.1 Top outlet flue system (100 mm outside diameter) The top outlet horizontal flue system (Art. No. 303 807) is suitable for installations up to 720 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 3.2 m. Both 90° bends and 45° elbows are also available to increase siting flexibility.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 10 4 General Requirements 4.5.3 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.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 11 General Requirements 4 4.6 Air supply Detailed recommendations for air supply are given in BS 5440: Part 2. It is not necessary to have an air vent in the room or internal space in which the boiler is installed. 4.7 Cupboard or compartment ventilation The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during operation is very low.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 12 4 General Requirements 4.9.7 Pump specifications 700 Lift [mbar] 4.9.6 Expansion vessel The aquaPLUS incorporates a 10 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 100 litres.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 13 Boiler Installation Sequence 5 5 Boiler Installation Sequence 5.1 General 210 5.1.1 Preparation of boiler location Clearances required Mount the boiler on a flat and vertical area of wall of sufficient area for the boiler plus the required clearances for installation and servicing.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 14 5 Boiler Installation Sequence 5.2 Using boiler template Fix the paper template to the wall ensuring that the correct flue exit point has been identified, ensure that the template is vertical. The template shows 2 60/100 > 210 122 - The position of the fixing holes for the boiler mounting bracket. - The position of the connections. - The position of the flue exit hole. - Upper hole (2) indicates top outlet flue with flue turret facing rearward.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 15 Boiler Installation Sequence 5 5.3 Fitting the boiler hanging bracket Fix the hanging bracket (2) to the wall using the fixings supplied. (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. 5.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 16 5 Boiler Installation Sequence 5 5.7 Gas supply • Connect the 15 mm compression gas service cock (1) and 22 mm copper outlet tail (3) as supplied with the appliance (2) and tighten. • Connect a gas supply pipe of not less than 22 mm diameter to the copper tail. • Tighten all connections. (Ensure the gas supply pipework is adequately sized such that a 20 mbar gas pressure is available at the boiler inlet at full flow rate). 5.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 17 Boiler Installation Sequence 5 5.9 Central heating flow and return pipework Before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris. 5.10 Connect the flue system to the boiler • Refer to separate air/flue duct installation instructions included with the boiler.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 18 5 Boiler Installation Sequence 5 5.11 Electrical installation General requirements Important: All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations). The boiler is supplied for connection to 230 V, ~ 50 Hz supply fused at 3 A rating. Connection to the mains supply shall be made via a fused 3 pin plug to an unswitched shuttered socket, both complying to the requirements of BS1363.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 19 Boiler Installation Sequence 5 2 1 Fig. 5.9: Exposed rear view of switchgear cabinet 3 7 8 9 L N 3 4 5 RT 24V 230V RT 230V Fig. 5.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 20 5 Boiler Installation Sequence 5 5.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 21 Boiler Installation Sequence 5 5.14 Controls External electrical controls The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. Terminals 3 and 4 are linked together when the boiler is supplied. If external controls are used, this link must be removed, and the controls connected across terminals 3 and 4.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 22 5 Boiler Installation Sequence 5 DO NOT USE IN UK! 20 VDC 7 8 9 L N MAINS SUPPLY 230 V 50 Hz N L 3 A FUSE 5.18 Anti-cycling ‘economiser’ control The boiler incorporates a built in anti-cycling control to ensure that energy wasteful short cycling of the boiler cannot occur.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 23 Commissioning Part I 6 6 Commissioning Part I 6.1 Preliminary electrical checks Check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity. 6.2 Gas supply The complete gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with BS 6891. In IE the current edition of IS 813.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 24 7 Gas supply adjustments (Commissioning Part II) 7 Gas supply adjustments (Commissioning Part II) 7.1 Gas inlet working pressure To check the gas inlet working pressure: • Lower the front panel of the boiler. • Lower the control panel. • Slacken the sealing screw (1) located at measuring point "P.IN". • Attach U-gauge to the inlet test point on the gas valve (2). • Ensure that the gas service valve is open.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 25 Gas supply adjustments (Commissioning Part II) 7 7.2 Main burner pressure The burner pressure on this appliance has been factory set and does not require adjustment. To check the main burner pressure connect the U-Gauge as follows. 1a • Remove front case and combustion chamber cover. Note! All measurements and adjustments to the gas valve must be done with the combustion chamber cover removed.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 26 7 Gas supply adjustments (Commissioning Part II) 7.3 Adjusting to the maximum heat load (nominal load) • Remove the cap (1). • Set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap. • Turn off the boiler at the main ON/OFF control. • Press and hold the "+" button, while pressing the button turn the main ON/OFF control to the "1" ON position.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 27 Gas supply adjustments (Commissioning Part II) 7 7.4 Adjusting the ignition rate • Undo screw and remove the cap (1). • Disconnect the modulating coil wires from the gas valve, set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap. • Turn off the boiler at the main ON/OFF control. • Press and hold the "+" button, while pressing the button turn the main ON/OFF control to the "1" ON position.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 28 7 Gas supply adjustments (Commissioning Part II) 7.5 Adjusting the central heating output (range rating) The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the boiler, as follows: • Connect the U-gauge to check burner pressure. • Use Table on page 30 to determine the central heating output required.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 29 Gas supply adjustments (Commissioning Part II) 7 Note! Following adjustment of the central heating output, the new output can be checked using the gas rate table as detailed. 5 After setting, press and hold the "i" button for five seconds or until the display stops flashing. The new setting value is now memorised. The new main burner pressure can now be checked. If the new output is not correct repeat steps 3 to 5.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 30 7 Gas supply adjustments (Commissioning Part II) 7 7.6 Checking the gas valve mid setting point To ensure the most efficient operation of the boiler a gas valve mid setting point is necessary. This mid setting point has been factory set and adjustment of this point is only required after exchanging either the electronic circuit board or gas valve or converting the boiler to another gas type. To check the mid setting point proceed as follows.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 31 Gas supply adjustments (Commissioning Part II) 7 7.8 Fit boiler casing • Carefully push case (1) onto the boiler such that the locating points either side at the top of the boiler engage. Push the casing onto the securing clips at the bottom of the boiler. • Close control panel (2). • Secure control panel by turning both securing fasteners (3) clockwise by 90°. • Close front door (4).
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 32 8 Functional checks (Commissioning Part III) 8 Functional checks (Commissioning Part III) 8.1 Functional checks Once the unit has been installed and the gas supply has been checked, operate the system to ensure that it is working correctly. • Operate the system, following the operating instructions supplied with the boiler. • Check the system for water leaks and escaping gas.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 33 Functional checks (Commissioning Part III) 8 8.4 Heating mode • Activate the system and ensure the tank is fully charged. • Ensure that the heating system is calling for heat. • Press the ”i“ key. 1 Status code “S.4” appears on the display to indicate that heating is functioning correctly. Fig. 8.5: Pump speed Fig. 8.4: Display indication during heating 8.5 Adjusting pump speed The unit is fitted with a two-speed pump.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 34 8 Functional checks (Commissioning Part III) 8.7 Handing over to the user Set the maximum radiator temperature control to the desired setting. Set the maximum hot water temperature control to the desired setting.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 35 Servicing 9 9.3 Cleaning the burner and primary heat exchanger • • • • • • • • • • • • • 2 Turn off the boiler. Isolate the electrical supply to the boiler. Remove the boiler case as described on page 15. Turn off the gas service valve. Turn off the boiler CH service valves. Turn off the cold water inlet service valve. Release the three clamps (1), remove the combustion chamber cover (2) and then remove the flue gas connector (2a) on the fan.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 36 10 Fault finding 10 Fault finding 8 7 10.1 Introduction The aquaPLUS boilers have an inbuilt advanced multifunction diagnostic display to assist with fault finding in the unlikely event of a boiler malfunction. The display features the following four modes: Normal Mode Under normal conditions the boiler display will show the boiler flow temperature, this indicates that the boiler is operating correctly after an internal self check.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 37 Fault finding 10 10.2.1 Procedure Note: Always check the operation of the boiler for central heating first before checking hot water operation. Do not open a hot water tap unless instructed to do so by the fault finding guide. 1. If a fault code is showing in the boiler display follow the fault finding charts referring also to the fault code and diagnostic mode tables. 2.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 38 10 Fault finding 10.3 Status Mode The status mode provides information about the current operating status of the boiler. To display status mode proceed as follows: • Press the "i" button below the display, and a status code will appear in the display indicating the current operational status of the boiler (see table below).
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 39 Fault finding 10 10.4 Diagnostic Modes In order to assist with the pinpointing of a particular fault it is possible to use the boiler display in a diagnostic mode to interrogate the boiler about the status of certain components. • If necessary, you can now alter the value by pressing "+" or "-" buttons. (When altering values display will flash).
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 40 10 Fault finding Display Indication Displayed values/adjustment values d.65 Maximum ignition time in s d.67 Remaining burner anti-cycling period in min d.68 Number of unsuccessful attempted 1st ignitions d.69 Number of unsuccessful attempted 2nd ignitions d.71 Maximum target value for heating system flow 0 = 82 ° C, 1 = 87 °C (factory-adjustment: 82 °C) temperature d.72 Pump over run time after filling hot water store 0, 1, 2, .....
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 41 Fault finding 10 10.5 Fault codes Fault codes take priority over all other display functions in the event of a system fault occurring. If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each. 10.6 Fault memory The fault memory stores detalis of the ten most recent faults. • Press the "i" and "-" buttons simultaneously. Display F.00 F.01 F.02 F.03 F.10 F.11 F.12 F.13 F.20 F.22 F.23 F.24 F.27 F.
Yes Go to sheet C No Boiler ON/OFF control defective, change electronic board Repair external fault No No Does ON/OFF knob operate switch on electronic board Seite 42 Yes Yes Replace switch mechanism Is 230VAC present across terminals L and N? Yes Is the continuity across fuse F1? No Is 230VAC present across terminals 3 and 5? Instructions for installation and servicing aquaPLUS VUI 362-7 No Yes Go to sheet B Is voltage between 16-26 VDC present across terminals 8 and 9? No Yes Note
834702_33GB_012005.qxd Sheet B Turn off the main ON/OFF control to the "0" position 09.03.2005 16:26 Uhr Disconnect the power supply to the boiler Replace fuse F1 Turn the main ON/OFF control to the "1" position No Is t here a display on the LCD panel? Seite 43 Instructions for installation and servicing aquaPLUS VUI 362-7 Check operation of pump and fan Check transformer 230 VAC primary (black/red) and approx. 17 VDC secondary (blue/brown) Yes Produce central heating demand.
Yes Does failure code show on LCD display? No Is 230 VAC present across terminals 4 and 5 No Go to sheet D No Yes Disconnect built in timer (if fitted) Does ignition commence? Instructions for installation and servicing aquaPLUS VUI 362-7 No Yes External fault: Check all external controls are calling for heat, replace or repair as necessary (see also note 1 sheet A) Replace defective timer Seite 44 Check diagnostic code D.08 (see page 39). Is heating demand present? 09.03.
No Does the boiler commence ignition No No Check diagnostic code D.24 (see page 39) equal 1? (see page 38) is S.33? Are electrodes sparking at the burner? Yes Yes Check pitot tube (in fan outlet) and air hoses are not obstructed and correctly aligned. Check or replace air pressure switch. 837/637 Check 4 pin connector for fan speed control.
No Does burner light within 3 ignition attempts? No Reset boiler Is burner indicator illuminated? Yes Does burner shut down after approx. 15 secs. No Yes Check flame rectification lead and electrode Does status code (see page 38) No Go to sheet F Yes Replace pump show S. 53? Yes Seite 46 Check gas supply Yes Does burner light? No Check/replace gas valve as necessary Is burner indicator illuminated Check water pressure in central heating system, refill and vent.
Yes Does burner flame modulate/ go out when radiator temperature control is turned left to the horizontal position at flow temperature of approx. °50 C? Yes Sheet F Does heating flow pipe temperature rise? Yes Go to sheet G No Replace electronic board 09.03.2005 16:26 Uhr Does flame indicator glow and flames increase in size to full gas rate after approx. 2 mins? 834702_33GB_012005.
Yes on display light up? Check hot water flow rate and temperature. Compare with technical data, if flow is not sufficient, check incoming main and cold water filter.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 49 Diagrams 11 11 Diagrams 11.
fan unit 23 11 X2 T 1,25 = F3 X1 L N 3 4 5 X3 X12 NTC DHW T2 X14 X13 X601 U100 NTC flow coding resistor NTC earth ionisation electrode lifting magnet Aqua sensor NTC DHW NTC tank NTC return pump air pressure switch 1 7 8 9 2 flow NTC 9 21 8 20 7 19 6 18 5 17 4 16 3 15 X2 X20 3 13 1 2 14 1 13 X4 (VUV) X7 accessories X8 4 14 Switch gear cabinet 5 15 22 10 gas valve 6 16 diverter valve 7 17 Aqua sensor DHW pump 8 18 air pressure switch 9 19 ignition electrod
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 51 Short parts list 12 12 Short parts list Description Part No. Burner Burner chamber group: Distributor tube: Natural gas: LPG: Key No. 031 532 Fig. 10.1 126 795 126 796 Ignition electrode 090 709 Fig. 10.2 Fan 190 215 Fig. 10.3 Gas valve Natural gas: 053 462 LPG: 053 463 Fig. 10.5 Flow-NTC/Return-NTC Storage tank-NTC Warmstart-NTC 252 805 Fig. 10.6 Main heat exchanger 065 087 Fig. 10.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 52 12 Short parts list Fig. 10.1 Fig. 10.2 Fig. 10.3 Fig. 10.5 Fig. 10.6 Fig. 10.7 Fig. 10.8 Fig. 10.9 Fig. 10.10 Fig. 10.11 Fig. 10.12 Fig. 10.
834702_33GB_012005.qxd 09.03.2005 16:26 Uhr Seite 53 Short parts list 12 Fig. 10.14 Fig. 10.15 Fig. 10.16 Fig. 10.17 Fig. 10.18 Fig. 10.19 * Fig. 10.20 * Fig. 10.21 * Fig. 10.22 * For these components, please observe the associated installation and removal instructions relating to spare parts.
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09.03.2005 16:26 Uhr Seite 60 834702_34 GB 03 2005 Subject to alteration 834702_33GB_012005.
