For the installer Instructions for installation and servicing aquaPLUS VUI 362-7 Gas fired room sealed fan assisted combination boiler with integrated 15 litre power store GB
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
2 Introduction 2 Introduction instructions. All boilers have a built in diagnostic system which indicates the operational status of the boiler. 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.
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.
3 Boiler Specification 3.2 Boiler connections 3.
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.
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.
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. A vertical flue system is also available (Art. No. 303 800).
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.
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.
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. If the nominal capacity of the built in expansion vessel is not sufficient for the heating system (for instance in case of modernization of old open systems) an additional expansion vessel can be installed external to the boiler.
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.
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.
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.
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.
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.
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.
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.
5 Boiler Installation Sequence 5 5.13 Electronic board layout Socket X2 for internal unit components Socket X4 for diverter valve Socket X7 for accessory box connection Socket X8 for VRC-VC connection F3 7 8 9 24V Do not use! L N Mains power supply: connections L, N and earth 3 4 5 230V Room thermostat, 230 V: connections 3, 4 and 5 Socket X12: pump connection Socket X14: gas valve connection Socket X13: fan unit connection Socket X601: store charging pump connection F1 Fig. 5.
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. Terminal 5 is an additional neutral connection for external neutrals such as from the anticipator of a room thermostat.
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. This control prevents the boiler from reigniting for a preset period of 5 minutes after central heating operation (the hot water operation is unaffected by this control and hot water can be drawn at any time).
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. The gas supply to the boiler can be purged by slackening the gas service valve beneath the boiler.
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. • Turn off the boiler at the main ON/OFF control.
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.
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. • Continue holding "+" button until display alternates between "P1, P2, P3, P11, P12 and P13".
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.
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. • Identify required range rating setting and note main burner pressure in mbar for that output.
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. 1 Simultaneously press the "i" and "+" buttons keys.
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. • Turn off the boiler at the main ON/OFF control.
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). • Open the punch-out holes in the cover panel (6) for the pipework installation. • Fit the bottom cover (6).
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. • Check that the flue has been correctly installed, according to the fitting instructions supplied with the flue assembly.
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. The pump is delivered with the switch (1) set to position III.
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. Instruct the user in the safe and efficient operation of the boiler, in particular the function of • • • • The boiler on/off control The maximum radiator temperature control The maximum hot water temperature control The pressure gauge Show the user how to operate any external controls.
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. Remove the retaining spring (3).
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.
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.
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). To cancel the status code mode proceed as follows: • Press the "i" button below the display or • Do not press any key for approximately four minutes.
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). Press and hold the "i" button to save the value to memory, when the value is saved the display will stop flashing.
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, .....250 s (factory-adjustment: 80 s) d.
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.28 F.29 F.
No Go to sheet B No Is the continuity across fuse F1? No Replace LCD display Yes Replace electronic board No Is 5 VDC present between 5V and GND test points on electronic board? Is there continuity across fuse F3? No No Yes Yes Is voltage between 16-26 VDC present across terminals 8 and 9? Yes Is 230VAC present across terminals 3 and 5? Yes Is 230VAC present across terminals L and N? Does ON/OFF knob operate switch on electronic board For test purposes, disconnect external controls fr
Instructions for installation and servicing aquaPLUS VUI 362-7 If fan commences operation, exchange gas valve No Yes Check/replace fan Replace electronic board Is there a display on the LCD panel? After approx. 20 secs. Does fuse F1 blow? Check/replace pump Check transformer 230 VAC primary (black/red) and approx. 17 VDC secondary (blue/brown) No Yes No No Produce central heating demand.
Yes Replace defective timer No External fault: Check all external controls are calling for heat, replace or repair as necessary (see also note 1 sheet A) Disconnect built in timer (if fitted) Go to sheet D Does ignition commence? Yes No Is 230 VAC present across terminals 4 and 5 Does failure code show on LCD display? No Yes No Check diagnostic code D.08 (see page 39).
Yes No Instructions for installation and servicing aquaPLUS VUI 362-7 Replace electronic board No Is 230 VAC present across fan terminals? No Yes Check/replace fan Replace electronic board Check air/flue gas system is correctly fitted and not obstructed Check flue restrictor correspond to flue length 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.
Yes Check burner pressure settings are correct Yes Does burner light? Check gas supply Yes Does burner light within 3 ignition attempts? No Does burner light 1st attempt? No No Replace electronic board No Does burner light? Check/replace gas valve as necessary Reset boiler Yes No Is burner indicator illuminated Replace electronic board No Is 230 VAC present at the pump plug connection? No Check pump is running? Check water pressure in central heating system, refill and vent.
Instructions for installation and servicing aquaPLUS VUI 362-7 Go to sheet G No Check partial load setting Yes Replace electronic board Check operation of boiler in DHW mode, does flame increase in size to full rate? Check connections and modulator, replace gas valve if burner still fails to increase to full rate Yes (see page 39) equals 1 Check diagnostic code D.
No No Check/replace hall sensor Does hot water indicator glow/flash now? Draw hot water at high rate Yes Replace electronic board Does green warmstart indicator flash now? Check/Clear impeller in Aquasensor, replace if necessary No indicator flash now? Does green warmstart Check cold water inlet is fully open and adjustment is at maximum flow rate Check cold water inlet pressure is sufficient and that cold water inlet filter is clear No on display light up? Does flow indicator (tap) Chec
Diagrams 11 11 Diagrams 11.
fan unit 22 10 X2 T 1,25 = F3 X1 L N 3 4 5 X3 X12 9 21 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 22 10 air pressure switch 1 7 8 9 2 flow NTC 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1 13 X2 X20 3 13 2 1 X4 (VUV) X7 accessories X8 4 14 Switch gear cabinet 5 15 3 gas valve 6 16 diverter valve 7 17 Aqua sensor DHW pump 8 18 air pressure switch 9 19 ignition el
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. 10.7 Expansion vessel (10 l) (heating) 181 079 Fig. 10.8 Switch and control board 130 821 Fig. 10.
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.
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.
Instructions for installation and servicing aquaPLUS VUI 362-7
Instructions for installation and servicing aquaPLUS VUI 362-7 55
83 47 02_30_GB 04/2003 Mü Subject to alteration Head Office: Vaillant Ltd.
