Vaillant ecoMAX 646 Installation And Maintenance Manual

Also see for ecoMAX 646: Instructions for use Installation and maintenance manual

Vaillant ecoMAX 646 Installation And Maintenance Manual Manual pdf 27 page image

27Installation and maintenance manual ecoMAX 646 / 0020020158_027.1.3 Overview of the inspection and maintenance tasksNo. Activity Column 1 In-spection mustbe carried outonce a yearColumn 2 Main-tenance1 Check the air / gas flue system and ensure it is not blocked, damaged and is fitted correctly. x2 Measure the gas rate during operation (see table 5.3 inside the chapter Start-up). If the gasrate is lower than the minimum gas rate follow the maintenance instructions (column 2). x3Check combustion by measuring the CO and CO2 values, compare to table 5.2. If the measure-ment is outside the tolerances follow the maintainance instructions, (column 2) If a flue gasanalyser is not available check the ignition and burner flame picture through the sight glass,if incomplete combustion is evident perform the maintanance instructions (column 2).x4 Isolate the appliance from the electrical mains supply, close the gas and water service valves. x5 Visually inspect the general heat exchanger area for signs of corrosion, sooting or otherforms of damage. If damage is evident perform the tasks in the maintenance column 2. x6Remove the compact thermal module (as described in section 7.2.1) if maintenance scheduleis required from steps 2, 3 or 5 above. Clean the primary heat exchanger. Fit a new burnerdoor seal kit (observe the assembly instructions enclosed with the seal kit). Refit the thermalcompact module and tighten the nuts.x7 Clean the air intake tube. x8 Check all the appliances electrical connections and make adjustments if necessary. x x9 Check the appliance generally, check for dirt / dust and clean if necessary. x x10 Check and clean the condensate trap and flexible condensate hose. x x11 Open the gas and water service valves, re-establish the electrical supply and turn on theboiler. x x12 Perform a test operation of the appliance including the heating and hot water systems andbleed the system if necessary. x x13 Re-pressurise the appliance/system up to between 1.0 - 2.0 bar (depending on the staticheight of the system). x x14 Measure the gas rate during operation and ensure it is within the tolerances specified (seetable 5.3 inside the chapter Start-up). x15Re-check the combustion by measuring the CO and CO2 values, (compare to table 5.2).Ensure that the measurement is within the tolerances. If a flue gas analyser is not availablecheck the ignition and burner flame picture visually through the site glass.x16 Check the boiler for leaks of any kind, rectify as necessary. x x17 Complete the gas commissioning checklist (Benchmark). x xTab. 7.1 Inspection and maintenance stepsInspection and maintenance 77.1.4 Functional check of boiler operation• Carry out a functional check of the boiler operationas previously detailed.• Remove the appliance casing as detailed and operatethe boiler.• Inspect the burner operation through the viewingwindow.• Check that the flames are evenly covering the surfaceof the burner.• Inspect for signs of excessive flame lift or sooting.7.2 Servicing the compact thermal module7.2.1 Removing the compact thermal moduleThe compact thermal module consists of a speed-con-trolled fan, combined gas/air electronic gas valve, the gassupply (mixer tube) for the fan of the pre-mix burner andthe pre-mix burner itself. These four components makeup the complete assembly that is the compact thermalmodule. Proceed as follows to dismount it: (see fig. 7.1)Danger!There is danger of being injured or scalded atthe compact thermal module and at all compo-nents carrying water. Only work on the compo-nents once they have cooled down.The mixer tube (7) between gas control unitand burner may not be opened. It can only beguaranteed that this component is gas-tightafter it has been inspected at the factory.• Turn off the gas supply to the appliance.• Lower the electronics box.• Undo the fastening screw of the air intakepipe (5) and pull the air intake pipe forward (3);remove the air intake pipe from the air intake socket.• Pull the two plugs of the ignition and earthingconnection off the ignition electrode (6).• Undo the gas pipe union (10) on the underside of theelectronic gas valve (fig. 7.2).• Pull the cables (9) off the fan motor and the cable (8)off the electronic gas valve.• Undo the five nuts (2).