Vaillant ecoTEC exclusive 832 Technical data

For the installer
Installation and maintenance instructions
ecoTEC exclusive
Gas wall boilers with condensing appliance technology
GB, IE
ecoTEC exclusive 832
ecoTEC exclusive 838
Contents
1
1.1
1.2
1.3
Notes on the documentation...........................
Storage of the documents ......................................
Safety instructions and symbols ...........................
Validity of the manual .............................................
2
2.1
2.2
2.3
2.4
2.5
2.6
Description of the appliance ........................... 4
Design .......................................................................... 4
Type overview ............................................................ 4
CE label ........................................................................ 4
Gas council numbers ................................................ 5
Intended use ............................................................... 5
Identification plate .................................................... 5
3
3.1
3.1.1
3.1.2
3.1.3
Safety instructions and regulations .............. 5
Safety instructions ................................................... 5
Installation and setting ............................................ 5
If you smell gas.......................................................... 5
Changes to the surroundings of the
heating device............................................................ 5
Related documents ................................................... 6
3.2
4
4.1
4.1.1
4.2
4.3
4.4
4.5
4.6
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.7
5.8
5.9
5.10
5.10.1
5.10.2
5.10.3
5.10.4
5.10.5
5.10.6
6
6.1
6.1.1
6.1.2
6.1.3
2
3
3
3
3
Assembly ........................................................... 7
Scope of delivery ...................................................... 7
Transporting the appliance .................................... 7
Dimensioned drawing and dimensions
for connection............................................................ 10
Installation site .......................................................... 11
Required minimum gaps/assembly clearances . 11
Mounting the appliance ........................................... 12
Removing the front case......................................... 12
Installation.........................................................
General instructions for heating system ............
Gas connection ..........................................................
Hot water and cold water connections ...............
Heating connection ..................................................
Pressure Relief Valve ...............................................
Flue pipe ......................................................................
100 mm standard flue pipe .....................................
Optional 125 mm flue pipe ......................................
Termination of the flue pipe ..................................
Air connection............................................................
Condensate discharge .............................................
Electrical connection ................................................
Mains connection ......................................................
Connection of controllers, accessories and
external installation components .........................
External electrical controllers (non eBUS) .........
Details for the connection of an external
timer to the connection rail ...................................
Optional plug-in timers by Vaillant .......................
Wiring diagrams.........................................................
12
12
12
13
14
14
15
15
15
15
16
17
17
17
18
18
19
19
20
Start-up.............................................................. 22
Filling the installation............................................... 22
Filling and bleeding from the heating side ......... 23
First flushing of the system ................................... 24
Filling and bleeding from the hot water side ..... 24
6.1.4 Filling the condense trap ........................................
6.2
Checking the gas setting .........................................
6.2.1 Checking for tightness of the flue gas
installation and flue gas recirculation .................
6.2.2 Checking the gas flow rate .....................................
6.2.3 Checking the gas inlet working pressure............
6.3
Checking the equipment function.........................
6.3.1 Heating ........................................................................
6.3.2 Hot water function....................................................
6.3.3 Subsequent flushing through of the
heating system ("hot") ............................................
6.4
Handing over the appliance to the owner ..........
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.3
8
8.1
8.1.1
24
24
25
25
26
27
27
28
28
28
Adapting the appliance to the heating
system................................................................ 29
Selection and setting the parameters ................. 29
Overview of the settable installation parameters ... 30
Setting the heating partial load ............................ 30
Setting the pump overrun time ............................. 30
Setting the maximum flow temperature............. 30
Setting the return temperature control.............. 30
Setting the burner anti-cycle time ....................... 31
Determination of the maintenance
interval/maintenance display ................................ 31
Setting the pump output ......................................... 32
Adjusting the bypass valve ..................................... 32
33
33
8.9
Inspection and maintenance ...........................
Inspection and maintenance intervals.................
General inspection and maintenance
instructions .................................................................
Safety instructions ...................................................
Checking the CO2 concentration ...........................
Adjusting the CO2 concentration
(or the air ratio).........................................................
Inspection and maintenance work steps.............
Filling/draining the heating installation ..............
Filling the unit and heating installation...............
Draining the unit .......................................................
Draining the entire installation..............................
Servicing the compact thermal module ..............
Dismantle compact thermal module ....................
Clean the heat exchanger .......................................
Checking the burner .................................................
Installing the burner assembly ..............................
Maintaining the secondary heat exchanger .......
Cleaning the condense trap ...................................
Checking the expansion vessel..............................
Checking the connection pressure
(gas inlet working pressure) ..................................
Checking CO2 content and adjusting if
necessary ....................................................................
Test operation............................................................
9
9.1
9.1.1
9.1.2
Troubleshooting ................................................
Diagnostics .................................................................
Status codes ...............................................................
Diagnosis codes .........................................................
41
41
41
42
8.1.2
8.1.3
8.1.4
8.1.5
8.2
8.2.1
8.2.2
8.2.3
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.4
8.5
8.6
8.7
8.8
33
34
34
35
36
37
37
37
37
37
37
38
38
38
39
39
40
40
40
40
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Contents
Notes on the documentation 1
1
Notes on the documentation
9.1.3
9.1.4
9.2
9.3
Error codes .................................................................
Error memory ............................................................
Test programs............................................................
Resetting parameter to factory settings ............
45
45
46
46
10
10.1
10.2
10.3
10.4
10.5
Replacing components .....................................
Safety instructions ...................................................
Replacing burner .......................................................
Replacing fan or gas fittings ..................................
Replacing primary heat exchanger ......................
Replacing electronics and display ........................
47
47
47
47
48
48
11
Vaillant service ................................................. 49
12
Recycling and disposal ..................................... 49
13
Technical data ................................................... 50
Other applicable documents
• Always observe all installation instructions for
structural parts and components of the system when
installing the ecoTEC exclusive. These installation
instructions are enclosed with the various system
components as well as additional components.
• Also observe all the operating instructions included
with the system components.
Appendix
EC declaration of conformity ............................................. 51
Benchmark gas boiler commissioning checklist ............ 54
1.1
Storage of the documents
Please pass on this operating and installation manual
and all other valid documents to the operator of the
installation in order for him or her to store it so that it
is available whenever it is required.
The following information is intended to help you
throughout the entire documentation.
Further documents apply in combination with this
installation and maintenance manual.
We accept no liability for any damage caused by
failure to observe these instructions.
1.2
Safety instructions and symbols
Please observe the safety instructions in this manual for
the installation of the appliance.
The symbols used in the manual are explained below:
d Danger!
Immediate danger to life and limb!
e Danger!
Risk of death from electric shock!
H Danger!
Risk of burns or scalding!
a Caution!
Potentially dangerous situation for the product
and environment!
h Note!
Useful information and instructions.
• Symbol for a necessary task
1.3
Validity of the manual
This installation manual applies exclusively to units with
the following part numbers:
– 0010002668
– 0010002669
The part number of the unit can be obtained from the
identification plate.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
3
2 Description of the appliance
2
Description of the appliance
2.1
Design
14
1
13
2
3
4
12
5
11
6
7
10
8
2.3
CE label
CE labelling shows that the appliances comply with
the basic requirements of the following directives:
– Directive 90/396/EEC of the Commission with revisions
"Directive for Harmonisation of Legal Regulations
of the Member States for Gas Consumer UNits" (Gas
equipment directive)
– Directive 92/42 EEC of the Commission with revisions
"Directive Concerning the Efficiency of New Hot Water
Heating Boilers Fired by Liquid or Gaseous Fuels“
(Efficiency directive)
– Directive 73/23/EEC of the Commission with revisions
"Directive Concerning Electrical Operating Equipment
for Use Within Specific Voltage Limits“ (Low voltage
directive)
– Directive 89/336/EEC of the Commission with revisions
"Directive Concerning Electromagnetic Compatibility"
The units comply with the prototype described in the EU
Prototype Test Approval:
PIN-No. CE-0085BR0308
The units comply with the following standards:
– EN 483
– EN 625
– EN 677
– EN 50165
– EN 55014
– EN 60335-1
– EN 60529
– EN 61000-3-2
– EN 61000-3-3
9
Fig. 2.1
Functional elements of ecoTEC exclusive
Legend:
1 Expansion vessel
2 Air intake pipe
3 Burner assembly
4 Ignition electrode
5 Gas Valve
6 Diverter valve
7 Hot water heat exchanger
2.2
8
9
10
11
12
13
14
Aqua-Sensor
Electronics box
Pump
Auto air vent
Pressure sensor
Heat exchanger
Air / flue gas duct
Ltd. supports the Benchmark Initiative.
h Vaillant
You will find the Benchmark Logbook on the
last page of this instruction manual. It is very
important that this document be filled out
properly when installing, commissioning and
handing-over to the operator of the installation.
Type overview
Appliance
type
Designated country
Approval
(designation in accordcategory
ance
with ISO 3166)
832
UK (Great Britain)
II2H3P
838
UK (Great Britain)
II2H3P
Type of gas
Nominal heat rating
in kW (heating)
Hot water output
in kW
Natural gas H G20
Liquid gas propane G31
27
31,4
Natural gas H G20
Liquid gas propane G31
30
37,2
Table 2.1 Type summary
4
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Description of the appliance 2
Safety instructions and regulations 3
2.4
3
Gas council numbers
Appliance
Gas council numbers
ecoTEC exclusive 832
ecoTEC exclusive 838
47 044 37
47 044 38
Table 2.2 Gas council numbers
2.5
Intended use
The Vaillant ecoTEC exclusive is a state-of-the-art
appliance which has been constructed in accordance
with recognised safety regulations. Nevertheless,
danger to the life and limb of the user or third parties
can still occur or the appliance or other material assets
be impaired in the event of improper use.
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental
capabilities, or lack of experience and/or knowledge,
unless they have been given supervision or instruction
concerning use of the unit by a person responsible for
their safety.
Children must be watched to ensure that they do not
play with the unit.
The unit is intended as a heat producer for closed hot
water central heating installations in households. Any
other use or extended use is considered to be improper.
The manufacturer or supplier is not liable for any
resulting damage. The user alone bears the risk.
Intended use includes the observance of the operating
and installation manual and the adherence to the
inspection and maintenance conditions.
a Caution!
Any incorrect use is forbidden.
2.6
Identification plate
The identification plate the Valliant ecoTEC exclusive is
attached at the factory to the bottom of the appliance.
3.1
Safety instructions and regulations
Safety instructions
a Caution!
To tighten or loosen screws, only use suitable
open-ended spanners (do not use pliers or
extensions etc.).
Improper use or unsuitable tools can cause
damage, such as gas or water leaks.
3.1.1
Installation and setting
Installation, setting work and maintenance and repairs
to the unit may only be carries out by an heating
engineer approved at the time by the Health and Safety
Executive.
3.1.2 If you smell gas
If you smell gas, the following safety instructions must
be observed:
• Do not actuate any electrical switches in the danger area
• Do not smoke in the danger area
• Do not use a telephone in the danger area
• Close the gas stop cock
• Ventilate the danger area
• Notify your gas supplier or a suitably qualified heating
engineer.
National phone number for gas emergencies: 0800 1 1 1 999
3.1.3
Changes to the surroundings of the heating
device
No changes must be made to the following objects:
- the heating device
- the gas, air, water and electricity supply pipes
- the exhaust pipe
- the constructional conditions that could affect the
operational reliability of the device
3.1.4
Important instructions for propane appliances
Bleeding the liquid gas tank when installing the system:
before installing the device, make sure that the gas tank
has been bled. The liquid gas supplier is responsible for
the proper bleeding of the tank. Ignition problems can
be caused if the tank is not bled properly. In such cases,
first contact the person in charge of filling the tank.
Affix tank sticker
Affix the enclosed tank sticker (propane quality) on the
tank where it is clearly visible or on the bottle cabinet, if
possible close to the filler nozzle.
d Danger!
Only use propane in accordance with
DIN 51622 or EN 437.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
5
3 Safety instructions and regulations
3.2
Related documents
The installation of the appliance and any associated hot
water system must be in accordance with (but not
limited to) the following; COSHH regulations, Gas Safety
(Installation and Use) Regulations 1998, Health and
Safety Document No. 635 (The Electricity at Work
Regulations 1989), BS7671 (IEE Wiring Regulations) and
the Water Supply (Water Fitting) Regulations 1999, or
The Water Bylaws 2000 (Scotland). It should also be in
accordance with the relevant requirements of the Local
Authority, Building Regulations, The Building
Regulations (Scotland), The Building Regulations
(Northern Ireland) and the relevant recommendations of
the following British Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired
boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water
central heating systems.
Institute of Gas Engineers Publication IGE/UP/7/1998:
”Guide for gas installations in timber framed housing”
BS. 5482 Pt. 1 Domestic butane and propane gas
burning installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2 Gas installation pipework, boosters and
compressors on industrial and commercial premises.
IGE/UP10 Installation of gas appliances in industrial and
commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating
systems.
BS. 5440: Installation and maintenance of flues and
ventilation for gas appliances of rated input not
exceeding 70 kW net (1st, 2nd and 3rd family gases).
Part 1 Specification for installation of flues.
Part 2 Specification for installation and maintenance
of ventilation for gas appliances.
6
European installation directive
a Caution!
Installation and maintenance of the unit may
only be undertaken by a competent person
approved at the time by the Health and Safety
Executive in accordance with the "Gas Safety
(Installation and Use) Regulations 1998".
In IE the installation must comply with the
current Version of I.S.813 ‘Domestic Gas
Installations’ and the current Building
Regulations. The current ETCI Regulations for
the installation of electrical equipment must
also be observed.
Caution!
To tighten or loosen screws, only use suitable
open-ended spanners (do not use wrenches or
extensions etc.).
Improper use or unsuitable tools can cause
damage, (such as gas or water leaks.)
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Assembly 4
4
Assembly
4.1.1
The Vaillant ecoTEC exclusive is delivered
pre-assembled in a package unit.
a Important:
With regards to the Manual Handling
4.1
Scope of delivery
Check the delivery for completeness and lack of damage
(see Fig. 4.1 and Table 4.1).
2
3
1
4
5
10
6
Transporting the appliance
7
8
9
Fig. 4.1 Scope of delivery for ecoTEC exclusive
Item
Quantity
Description
1
1
Boiler
2
1
Hanging bracket
3
3
Installation and Servicing, Users and
Flue Installation Instructions
4
1
Installation and connection accessories
5
1
Guarantee Card
6
1
Template
7
4
Copper tails for gas and water pipework
8
3
Flow and return service valve, gas service
valve
9
1
Pressure relief valve/double check valve
10
1
Lower cover (packed inside boiler)
Table 4.1 Scope of supply ecoTEC exclusive
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Operations, 1992 Regulations, the following lift
operation exceeds the recommended weight for
a one man lift.
General recommendations when handling
• Clear the route before attempting the lift.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible. Do not
twist – reposition feet instead.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Avoid upper body/top heavy bending - do not lean
forward/sideways.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip.
• Always use assistance if required.
Removal of carton from delivery van
• Recommend 2 person lift or 1 person with use of sack truck.
• If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
• Recommend secure appliance onto truck with suitable
straps.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Always use assistance if required.
Carriage of carton from point of delivery to point of
installation – ground floor.
• Recommend 2 person lift or 1 person with use of sack truck.
• If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
• Recommend secure appliance onto truck with suitable
straps.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Clear the route before attempting the lift.
• If removing boiler from truck straddle the load and tilt
forwards to facilitate secure grip.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Do not twist – reposition feet instead.
• Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs.
• Always use assistance if required.
7
4 Assembly
Carriage of carton from point of delivery to point of
installation – first or higher floor, cellar.
• Recommend 2-person lift or 1 person with use of sack
truck.
• If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
• Recommend secure appliance onto truck with suitable
straps.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Avoid upper body/top heavy bending - do not lean
forward/sideways.
• Clear the route before attempting the lift.
• If removing boiler from truck straddle the load and tilt
forwards to facilitate secure grip.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Do not twist – reposition feet instead.
• Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs.
• Always use assistance if required.
Carriage of carton from point of delivery to point of
installation – roofspace.
• Recommend 2-person lift.
• Ensure co-ordinated movements during lift.
• Avoid upper body/top heavy bending - do not lean
forward/sideways.
• Clear the route before attempting the lift.
• Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs.
• When transferring appliance into roofspace,
recommend 1 person to be in roofspace to receive the
appliance and other person to be below to pass up
and support appliance.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• Always use assistance if required.
• It is assumed safe access, flooring and adequate
lighting are provided in the roof space.
• It is recommended a risk assessment of the roof space
area be carried out before moving the appliance into the
area to take into account access, stability of flooring,
lighting and other factors, and appropriate measures
taken.
8
Unpacking of appliance from carton.
• Recommend 2 persons unpack appliance from carton.
• Always keep working area clear.
• Recommend straps and open carton flaps, then
remove items from the top including the polystyrene
packing and remove carton by sliding up over the
boiler.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• Always use assistance if required.
• Dispose of packaging in a responsible manner.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance outside packaging.
Positioning of Appliance for Final Installation – no
obstructions.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Fit bracket securely onto wall before lifting appliance
into position.
• Obtain firm grip on front and sides of appliance, lift
upwards, ensure stable balance achieved and lift
upwards to position in place on bracket.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Ensure co-ordinated movements to ensure equal
spread of weight of load.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Assembly 4
Positioning of Appliance for Final Installation – above
worktop, foreseeable obstructions etc.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Fit bracket securely onto wall before lifting appliance
into position.
• Obtain firm grip on front and sides of appliance, lift
upwards, onto worktop if practicable.
• Ensure stable balance achieved and lift upwards to
position in place on bracket.
• If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler.
• Ensure coordinated movements during 2 person lifts
to ensure equal spread of weight of load.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Avoid upper body/top heavy bending - do not lean
forward/sideways.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
Positioning of Appliance for Final Installation – within
compartment etc. restricting installation.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Fit bracket securely onto wall before lifting appliance
into position.
• Obtain firm grip on front and sides of appliance, lift
upwards, onto worktop if practicable.
• Ensure stable balance achieved and lift upwards to
drop into place onto bracket.
• If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler.
• Ensure coordinated movements during 2 person lifts
to ensure equal spread of weight of load.
• If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Positioning of Appliance for Final Installation – in
roof space restricting installation.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Obtain firm grip on front and sides of appliance, lift
upwards, ensure stable balance achieved and lift
upwards to drop into place onto bracket.
• If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler.
• Ensure co-ordinated movements during 2 person lifts
to ensure equal spread of weight of load.
• If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler.
• Ensure safe lifting techniques are used - keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
• It is recommended a risk assessment of the roof space
area be carried out before moving the appliance into
the area to take into account access, stability of
flooring, lighting and other factors, and appropriate
measures taken.
9
4 Assembly
4.2
Dimensioned drawing and dimensions
for connection
190
480
7
4
3
Ø 20
Ø 20
70
100 100
7
25
Ø 20
5
20
6
R 1/2
800
2
180
450
Fig. 4.2 Dimensions for connection (mm)
Legend:
1 Flue connection
2 Mounting bracket
3 Heating return
4 Cold water connection
5 Gas connection
6 Hot water connection
7 Heating flow
10
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Assembly 4
Particularly in hairdessing salons, lacquering and
finishing workshops, cleaning facilities, etc., the
appliance must be operated independently of the
ambient air. Otherwise, a separate installation room is
required to guarantee that the combustion air supply is
free from the above substances.
Required minimum gaps/assembly clearances
e Danger!
Danger of death by electric shock! If a room
In the event of installation in unusual locations, special
provisions may have to be made. Detailed instructions
for this can be found in BS 5546 and in BS 6798. The
boiler must be installed on a flat vertical wall which is
adequately robust to carry the weight of the boiler.
It is possible to mount onto a wall made of flammable
material if the regulations of the Local Authority and
the legal building stipulations are fulfilled.
In this case however, the unit would have to be mounted
in a specially made enclosure. (You can also use an
existing cabinet or existing enclosure as long as it can
be modified accordingly to suit the new application.)
Further details concerning the fundamental characteristics
when modifying existing cabinets or enclosures, including
the requirements for ventilation, are described in BS 6798.
If the boiler is to be installed in a half-timbered house,
the installation must be undertaken in accordance with
the Institute of Gas Engineers Publication "IGE/UP/7
Edition 2 Gas installation in timber framed and light steel
framed buildings". Please note the following instructions
before choosing where to install the heater:
a Caution!
Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance must be operated independently
of the ventilation!
When choosing the place of installation and while
operating the appliance, make sure that the combustion
air is free from chemical substances such as e.g.
fluorine, chlorine, sulphur, ammonia etc. Sprays,
solvents and cleaning agents, paints, adhesives etc.
contain these kinds of substances, which - in the worst
case scenario - can lead to corrosion, even in the
exhaust system, during ambient air dependent operating
of the appliance.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
min 500**
min 5
min 5
min 145
sealed boiler is installed in a room with a bath
or a shower, the electrical switches and the
boiler controller, which operate at mains
voltage must be mounted in locations where
any person in the bath or in the shower cannot
reach them
165/246*
4.4
min
4.3
Installation site
The site of erection of the boiler should allow proper
connection of the air/exhaust ducting. In addition, there
should be adequate room for maintenance work and air
circulation around the boiler. The boiler can be installed
in any room, however, in rooms with a bath or a shower,
the special requirements of BS 7671 (IEE Regulations),
the electro-technical stipulations of the Building
Standards (Scotland) Regulations and, in IE, the current
issue of IS 813 and the current ETCI Stipulations must
especially be observed.
Fig. 4.3 Required minimum gaps/assembly clearances
The boiler must be mounted on a flat, vertical wall
surface which is large enough for the boiler including
the required minimum space requirement and the space
required for assembly (Fig. 4.3). These are shown on the
mounting template supplied with the boiler, and are:
– 5 mm on each side of the boiler,
– 145 mm underneath the boiler,
– 165 mm* above the boiler if using a flue pipe of
100 mm outside diameter,
– 246 mm* above the boiler if using a flue pipe of
125 mm outside diameter,
– 500 mm** in front of the boiler.
h Note!
If the boiler is to be installed in a timber framed
building, it should be fitted in accordance with
“IGE/UP/7 Edition 2 Gas installations in timber
framed and light steel framed buildings“.
It is not necessary to maintain a clearance between the
appliance and combustible materials or components,
since, at the rated heating power of the appliance, the
temperature here is always lower than the permitted
temperature of 85 °C.
11
4 Assembly
5 Installation
4.5
Mounting the appliance
240
75
75
2
50 50
5
d Danger!
The Vaillant ecoTEC exclusive may only be
installed by a suitably qualified heating
engineer approved at the time by the Health
and Safety Executive who also assumes the
responsibility for installing the appliance
properly and fully commissioning the appliance
prior to first use, along with demonstrating its
correct use to the end user.
85
23
1
5.1
General instructions for heating system
a Caution!
Flush the heating system thoroughly before
3
connecting the appliance!
By doing that, residue such as welds, cinder,
hemp, putty, rust, rough dust and similar
substances are removed from the pipes.
Otherwise such substances can be deposited in
the appliance and cause damage.
Fig. 4.4 Mounting the appliance
• Fix the hanging bracket (1) to the wall using the plugs
and screws (2) provided with the appliance.
• Hang the top of the appliance (3) onto the hanging
bracket using the suspension bracket.
4.6
Installation
Removing the front case
2
5.2
Gas connection
d Danger!
The gas installation may only be established by
an authorised engineer approved at the time by
the Health and Safety Executive. The legal
directives and the local regulations for gas
supply companies must be observed.
a Caution!
Ensure stress-free assembly of the gas pipes
to avoid leakages!
1
Caution!
The gas regulating block may be tested for
leakage only with a maximum pressure of
110 mbar! The operating pressure may not
exceed 60 mbar. If these pressures are
exceeded, the gas fitting may be damaged.
Fig. 4.5 Removing the front case
To disassemble the front housing of the appliance,
proceed as follows:
• Release the screw (1) on the bottom of the appliance.
• Push both the clamps (2) on the bottom of the
appliance together so that the front cladding releases.
• Pull the housing forwards at the lower edge and
remove the front cladding upwards.
12
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Installation 5
5.3
Hot water and cold water connections
5
2
4
1
2
3
Fig. 5.2 Hot water and cold water connection
a Caution!
Mount the hot water and cold water lines so
they are tension-free, this prevents leaks!
Fig. 5.1 Gas connection
The Vaillant ecoTEC exclusive is supplied for use with
natural gas G20 and can only be converted to the use
of propane gas G31 by the Vaillant service engineer or
a suitably qualified installer approved at the time by the
Health and Safety Executive.
The gas connection is to be via 20 mm Ø steel piping.
The dynamic gas connection pressure must be at least
19 – 23 mbar for natural gas and 37 mbar for propane
gas.
• The gas pipe should first be cleaned by blowing out
with compressed air. This prevents damage to the
appliance.
• Connect the compression gas service cock and 15 mm
copper outlet tail as supplied with the appliance and
tighten.
• Connect a gas supply pipe of not less than 15 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).
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Flush all foreign matter from the mains supply before
connecting to the boiler.
• Connect the cold water service valve (1) to the cold
inlet water connection of the appliance with the
washer provided and tighten.
• Connect a 15 mm cold water inlet copper pipe (3) to
the cold water service valve (1) and tighten.
• Connect a 15 mm hot water outlet pipe (4) to the
outlet connection (5) of the appliance.
The Vaillant ecoTEC exclusive is set in the factory to a
nominal water quantity of 11.6 l/min. (38 kW unit) and
9.8 l/min. (32 kW unit).
13
5 Installation
5.4
Heating connection
Fig. 5.3 Heating connection
a
Caution!
Mount the heating lines so they are
tension-free, this prevents leaks!
Before connecting the heating circuit to the boiler, all
pipework and radiators must be thoroughly flushed to
remove any installation debris.
• Connect the central heating flow and return service
valves to the appliance.
• Connect the 22 mm copper pipe tails to the service
valves as shown in the illustration and tighten the nuts.
• Connect the central heating pipework to the flow and
return tails.
Two additional tubes are supplied with the appliance for
top connection of the flow and return pipework within
the casing.
14
5.5
Pressure Relief Valve
Fig. 5.4 Fitting the pressure relief valve
The pressure relief valve and filling loop connection is
provided within the boiler cardboard box and should be
assembled as shown below.
• Remove plug from connection.
• Fit and install the complete unit "pressure relief valve,
filling valve and flexible connection" to the
connection.
• Connect the corrugated hose to the double check
valve.
• Connect the discharge pipe to the pressure relief
valve.
The discharge pipework should be as short as possible
and installed with a continuous fall away from the boiler.
The pipe should terminate in a position which ensures
that any discharge of water or steam from the valve
cannot create a hazard to persons in or about the
premises, or cause damage to any electrical
components or external wiring,and the point of
discharge should be clearly visible.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Installation 5
5.6
Flue pipe
d Danger!
Vaillant appliances are only system-certified if
genuine Vaillant flue pipes are used. 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.
1103
70
100 mm standard flue pipe
70
5.6.1
5.6.2 Optional 125 mm flue pipe
A concentric flue pipe having an outside diameter of
125 mm is available, which can be extended to a length
of up to 21 m. You can also get a vertical system.
Further information can be obtained from the
installation instructions for the flue pipe.
65
48
15
87
74
754
650
30
Fig. 5.7 Item No. 303209
70
880
A 100 mm standard flue pipe (Item No. 303933) is
available. Further information can be obtained from the
installation instructions for the flue pipe. Extensions are
available to increase this length to a maximum of 8 m.
90° elbows and 45° elbows are also available to
increase the flexibility during installation.
1530
Fig. 5.5 Item No. 303933
40
880
1435
10
550
Fig. 5.8 Item No. 303200
5.7
Termination of the flue pipe
The following information applies to both flue pipe
systems.
a. The flue terminal must be located in such a position
that any flammable substances can be freely
dissipated.
b. Water condensation (known as pluming) can also arise
at the terminal of the flue pipe. Installation sites
where these appearances may cause a problem should
be avoided.
c. If the flue terminal is less than 2 m above a balcony,
the ground or a flat roof that is accessible by persons,
a suitable protection guard should be fitted
(manufactured by Tower Flue Components, Tonbridge,
TN9 1TB, Model K3, plastic-coated).
Fig. 5.6 Item No. 303900
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
15
5 Installation
BS 5440–1: We recommend that the terminal of a
fan-assisted flue pipe system be positioned as follows:
a) At least 2 m from an opening in the building directly
opposite, and
b) so that the combustion products do not flow out at
right angles to a boundry.
A
G
H,
I
F
B F
G
BCD
J
A
A
E
F
M
F
L
K
LK
A
G
Fig. 5.9 Terminal Locations
h Note!
Vertical flue pipes must not terminate within
600 mm of an opening window, an extraction
opening or any other ventilation opening.
The flue pipe must be fitted, or screened, in such a way
that ignition or damage to sections of the building are
avoided.
Terminal location
A
B
Under gullies, down-pipes or drainpipes
75
C
Unter gutters
200
D
Under balconies
200
E
From vertical drainpipes and down-pipes
25
F
From external and internal corners
300
G
Above the ground, a roof or a balcony
300
H
Opposite another surface
600
I
Opposite another termination
1200
J
Next to an opening (e.g. a door, window) within a car-port 1200
K
Vertically away from a terminal on the same wall
1500
L
Horizontally away from a terminal on the same wall
300
M
Distance away from an adjacent vertical flue pipe
500
Table 5.1 Position of the flue terminal in a fan-assisted
con-centric flue pipe
Note!
In addition, the terminal should not be located
closer than 150 mm from a wall-opening provided
for e.g. a window.
Boundary flue terminations must as a minimum comply
with Building regulation part „J“ 600 mm and should
also be in accordance with the Guide to Condensing
Boiler Installation which recommends 2.5 m from wall,
fence or boundary.
Where a plume diverter terminal is used this is
measured in the direction of the flow of products.
16
2) Dimension F:
This dimension can be reduced to 25 mm without
having a negative effect on the output of the boiler.
In order to prevent the smoke and condensation
emission from impinging on any bordering surfaces,
however, a gap of 300 mm is recommended. For IE,
recommendations are given in the current issue of
the IS 813.
mm
Directly under or above an opening or the horizontal
to an opening, a hollow ventilation tile, an opening win- 300
dow etc.
h
1) Dimensions B, C and D:
These dimensions can be reduced to 25 mm without
having a negative effect on the output of the boiler.
In order to prevent the products and condensation
emission from impinging on any bordering surfaces,
the terminal should be extended as shown in
Fig. 5.10.
Fig. 5.10 Flue pipe terminating under balconies or gutters
5.8
Air connection
Detailed recommendations concerning air connection
are given in BS 5440, Part 2.
A ventilation opening in the room or inner room section
where the boiler is installed is not required.
Ventilating a compartment or enclosure
The boilers have a very high energy efficiency. As a
result of this, only small heat losses are produced at the
casing of the appliance. For this reason, cabinets and
enclosures in which the boiler is fitted do not need to
have permanent ventilation openings at the top and
bottom for cooling.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Installation 5
5.9
The condensate drain pipe should have a minimum
diameter of 22 mm, without length restriction, and
also be fitted with a siphon (3) having a connection
head of 75 mm (fitted within the boiler already). The
connection should be made after the drain siphon if
possible. If the installation is only possible in front of
the siphon, there must be a ventilation valve between
the two siphons. This is normally provided in a drain.
c) Draining into a gully (5) under the grid (6) and above
the water level. The external piping should be kept as
short as possible to minimise the frost risk, and
should be no longer than 3 m.
d) To the condensate absorption point (drainage ditch) (7).
The external pipe should have a maximum length of
3 m.
Condensate discharge
1
2
4
a
c
b
d
6
3
Internal
stackpipe
3
Internal
discharge system
5
7
Gulley
Soakaway
Further information can be obtained from "BS 6798
Specification for installation of gas–fired boilers of rated
input not exceeding 70 kW net". The condense trap (1)
must be filled with water as described in the relevant
chapter before the boiler is commissioned.
Fig. 5.11 Condensate discharge
5.10
The ecoTEC exclusive units are equipped with a normal
water condensate collector where the condensate is
continuously diverted into the drain pipe.
• Connect the condensate drain (1) of the boiler to a
condensate drain pipe (2) which has a minimum
internal diameter of 19 mm (22 mm outside diameter
for all external pipes) and which is made from an
acid-resistant material (e.g. plastic overflow pipe).
h Note!
The drain pipe connected to the condensate
drain of the boiler must have a constant
gradient (45 mm per metre) and should be
installed and terminate within the building to
prevent the possibility of freezing up.
The condensate drain pipe should terminate in a
suitable location, e.g.:
a) The drain pipe should preferably terminate in the
floor of the house in the ventilation duct (at least
450 mm above the duct base). There must be a siphon
(3) fitted in the line (mounted in the boiler) producing
a connection head of at least 75 mm of water.
A ventilation valve (4) must be fitted in the drain pipe
in front of the siphon. The connection to the ducting
should not allow overflow into another drain pipe or
allow overflow from another drain pipe into the
condensate drain pipe. This can be achieved by
keeping a gap between the pipe branches of at least
110 mm, with a duct diameter of 100 mm, and 250 mm
with a duct diameter of 150 mm.
b) Connection into the domestic waste water drain pipe
(e.g. a sink or washing machine) with an external
termination.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Electrical connection
d Danger!
The electrical installation may only be
undertaken by an authorised engineer.
Risk of fatal electric shock from touching live
connections. Always disconnect the power
supply first by pulling the plug out of the wall
socket. Only after this can the installation be
undertaken. Continuous voltage is present on
the mains connection terminals L and N, even if
the main switch is turned off!
5.10.1 Mains connection
The appliance is fitted with a 1.0 m long connection
cable with mains plug. The three-pole mains plug is
fitted with a 3.0 A fuse. The connection cable is wired
into the appliance in the factory.
Connection to the mains supply shall be made via the
fused 3 pin plug to an unswitched shuttered socket,
complying to the requirements of BS 1363.
17
5 Installation
5.10.2 Connection of controllers, accessories and
external installation components
The following controllers, accessories and installation
components can be connected to the ecoTEC exclusive
(see Table 5.2).
The installation should be carried out in accordance with the
individual instruction manual. The required connections to
the electronic system of the boiler (e.g. for external
controllers, external sensors etc.) should be undertaken as
follows:
• Remove the front cover of the device, and lower the
electronic box forward.
• Unclip the rear cover of the electronic box and hinge
the cover upwards.
• Insert the connection lines of the components to be
connected through the cable openings (1) on the left
hand side of the underside of the appliance.
• Then insert the connection lines through the cable
openings (2) into the electronic box and cut them to
length.
- + 7 89
L N
3 45
- + 7 89
L N
3 45
Fig. 5.13 Example for cable routing
• Remove the insulation over a length of 2 - 3 cm and
insulate the cores.
• Connect the connection cable in accordance with
Table 5.2 and Fig. 5.13 to the relevant screwed
terminals in the electronic system.
a Caution!
Do not connect mains voltage to the terminals
7, 8, 9! Danger of destroying the electronics!
h Note!
There is no provision set in the factory for
connection of an installation thermostat for
underfloor heating.
1
2
Fig. 5.12 Opening the switchgear box rear wall
Note!
Make sure that the connection cables are
securely fastened in to the screw terminals.
5.10.3 External electrical controllers (non eBUS)
The boiler connections 3, 4 and 5 serve for the
connection of external controllers, for example a timer
and/or a room thermostat. The connections 3 and 4 are
connected to each other in the factory. If external
controllers are used, this connection must be removed
and the controllers must be connected to connections
3 and 4. The connection 5 is an additional neutral line
for external neutral lines, for example for the sensor of
a room thermostat.
18
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Installation 5
5.10.4 Details for the connection of an external
timer to the connection rail
20 VDC
7
8
(DO NOT USE 7, 8, 9 IN UK!)
9
L N
5
3 4
N
L
SWITCH
CONTACTS
3 A FUSE
ROOM
THERMOSTAT
MAINS
SUPPLY
230 V
50 Hz
L
N
CLOCK
N
Fig. 5.14 Details for the connection of timers
If it is intended to connect a room thermostat in
addition to a timer, the connection between the ON
connection of the timer and connection 4 on the boiler
must be interrupted by the contacts of the room
thermostat (see circuit diagram Fig. 5.14).
5.10.5 Optional plug-in timers by Vaillant
Further details for the connection can be found in the
relevant instructions of the accessories. The cover on
the connection box should be replaced after all the
electrical connections have been made. The cover is
secured with two clips.
Controller
Item no.
Connection
VRT 400 (single-circuit weather compensator)
307 409
Installation in electronics box (plug-and-play)
VRT 240 (room thermostat)
307 401
Wall mounting, terminal 3 - 4
VRT 360f (room thermostat)
0020018253
Remote controller, receiver wall mounting
VRT 360 (room thermostat)
307 406
Wall-mounted, 2-wire bus
VRT 40 (room thermostat)
300 662
Wall-mounted, 3-wire connection to terminals 7-8-9
VRT 50 (room thermostat)
0020018265
Wall-mounted, eBus
Telecommunication
Item no.
Connection
vrnetDIALOG 830
vrnetDIALOG 840/2
00 2000 3988 GSM/GPRS, wall-mounted or installation in electronics box
(plug-and-play)
00 2000 3983 Wall-mounted, analogue telephone line up to 16 appliances
vrnetDIALOG 860/2 (Int)
00 2000 3984 Wall-mounted, GSM/GPRS, up to 16 appliances
Accessories
Item no.
Connection
Accessory module 2 from 7
00 2001 7744
Fitting in the electronics box
vrDIALOG 810
306 743
Visualisation and configuration software
Table 5.2 Controller and accessories
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
19
5 Installation
5.10.6 Wiring diagrams
Connection eBUS accessories
Cable harness compact thermal module
X22
PWM pump
Connection accessories module
Diagnosis via eBUS,
vrnetDIALOG
External sensor
External flow or return sensor
Cable harness hydraulics
Connection for external
eBUS controller
Room thermostat 24 V:
Connection 7, 8 and 9
No bi-directional interface
(only analogue)
Caution:
Do not connect mains voltage!
Danger of damage to
the electronics!
Mains connection: 230 V/50 Hz
Room thermostat 230 V/50 Hz
(Remove bridge when connecting)
Heating pump
Fan
2nd pump: - circulation pump
- storage tank charging pump
- 2nd external pump
Fuse 2A, slow-response
- solar pump
Igniter
Fig. 5.15 Connection wiring ecoTEC exclusive
20
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Installation 5
Flow temperature
sensor (NTC)
Return temperature
sensor (NTC)
Ignition electrode
X 20/5 red
X 20/7 black
X 20/8 blue
X 20/7 black
Plug connection
Gas valve
Fan
X 20/16 blue (Earth)
X 20/4 grey (PWM)
X 20/3 black (Hall signal)
X 20/18 red (24 VDC)
X 20/17 red (24 VDC)
X 20/9 blue (Earth)
X 2/16 black A
X 2/7 pink B
X 2/15 brown C
Water pressure sensor
X 2/8 blue D
Preference changeover valve
X 2/9 black
Water
through flow
sensor
X 2/11 red
X 2/12 green
Pump
X 2/4 orange
X 2/3 red (+ 5V)
X 2/10 black
X 2/2 black (Earth)
X 2/6 green (Signal)
X 2/5 violet (Signal)
X 2/1 black
Mains plug
X 22
Hot water outlet
(NTC)
X41
X2
X31
X 20
X 40
Secondary
heat exchanger
(NTC)
Switchgear box
Fig. 5.16 Electronic board layout ecoTEC exclusive
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
21
6 Start-up
6
Start-up
6.1
Filling the installation
Mixing additives with the heating water can result in
material damage. However, up to now, no
incompatibility with Vaillant appliances has been
detected with proper use of the following products.
• When using additives, follow the additive
manufacturer‘s instructions without exception.
Vaillant accepts no liability for the compatibility of any
additive or its effectiveness in the entire heating
system.
Additives for cleaning purposes
(subsequent flushing required)
- Fernox F3
- Jenaqua 200
- Jenaqua 300
- Jenaqua 400
- Sentinel X 300
- Sentinel X 400
Provided the national regulations and technical
standards do not specify any higher requirements, the
following applies:
• You must treat the heating water
- if the total volume of filling and top-up water
exceeds thrice the nominal volume of the heating
system over the service life of the system
or
- if the limits given in the following tables are not
adhered to.
Heating water
qualities
Low-salt
saline
Electric conductivity
μS/cm
at 25 °C
< 100
100-1500
Appearance
Free of sedimentary substances
pH-value at 25 °C
8,2-10,01)
8,2-10,01)
< 0,1
< 0,02
Oxygen
Unit
mg/L
1) With aluminium and aluminium alloys, the ph value range is
restricted from 6.5 to 8.5.
Table 6.2 Guidelines for heating water: Salinity
Additives intended to remain permanently in the
system
- Fernox F1
- Fernox F2
- Jenaqua 100
- Jenaqua 110
- Sentinel X 100
- Sentinel X 200
a Caution!
Aluminium corrosion resulting in leakages
caused by unsuitable heating water!
Unlike materials such as steel, cast iron or
copper, aluminium is reactive to alkalised
heating water (pH-value > 8,5) which results in
significant corrosion.
With aluminium, ensure that the pH value of
the heating water ranges between 6.5 up to a
maximum of 8.5.
Additives for frost protection intended to remain
permanently in the system
- Fernox Antifreeze Alphi 11
- Sentinel X 500
• Inform the operator of the necessary measures in
case you have used any of these additives.
• Inform the operator of the required procedures for
frost protection.
• Observe the applicable national regulations and
technical standards for the treatment of filling and
top-up water.
Total heating
output
kW
Total hardness at 20 l/kW
for the smallest boiler heating
surface2)
mol/m3
Total hardness at > 20 l/kW
< 50 l/kW for the smallest boiler
heating surface2)
mol/m3
Total hardness at > 50 l/kW
for the smallest boiler heating
surface2)
mol/m3
< 50
No requirement or < 31)
2
0,02
> 50 to ≤ 200
2
1,5
0,02
> 200 to ≤ 600
1,5
0,02
0,02
0,02
0,02
> 600
1) with systems equipped with wall-hung boiler and systems with electric heating elements
0,02
2) of the specific system volume (nominal capacity in litres/heating output; in case of multiple boiler systems the lowest individual
heating output should be used)
These data only apply up to 3x the system volume for filling and top-up water. Once this triple system volume is exceeded, the
water will have to be treated exactly the same as in case of exceeding the limit values given in table 6.2 (softening, desalination,
hardness stabilisation and desludging).
Table 6.1 Guidelines for the heating water: Water hardness
22
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Start-up 6
a Caution!
h Note!
Risk of material damage if the heating water is
The ecoTEC units are supplied with a pressure
treated with unsuitable frost or corrosion
protection agents!
Frost and corrosion protection agents may
cause changes in the seals, noises during
heating and possibly subsequent damage.
Do not use any unsuitable frost or corrosion
protection agents.
6.1.1
Filling and bleeding from the heating side
gauge and a digital pressure display (2). Using
the pressure gauge you can perform a quick
check whether the filling pressure is within the
prescribed range or not, even when the unit is
switched off. With the unit switched on, you
can read off the exact pressure by pushing the
minus button „-“.
• Turn the rotary knobs (1) and (4) to the left hand stop
and switch the unit on using the main switch (3).
h Note!
Use the test programme P.6 for filling the
heating system: The priority changeover valve
moves to the central position, the heating
pump is not running and the unit does not go
into heating mode, see Section 9.2.
1
Note!
To avoid running the system with too little water
and thus to prevent damage, your appliance has
a water pressure sensor. This signals the low
pressure level if the level falls below 0.6 bar by
the water pressure value in the display flashing.
If the water pressure falls below 0.3 bar the unit
switches off. The error message F.22 appears in
the display. Fill the system up with water before
you start up the appliance again.
Fig. 6.1 Auto air vent
Legend:
1 Auto air vent
Filling the heating system:
A water pressure/filling pressure between 1.0 and
2.0 bar is required for proper functioning of the boiler.
If the heating installation operates over several floors,
it may be necessary to have higher water levels on the
pressure gauge.
• Rotate the cap of the auto air vent (1) on the pump
a couple of times to loosen it (the appliance is
ventilated automatically by the auto air vent during
continuous operation).
• Open all radiator valves in the installation.
1
2
Fig. 6.3 Filling the heating system
1
2
Proceed as follows to fill the system:
• Open all radiator valves on the system.
• Ensure that the boiler CH service valves are open.
• Check the flexible filling loop is connected.
• Locate the filling valve handle (1) and open.
• Locate the filling valve handle (2) and open to allow
water to enter the system. Starting with the lowest
radiator, open the radiator air release until water
(clear of bubbles) is emitted.
bar
4
bar
3
Fig. 6.2 Check the filling pressure of the heating installation
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
23
6 Start-up
• Repeat this at all radiators until the complete system
is full, all air locks have been cleared and the boiler
pressure gauge reads 1.5 bar. Release any air from
the pump by slackening the centre screw. Turn off
the filling valve (2) and fully close filling valve (1).
• The boiler is equipped with an automatic air release
valve. To allow this to vent the boiler, the cap on the
top must be slackened by 1 –2 turns (This cap must be
left slackened during boiler operation to ensure any
residual air or system gases are released).
• Check the heating system and boiler connections
are sound.
6.1.4
Filling the condense trap
1
h Note!
Use the test programme P.0 to vent the boiler
and the heating system: The unit does not start
in heating mode, the heating pump switches on
and off and alternately vents the heating
circuit and the hot water circuit, see Section
9.2.
6.1.2
First flushing of the system
h Note!
The entire heating system must be flushed
through completely at least twice: once cold
and once hot, in accordance with the following
instructions.
• Check if all radiator thermostat valves and both
maintenance cocks on the boiler are open.
• Connect a hose to the drain valve which is located
at the lowest position in the heating system.
• Open the 1/2" KFE drain cocks and all the vent valves
on the radiators so that the water flows quickly and
completely out of the heating system and the boiler,
in order to remove the contamination caused during
the installation out of the heating system before the
boiler is started up.
• Close the 1/2” KFE drain cocks.
• Re-fill the heating system with water as described
in Section 6.1.1.
• Check that the over-pressure valve in the heating
system is functioning correctly by turning the handle
on the valve.
• Check the pressure in the heating system and top
up with water if necessary.
• Close filling valve 1 and filling valve 2.
6.1.3 Filling and bleeding from the hot water side
• Open the cold water stop cock on the appliance on
the inlet combination.
• Fill the hot water system by opening all the hot water
taps until water comes out.
• As soon as water comes out of all the hot water taps,
the hot water circuit is filled completely and also vented.
24
Fig. 6.4 Filling the condense trap
d Danger!
If the appliance is started up with an unfilled
condense trap, there is a danger of poisoning
by exhaust gas emission.
Fill the trap as follows:
• Unscrew the lower section of the trap (1) from the
condense trap.
• Fill the lower section of the trap (1) 3/4 full with water.
• Screw the lower section of the trap back onto the
condense trap.
6.2
Checking the gas setting
Caution!
Malfunctions or reduction in working life of the
boiler!
If the boiler version does not correspond to the
local gas family, there will be malfunctions or
you have to change components of the boiler
ahead of schedule, e. g. do not use a LPG boiler
on natural gas.
• Before starting up the boiler compare the
details of the type of gas specified on the
identification plate with the type of gas
supplied at the installation site.
If the boiler version corresponds to the local gas family:
• Proceed as described below.
If the boiler version does not correspond to the local
gas family:
• Perform the gas conversion in accordance with the
gas conversion kit 0020010641.
• Adjust the gas setting as described below
(see Section 6.2.1 to 6.2.3).
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Start-up 6
The combustion of this boiler has been checked,
adjusted and preset at the factory for operation on the
type of gas defined on the identification plate. No
measurement of the combustion is necessary to set up
the boiler.
• Do not adjust the multifunctional automatic gas valve.
• Ensure
- that the boiler has been installed in accordance with
these instructions,
- the integrity of the flue system and the flue seals,
as described in the flue installation instructions
enclosed with this boiler, and as described below,
- a visual check is carried out on the boiler
combustion circuit and the relevant seals,
- that any defects have been corrected at this stage.
• For checking the system for recirculation use the air
measure point (2).
• Use the flue gas analyser.
• If you detect any CO or CO2 in the fresh air, search for
the flue gas leakage or recirculation.
• Correct the defects.
• Check again as described before, if there is any CO or
CO2 in the fresh air.
• If you cannot correct the defects you must not start
up the boiler.
6.2.2 Checking the gas flow rate
The boiler is fitted with a multifunctional automatic gas
valve which ensures that the precise air/gas ratio is
provided under all operating conditions. The gas flow
rate has been set during production and does not
require adjustment. With the front casing fitted check
the gas flow rate of the boiler as follows:
• Start the boiler by activating the test program P.1 as
described in Section 9.2.
• In addition, ensure that maximum heat can be
dissipated into the heating system by turning up the
room thermostat.
• Alternatively, fully open the hot water taps to ensure
full flow rate through the boiler.
• Wait at least 5 minutes until the boiler has reached its
operating temperature.
• Ensure that all other gas appliances in the property
are turned off.
• Measure the gas flow rate at the gas meter.
• Check that the gas flow rate is as stated in Table 6.3.
• If the measured gas flow rate lies outside the
tolerance limits specified in Table 6.3, do not operate
the boiler and inform the Vaillant Service Solutions
(0870 6060 777).
To further validate the integrity of the flue system and
confirm correct operation of the boiler it is possible to
conduct flue gas and air measurements on this
boiler - for details see Section 6.2.1.
Proceed to put the boiler into operation as follows:
• Check the maximum gas flow rate as detailed in
Section 6.2.2.
• Check the gas inlet working pressure as detailed in
Section 6.2.3.
• Note that you must re-measure the gas flow rate or
the gas inlet working pressure, if changes were
required to correct any issues found.
6.2.1
Checking for tightness of the flue gas
installation and flue gas recirculation
• Check the integrity off the flue gas installation
according to TB 200.
• Should the flue gas installation be longer than 2 m we
strongly recommend to check the system for flue gas
recirculation as described below.
If the measured gas flow rate is within the tolerance
limits shown in Table 6.3, then proceed as follows:
• Take the boiler out of operation by
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
- Allow the boiler to cool down by turning off water
taps and allow pump overrun to operate for a
minimum of two minutes.
• Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
1
2
Fig. 6.5 Flue gas and air measure points
Legend:
1 Flue gas measure point
2 Air measure point
Boiler
Nominal net heat
input in kW as per
BS EN 483
ecoTEC exclusive 832
32
ecoTEC exclusive 838
38
Gas flow rate
Natural gas in m3/h
nominal
+5%
- 10 %
nominal
3,39
3,56
3,05
2,49
4,02
4,22
3,62
2,95
Propane in kg/h
+5%
2,61
- 10 %
2,24
3,10
2,66
Table 6.3 Gas flow rates
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
25
6 Start-up
6.2.3 Checking the gas inlet working pressure
• Ensure that the gas inlet working pressure can be
obtained with all other gas appliances in the property
working.
• Remove the front casing from the boiler.
• Close the gas isolation valve of the boiler.
• In addition, ensure that maximum heat can be
dissipated into the heating system by turning up the
room thermostat.
• Alternatively, fully open the hot water taps to ensure
full flow rate through the boiler.
• With the boiler operating at full load check that the
gas inlet working pressure at the reference test
point (1) complies with the requirements of Table 6.4
• Should the pressure recorded at the reference test
point in the boiler be lower than indicated (Table 6.4)
check if there is any blockage in the pipework or if the
pipework is undersized.
• If the supply pressure is out of tolerance contact your
Emergency Service Provider.
1
If the gas inlet working pressure at the reference test
point (1) is not within the permissible range and you
cannot correct the failure, notify the gas supply
company or the Vaillant Service Solutions team and
proceed as follows:
• Take the boiler out of operation by
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
- Allow the boiler to cool down by turning off water
taps and allow pump overrun to operate for a
minimum of two minutes.
• Close the gas isolation valve of the boiler.
• Remove the pressure gauge and re-tighten the sealing
screw (1).
• Turn on gas at the gas isolation valve.
• Make sure that there is no leakage at the sealing
screw.
• Turn off gas at the gas isolation valve.
• Put the front casing back on.
• Turn off electrical supply to the boiler.
• You must not start up the boiler.
2
Fig. 6.6 Measuring the gas inlet working pressure
• Loosen the sealing screw marked “in” (1) on the gas
valve.
• Connect a digital pressure gauge or U-tube
manometer (2).
• Open the gas isolation valve of the boiler.
• Start the boiler by activating the test program P.1 as
described in Section 9.2.
Natural gas (G20)
ecoTEC appliance
LPG (G31)
Minimum pressure at
reference test point in
mbar
Maximum pressure at
reference test point in
mbar
Minimum pressure at
reference test point in
mbar
Maximum pressure at
reference test point in
mbar
ecoTEC exclusive 832
16
23
23
43
ecoTEC exclusive 838
15
23
23
43
Table 6.4 Gas inlet working pressures at the reference test point
26
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Start-up 6
If the gas inlet working pressure is within the
permissible range, proceed as follows:
• Take the boiler out of operation by
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
- Allow the boiler to cool down by turning off water
taps and allow pump overrun to operate for a
minimum of two minutes.
• Close the gas isolation valve of the boiler.
• Remove the pressure gauge and re-tighten the sealing
screw (1).
• Open the gas isolation valve of the boiler.
• Make sure that there is no leakage at the sealing
screw.
• Put the front casing back on.
• Reset boiler controls for normal operation.
• Record the appliance gas inlet working pressure
(mbar) in the Benchmark gas boiler commissioning
checklist.
Fig. 6.7 Function check
6.3
Checking the equipment function
After installing and checking the gas supply pressure,
perform a function check before commissioning the
appliance and handing over to the user.
• Commission the appliance in accordance with the
instructions in the relevant operating manual.
• Check the gas infeed, exhaust gas installation, boiler and
heating installation and the hot water pipes for leaks.
• Check the flue pipe for proper installation.
• Check over-ignition and that the flame on the burner
is burning evenly.
• Check the function of the heating (see Section 6.3.1)
and the hot water preparation (see Section 6.3.2)
• Hand the unit over to the user.
6.3.1 Heating
• Switch on the appliance.
• Make sure that there is a heat demand for heating
(set the room thermostat or the weather-controlled
controller to "demand").
• Press "i" to activate the status indicator.
The Vaillant ecoTEC exclusive has status codes which
indicate the operating condition of the appliance in the
display. Functional checks of the hot water and heating
operation can be undertaken using these status codes
by pushing the button "i".
Fig. 6.8 Display during heating mode
As soon as there is a heat demand, the appliance goes
through the status displays "S. 1" to "S. 3", until the
appliance is running properly in normal operation and
the display "S. 4" appears.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
27
6 Start-up
6.3.2 Hot water function
• Switch on the appliance.
• Turn on a hot water tap fully.
• Press "i" to activate the status indicator.
When the hot water function is working correctly the
display shows "S.14".
Fig. 6.9 Display during hot water preparation
6.3.3
•
•
•
•
•
•
•
•
•
•
Subsequent flushing through of the heating
system ("hot")
Allow the appliance to run until both the appliance
and the heating system have reached their operating
temperature.
Check the heating system for leaks.
Connect a hose to the drain valve which is located at
the lowest position in the heating system.
Shut off the appliance, open the drain valve and all
vent valves on the radiators and allow the water to
flow out of the heating system and the boiler quickly
and fully.
Close the drain valve.
Re-fill the heating system with water (see Section 6.1.1).
Drain water out of the system until a system pressure
of 1.0 bar is reached. (The ideal measured value on the
pressure gauge is 0.5 bar plus an extra amount
corresponding to the highest point of the system
above the boiler. A height of 10 m corresponds to a
pressure increase on the pressure gauge of around
1 bar. The pressure must not be less than 1 bar on any
installation.)
If the system is to be protected by an inhibitor, it
should be added at this stage in accordance with the
manufacturer's instructions.
Further information can be obtained from Sentinel,
Betz Dearborn Ltd., Tel.: 0151 420 9595, or from
Fernox, Alpha–Fry technologies, Tel.: 0870 8700362.
Re-mount the enclosure of the boiler.
Attach the bottom cover to the boiler by sliding the
front edge of the cover into the lip at the bottom front
edge of the appliance chassis.
Carefully push the rear of the bottom cover upwards
until the spring retaining clips engage at the side of
28
the appliance. It may be necessary to adapt the
bottom cover by removing the easy break sections.
6.4
Handing over the appliance to the owner
• Set the controller for the maximum radiator
temperature to the required temperature.
• Set the controller for the maximum hot water
temperature to the required temperature.
• Instruct the operator in the safe and efficient
operation of the boiler, paying particular attention to
the functions of:
– the ON/OFF switch of the boiler,
– the controller for the maximum radiator
temperature,
– the controller for the maximum hot water
temperature,
– the pressure gauge.
• Make the operator acquainted with the operation of
any external controllers.
• Explain to the operator the importance of regular
maintenance by a competent heating engineer. It is
strongly recommended that a maintenance contract
be taken out to ensure regular maintenance. Further
information can be obtained from Vaillant Service
Solutions (0870 6060 777).
• Enter the operating pressure of the central heating
system, the heat feed (in kW) and the temperature
difference between the flow and return in the
Benchmark gas boiler commissioning checklist.
If the appliance is not installed and commissioned in
accordance with manufacturer's instructions this can
lead to invalidation of the guarantee (Note: Your legal
rights remain unaffected by this.).
• Leave the operating and installation instructions with
the operator of the appliance.
• Go through the operating manual with the operator
and answer any questions.
• Draw special attention to the safety instructions,
which the operator must follow.
• Instruct the operator about the methods used for
combustion air supply and flue conducting. In
particular, point out that these measures must not be
altered.
• Inform the operator that the instruction manuals
should be kept near the appliance.
h Note!
When you have finished the installation, attach
the sticker supplied (835593) to the front case
of the appliance in the user’s language.
a Caution!
The front cover should only be removed
- for initial installation access
- for servicing
- for testing
For continuous and safe operation the front
cover must be fitted together with a correctly
fitted and sealed flue system.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Adapting the appliance to the heating system 7
7
Adapting the appliance to the
heating system
The ecoTEC exclusive units are fitted with a digital
information and analysis system.
+
7.1
Selection and setting the parameters
In the diagnostic mode, you can change the various
parameters required to match the boiler to the heating
system.
Table 7.1 shows only those diagnostic points where
modifications are possible. All the other diagnostic
points are only required for diagnosis and fault
rectification (see Section 8).
Using the following description you can select the
relevant parameters :
• Press the "i" and "+" buttons simultaneously.
The display shows "d.0".
• Scroll to the desired diagnosis number with the "+" or
"–" buttons.
• Press the "i" button.
The display shows the relevant diagnosis information.
• If necessary, use the "+" or "–" keys to change the
value (display flashes).
• Save the new value by holding down the "i" button for
approx. 5 seconds until the display no longer blinks.
You can end the diagnosis mode as follows:
• Press the keys "i" and "+" simultaneously or do not
press any key for about 4 minutes.
The current pressure in the heating system appears in
the display again.
~5s
+
Fig. 7.1. Setting the parameters
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
29
7 Adapting the appliance to the heating system
7.2
Overview of the settable installation parameters
The following parameters can be set to match the
appliance to the heating system and to suit the
customers requirements:
Adjustable parameters
Default
setting
22 kW
27 kW
Display
Meaning
d.0
Heating partial load ecoTEC exclusive 832 27 kW
ecoTEC exclusive 838 30 kW
d.1
Pump overrun time for heating operation
(starts after completion of heat demand)
2 - 60 min
5 min
d.2
Max. blocking time heating at 20°C feed
temperature
2 - 60 min
20 min
d.14
Pump speed target value
Target value internal pump in % - possible
settings: Auto, 53, 60, 70, 85, 100 %
Auto
d.17
Heating flow/return regulation changeover 0 = flow, 1 = return
0
d.18
d.26
Pump mode (return flow)
Changeover option relay to electronic
0
2
d.71
Target value max. heating flow temperature 40 to 85 °C
75 °C
d.84
Maintenance indicator: Number of hours
until the next maintenance
-
0 = return, 1 = nonstop, 2 = winter
1 = circulation pump
2 = Ext. pump (default)
3 = storage charging pump
4 = vapour extraction hood
5 = external throttle
6 = ext. fault signal (without maintenance
display)
0 to 3000h and „-“
(300 corresponds to 3000 h, „-“ = deactivated)
Appliance-specific
setting
Table 7.1 Adjustable parameters
h Note!
You can enter your settings in the end column
after setting the appliance-specific parameters.
Note!
The diagnosis points d.17, d.71 and d.84 are located in the 2nd. diagnosis level, see Section
9.1.2
7.2.1 Setting the heating partial load
The units are set in the factory to a possible heat load
but not yet to the maximum value. Under diagnosis
point "d.0" you can set a value which corresponds to
the required output in the heating system in kW.
7.2.2 Setting the pump overrun time
The pump overrun time for the heating operation is set in
the factory to a value of 5 minutes. It can be set under
diagnosis point "1" within the range two minutes to
60 minutes. Under diagnosis point "d.18" you can set the
overrun behaviour of the pump to a different mode.
Overrun: After completion of the heat demand the heating
pump continues to run for the time set under "d.1".
30
Continuous: The internal heating pump is switched
on when the rotary knob for setting the heating feed
temperature is not in the left-hand stop position and the
heat demand is released by an external controller.
Winter: The internal heating pump is switched on when
the rotary knob for setting the heating feed temperature
is not in the left-hand stop position.
7.2.3 Setting the maximum flow temperature
The maximum feed temperature for the heating is set in
the factory to 75 °C. Under diagnosis point "d.71" it can
be set to between 40 und 85 °C.
7.2.4 Setting the return temperature control
When connecting underfloor heating or wall heating to
the appliance which does not have its own temperature
regulation, the temperature regulation mode can be
changed from feed temperature regulation (factory
setting) to return temperature regulation under
diagnosis point "d.17".
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Adapting the appliance to the heating system 7
7.2.5
Setting the burner anti-cycle time
TFeed(target) Set maximum burner anti-cycle time [min]
[°C]
1
5
10
15
20
25
30
35
40
45
50
55
60
20
2,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
50,0
55,0
60,0
25
2,0
4,5
9,2
14,0
18,5
23,0
27,5
32,0
36,5
41,0
45,0
50,0
54,5
30
2,0
4,0
8,5
12,5
16,5
20,5
25,0
29,0
33,0
37,0
41,0
45,0
49,5
35
2,0
4,0
7,5
11,0
15,0
18,5
22,0
25,5
29,5
33,0
36,5
40,5
44,0
40
2,0
3,5
6,5
10,0
13,0
16,5
19,5
22,5
26,0
29,0
32,0
35,5
38,5
45
2,0
3,0
6,0
8,5
11,5
14,0
17,0
19,5
22,5
25,0
27,5
30,5
33,0
50
2,0
3,0
5,0
7,5
9,5
12,0
14,0
16,5
18,5
21,0
23,5
25,5
28,0
55
2,0
2,5
4,5
6,0
8,0
10,0
11,5
13,5
15,0
17,0
19,0
20,5
22,5
60
2,0
2,0
3,5
5,0
6,0
7,5
9,0
10,5
11,5
13,0
14,5
15,5
17,0
65
2,0
1,5
2,5
3,5
4,5
5,5
6,5
7,0
8,0
9,0
10,0
11,0
11,5
70
2,0
1,5
2,0
2,5
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
75
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
Table 7.2 Effective burner anti-cycle time
The burner is electronically locked for a specific time
after each time it is switched off ("re-start interlock")
to avoid frequent switching on and off of the burner
(energy losses).
The burner anti-cycle time is only activated for the
heating operation. Hot water operation during a burner
anti-cycle time does not affect the timer.
The individual anti-cycle time can be matched to the
hydraulic and thermal properties of the heating
installation. In the factory the burner anti-cycle time is
set to a value of 20 minutes. It can be varied under
diagnosis point "d.02" within the range 2 minutes to
60 minutes. The individual effective anti-cycle time is
calculated from the momentary target feed temperature
and the set maximum burner anti-cycle time.
The timer can be reset or cancelled by actuating the
appliance main switch. The remaining burner anti-cycle
time left after switching off by the controller in heating
operation can be called up under diagnosis point "d.67".
The individually effective burner anti-cycle times with
respect to the feed temperature and the maximum set
burner anti-cycle time can be taken from Table 7.2.
7.2.6
Determination of the maintenance interval/
maintenance display
The electronics of the ecoTEC exclusive allow you to
determine the maintenance intervals for the appliance.
This function serves to provide a signal that, after a
specific, adjustable, number of burner operating hours,
the boiler needs to be serviced. The service signal SEr is
shown in the display of the ecoTEC exclusive alternately
with the current pressure after expiry of the set number
of burner operating hours. The display also appears on
the VRT 360 and 400 (accessories).
Heat demand
Burner operating hours to the next
Number of
inspection/service (dependent
persons
upon the type of appliance)
32 kW
3-4
4-6
2.800 h
2.900 h
38 kW
4-6
4-8
3.000 h
3.100 h
Table 7.3 Guide values for operating hours
The operating hours to the next service can be set under
diagnosis point "d.84". Guide values can be taken from
Table 7.3; these values correspond to an approximate
operating time for the appliance of one year.
The operating hours can be set in steps of ten from
0 to 3000 h.
If there is no number in the diagnosis point "d.84", but
there is the symbol "-", then the "maintenance display"
is not active.
h Note!
After the set number of hours have expired, the
service interval must be entered in the
diagnosis mode again.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
31
7 Adapting the appliance to the heating system
7.2.7 Setting the pump output
The ecoTEC exclusive is fitted with a speed controlled
pump which sets itself to the hydraulic conditions and
the heat demand of the heating system.
Under certain conditions the output of the pump can be
set, in five steps to 53, 60, 70, 85 or 100% of the
maximum pump output using the diagnosis system. This
switches the speed control off.
Lift [mbar]
a
7.3
Adjusting the bypass valve
The appliances have a bypass valve.
The pressure can be adjusted between 170 and 350 mbar.
Approx. 250 mbar is preset (mid-position). The pressure
changes by approx. 10 mbar each time the adjusting
screw is rotated. By turning right, the pressure
increases and turning left decreases it.
1
Caution!
When using an flow header we recommend turning off the speed control and setting the pump
output to 100%.
400
2
300
200
1
100
0
0
200
400
600
800
1000
1200
1400
1600
1800
Volumeflow [l/h]
Fig. 7.3. Setting the by-pass valve
• Regulate the pressure using the setting screw (1).
Fig. 7.2 Characteristic pump line for ecoTEC exclusive 832 and 838
Legend:
1 at 27 kW
2 at 30 kW
PresPosition of the setting
sure
screw
(mbar)
Notes/application
Right-hand stop
(turned all the way
down)
350
If the radiators do not get
properly hot in the works setting
Mid-position (5 turns
to the left)
250
Default setting
5 further turns to
the left from the
mid-position
170
If noises in the radiators or
radiator valves are produced
Table 7.4 Setting value for the bypass valve
32
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Inspection and maintenance 8
8
8.1
Inspection and maintenance
Inspection and maintenance intervals
Danger!
Risk of injury and risk of damage to property
due to neglected inspection and maintenance!
Neglected inspection and maintenance works or
not observing the stated inspection and
maintenance intervals can interfere with the
operational safety of the boiler and can result
in damage to property and to persons.
• Point out to the operator that he must
observe the demanded inspection and
maintenance intervals as a minimum.
• Carry out proper regular inspections once a
year.
• Carry out regular maintenance as dictated by
findings during the inspection process.
The frequency of maintenance must not be
longer than every 5 years.
This normally is done by cleaning, adjustment and, if
necessary, replacing individual components that are subject
to wear.
You must carry out an annual inspection of the
Vaillant ecoTEC.
It is possible to perform a quick, accurate inspection without
removing components by requesting data from the DIA
system, carrying out the simple visual checks indicated in
Table 8.2 and performing a flue gas measurement.
The maintenance intervals (at least once every 5 years) and
their scope are determined by the heating engineer based on
the condition of the boiler found during the inspection.
All inspection and maintenance work should be performed in
the order specified in Table 8.2.
d Danger!
Possible poisoning and burning by escaping hot
flue gases!
It is possible that hot flue gases escape and
could result in poisoning or burning, if the boiler
is operated
- without a completely installed air/flue gas
duct
- with an opened air/flue gas duct
- with internal leakages and an opened front
casing.
• Operate the boiler
- for commissioning
- for testing purposes
- in continuous mode
only with closed front casing and completely
mounted and closed air/flue gas duct.
Danger!
Danger of life and limb due to improper
inspection/maintenance!
Inspections/Maintenance work carried out
improperly can result in leakages and explosion.
• The boiler may only be inspected/maintained
by a competent person.
All service work must be carried out by a competent
person in accordance with the Gas safety, installation
and use regulations. In the UK this is considered to be a
person approved at the time by the Health and Safety
Executive.
In addition BS 6798: 2009 “Specification for installation and
maintenance of gas-fired boilers of rated input not exceeding
70 kW net” advises that:
- The person carrying out a combustion measurement
must be assessed as competent in the use of a flue
gas analyser and the interpretation of the results.
- The flue gas analyser used must be one meeting the
requirements of BS7927 or BS-EN50379-3 and be
calibrated in accordance with the analyser
manufacturers’ requirements.
- Competence can be demonstrated by satisfactory
completion of the relevant ACS standard assessment,
which covers the use of electronic portable flue gas
analysers’ in accordance with BS 7967, parts 1 to 4.
- The flue gas analyser is set to the correct fuel setting.
We recommend the conclusion of an inspection and
maintenance contract with an approved company or installer.
The inspection serves to determine the actual condition of
the respective boiler and compare it with the specified
condition. This is done by measuring, checking and observing.
Maintenance is required in order to eliminate any deviations
of the actual condition from the specified condition.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
8.1.1
General inspection and maintenance
instructions
To ensure the faultless operation, long term availability
of all functions and long working life of your Vaillant
boiler and to prevent modifications to the approved
series status only genuine Vaillant spare parts must be
used when carrying out inspection, maintenance and
repair work.
For an overview of the available original Vaillant spare
parts, contact the Vaillant sales office on
01634 292310.
During any inspection and maintenance or after change
of parts of the combustion circuit, the following must be
checked:
- The appliance has been installed in accordance with
the relevant installation instructions.
- The integrity of the flue gas installation and flue seals
is in accordance with the relevant flue installation
instructions enclosed.
- Visual, the integrity of the boiler combustion circuit
and relevant seals.
- The gas inlet working pressure at maximum rate as
described in Section 6.2.3.
33
8 Inspection and maintenance
-
The gas flow rates as described in Section 6.2.2.
Correctness of electrical, water and gas connections.
Correctness of the water pressure.
The condition of the whole system, in particular the
condition of radiator valves, evidence of leakage from
the heating system and dripping taps.
• Correct any faults before proceeding.
8.1.2
• Check the boiler for gas and water leaks.
• If necessary, refill and re-bleed the heating
installation.
• Replace the front casing to the boiler.
• Carry out a functional check of the boiler
(see Section 6).
• Always check earth continuity, polarity and resistance
to earth with a multimeter after any service work and
after replacing any electrical component.
Safety instructions
8.1.3
Danger!
Danger of life and limb by electric shock!
The supply terminals of the boiler are under
mains voltage even if the boiler main switch is
off.
• Don’t touch the supply terminals.
• Protect the electronic box from any water or
spray.
• Before working on the boiler, turn off the
power and secure against restart.
Checking the CO2 concentration
Note
Checking/adjustment of the CO2 concentration
is required in the following instances:
- replacement of gas valve,
- conversion to or from Natural Gas/LPG
- or if an incorrect combustion is suspected.
1
Note
If it is necessary to keep the electricity to the
boiler switched on for certain inspection and
maintenance, this is indicated in the description
of the maintenance task.
Always perform the following steps prior to inspection
or maintenance work:
• Switch off the main switch.
• Disconnect the boiler from the power mains by
- disconnecting the mains plug or
- de-energising the boiler via an isolating device with a
contact opening of at least 3 mm (e. g. fuses or
power switches).
• Further check for electrical isolation of the appliance
by use of a test meter.
• Close the gas isolation valve.
• Close the service valves in the heating flow and
return.
• Remove the front casing from the boiler.
• When removing any water carrying components
ensure that water is kept away from all electrical
components.
Always perform the following steps after performing
any inspection or maintenance work:
• Always use new seals and O-rings when parts are
replaced.
• Open the service valves in the heating flow and
return.
• Reconnect the boiler to the power mains.
• Switch the main switch on.
• Fill the heating circuit of the boiler to a pressure of
between 1.0 and 2.0 bar if required.
• Bleed the heating installation (see Section 6.1.1, Filling
and bleeding from the heating side).
• Open the gas isolation valve.
34
2
3
4
Fig. 8.1 Measuring the CO2 concentration, specifying the air
ratio (gas setting)
Legend:
1 Flue gas analysis point
2 Screw
3 Air intake pipe
4 Main throttle
Note
The boiler is fitted with a flue gas analysis
point (1). A suitable flue gas analyser can be
connected to this point to establish the
combustion performance of the boiler.
• Remove the front casing.
• Start the testing program P.1.
• Wait at least 5 minutes until the boiler reaches its
operating temperature.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Inspection and maintenance 8
• Measure the CO2 concentration at the flue gas
analysis point (1). Compare the measured value with
the corresponding value in Table 8.1.
• If all these points are as required, proceed as
described in Section 8.1.5.
• If one of the flue gas values is greater than the
acceptable values in Table 8.1, then proceed as
described in the following Section 8.1.4.
8.1.4
Adjusting the CO2 concentration (or the air
ratio)
d Danger!
Increased risk of poisoning due to incorrect
settings!
Incorrect setting may increase the risk of
poisoning.
• If one of the flue gas values is greater than
the acceptable values in Table 8.1 then check
- the integrity of the complete flue gas
installation
- the integrity of the combustion circuit seals
- the gas inlet working pressure
- the gas flow rate.
• Re-secure the air intake pipe with the screw (2).
• Put the front casing back on.
Settings
Natural gas (H) Propane
Tolerance
Tolerance
CO2 after 5 minutes full
load mode with
boiler front casing closed
CO2 after 5 minutes full
load mode with boiler
front casing removed
Set for Wobbe-Index W0
CO value with full load
CO/CO2
Unit
9.2
1,0
10.2
0,5 Vol.–%
9.0
1,0
10.0
0,5 Vol.–%
15
< 250
< 0,0031
22.5
< 250
< 0,0026
kWh/m3
ppm
Table 8.1 Factory gas settings
Danger!
d Risk
to life due to poisoning!
CO is an extremely toxic gas. Risk to life due to
excessive CO concentrations.
• If you are not able to adjust the boiler
correctly and the flue gas values remain
higher than allowed in Table 8.1, call the
Vaillant Service Solutions.
• Do not start up the boiler!
If the flue gas value needs to be adjusted,
• unfasten the screw (Fig. 8.1, 2) and
• fold the air intake pipe (Fig. 8.1, 3) forwards through
90°. Do not remove the air intake pipe.
• Specify the required flue gas value if necessary (value
with front casing of boiler removed, see Table 8.1) by
turning the screw of the main throttle (Fig. 8.1, 4)
h Note
Use a 4 mm hexagon socket spanner to turn
the screw.
• Turn to the left: higher CO2 concentration,
• Turn to the right: lower CO2 concentration.
h Note
Natural gas: Only perform the adjustment in
increments of 1/8 turn and wait approximately
1 minute after each adjustment until the value
stabilises.
Liquid gas: Only perform the adjustment in very
small increments (approximately 1/16 turns),
and wait approximately 1 minute after each
adjustment until the value stabilises.
• After performing the adjustments, fold the air intake
pipe back up.
• Check the CO2 concentration once again.
• If necessary, repeat the setting process.
• Push the „i“ button to deactivate the full load mode.
The full load mode is also deactivated if no button is
pushed for 15 minutes.
• The adjusting screw shall be sealed after the
adjustment.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
35
8 Inspection and maintenance
8.1.5
Inspection and maintenance work steps
Column 2
Maintenance
Column 1
must be carried
Inspection must
out at regular
be carried out
intervals – but
each year
no longer than
5 years
No. Activity
1
Check the air flue gas installation for leaks and for proper fixation and ensure it is not blocked
or damaged and is fitted correctly, complying with the relevant installation instructions.
x
x
2
Carry out a general inspection of the boiler for dirt and dust and clean as necessary.
x
x
3
Visually inspect the complete heat engine for its general condition and for signs of corrosion,
sooting or other forms of damage. If damage is evident proceed to column 2.
x
x
4
Measure the gas flow rate during operation with maximum load (Section 6.2.2). If the gas flow
rate complies to the Table 6.3 continue with column 1, if not proceed to column 2.
x
x
x
x
5
6
Check the gas inlet working pressure (Section 6.2.3) operation with maximum load. If the gas
inlet working pressure complies to the Table 6.4 continue with column 1, if not proceed to
column 2.
Check combustion by measuring CO, CO2 and CO/CO2. If the values are outside the
tolerances of Table 8.1 proceed to maintenance column 2. You must not proceed with the
maintenance if a new burner door seal kit is not available.
x
7
Isolate the boiler from the power mains. Check whether the electrical plug connections and
the other electrical connections are fitted tightly and correct them if necessary.
8
Close the gas isolation valve and the service valves.
x
9
Dump the pressure in the boiler on the water side (observe pressure gauge) and check the
charge pressure of the expansion vessel. Top up if necessary.
x
x
10 Remove the compact thermal module.
11
x
x
Check the integrity of all combustion circuit seals, especially the burner door seal. If there are
any damages repair them before proceeding.
x
12 Clean the heat exchanger.
x
13
x
Check whether the burner is dirty and clean it if necessary.
14 Check the condensate siphon in the boiler, clean and fill if necessary.
x
x
15 Check the condensate ducts in the boiler and clean if necessary.
x
x
16 Install the compact thermal module. Caution: Use new seals and nuts!
x
Open the service valves and fill up the boiler/appliance to approximately 1.0 - 2.0 bar
(depending on the static height of the system). Start the bleeding program P.0.
Open the gas isolation valve, reconnect the boiler with the power mains and switch on the
18
boiler.
Perform a test operation of the boiler and heating installation, including water heating and
19
bleed again if necessary.
x
x
x
x
20 Check visually the ignition and burner performance.
x
x
x
x
17
21
Check the boiler for leaks of any kind (gas, flue gas, water, condensate) and rectify as
necessary.
x
If you had problems with the CO, CO2, CO/CO2-values in Step 6 before the maintenance, check
22 them again now (see Table 8.1). If they are outside of the tolerances of Table 8.1 make an
adjustment, see Section 8.1.4.
23 Complete the gas commission checklist (benchmark book).
x
x
x
Table 8.2 Inspection and maintenance steps
36
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Inspection and maintenance 8
8.2
Filling/draining the heating installation
1
8.2.1 Filling the unit and heating installation
The filling of the appliance and the heating system is
described in Section 6.1.
2
8.2.2 Draining the unit
• Close the maintenance cocks (if fitted) on the appliance.
• Open the drain valves on the maintenance cocks.
3
4
8.2.3 Draining the entire installation
• Attach a hose to the filling/draining cock on the system.
• Bring the open end of the hose to an appropriate
drain point.
• Check that the maintenance cocks of the boiler are
open.
• Open the filling/drain cock.
• Open the bleed valves on the radiators.
Start at the highest radiator and then work from the
top to the bottom.
• When the water has drained out of the heating
system, close the bleeding valves on the radiators and
close the filling/drain cock again.
8.3
Servicing the compact thermal module
8.3.1 Dismantle compact thermal module
The compact thermal module consists of a
speed-controlled fan, the gas fitting, the gas mixer pipe
for the fan pre-mix burner and the pre-mix burner itself.
These four individual parts form the compact thermal
module component.
d Danger!
Danger of explosion through gas leakage!
The mixer tube between the gas control unit
and burner must not be opened. It can only be
guaranteed that this component is gas-tight
after it has been inspected at the factory.
Danger!
There is danger of being burned or scalded at
the compact thermal module and at all
components carrying water. Only carry out
work on these components once they have
cooled down.
5
6
Fig. 8.2 Dismantling compact thermal module
• Remove the screw (3) and remove the air inlet pipe (1)
from the inlet spigot on the gas fitting.
• Separate the gas supply pipe (6) on the gas fitting.
Secure the gas corrugated pipe against twisting by
bracing the pipe on the wrench surface while
loosening the union nut.
a Caution!
Damage to the gas pipe!
Under no circumstance may the compact
thermal module be suspended from the flexible
corrugated gas pipe.
• Pull the two plugs of the ignition und grounding lines
off the ignition electrode (4).
• Only ecoTEC exclusive 832: Pull the cable plug off the
fan motor and the cable off the gas fitting.
Only ecoTEC exclusive 838: Open the mains coupling
to the fan.
• Undo the five nuts (2).
• Pull the entire compact thermal module (5) off the
heat exchanger.
• After dismantling the burner and the heat exchanger,
check for damage and dust and, if necessary, clean
the components as described below.
Proceed as follows to dismount it:
• Turn the appliance off on the main switch.
• Isolate the unit from the electrical mains.
• Cut off the gas supply to the device.
• Close the maintenance cocks on the appliance.
• Remove the front cover from the device.
• Swing off the electronic box.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
37
8 Inspection and maintenance
8.3.2
Clean the heat exchanger
8.3.4 Installing the burner assembly
a Caution!
Protect the electronics box turned down
1
against sprayed water.
2
1
Fig. 8.5 Replacing silicone gaskets
2
• Insert the new graphite seals (1) in the burner flange.
3
a Danger!
The two seals (1 - Fig. 8.5) on the burner assembly
4
(must be replaced each time the module is
removed (for example during maintenance).
The burner flange insulation (2 - Fig. 8.5) on
the compact thermal module (SP no. 21-0734)
may not show any signs of damage; otherwise
it must also be replaced.
Fig. 8.3 Clean the heat exchanger
• Remove the compact thermal module (see Section 8.3.1).
• Clean the pipes (3) of the heat exchanger (4) using
regular vinegar. Flush with water. The water flows out
of the heat exchanger through the water condense trap.
• After a soaking time of approx. 20 minutes, flush away
the dirt particles that have come loose with a powerful
water jet. Avoid pointing the water jet directly at the
insulating surface (2) on the back of the heat exchanger.
8.3.3
1
2
Checking the burner
3
4
5
1
6
Fig. 8.4 Checking burner
The burner (1) is maintenance-free and needs no cleaning.
• Check the burner surface for damage, replace the
burner if necessary.
• After checking/replacing the burner, dismantle the
compact thermo module as described in Section 8.3.4.
38
Fig. 8.6 Installing compact thermal module
• Place the entire compact thermal module (5) onto the
integral condensation heat exchanger.
• Tighten the five nuts (2) across the diagonal until the
burner door fits closely and uniformly onto the mating
surfaces.
• Insert the ignition cable and the earth cable of the
ignition electrode (4).
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Inspection and maintenance 8
• Only ecoTEC exclusive 832: Insert the cables on the
fan motor and the cable on the gas fitting.
Only ecoTEC exclusive 838: Close the mains coupling
to the fan.
• Connect the gas supply (6) with a new gasket to the
gas fitting. Use the spanner flat at the flexible gas line
to hold the gas line.
a Caution!
Open the gas supply and check the appliance
for gas leaks using a leak testing spray. Pay
particular attention to the gas fitting (6).
• Check that the blue gasket in the air intake pipe (1)
is correctly located in the gasket seat.
• Insert the air intake pipe on the suction nozzles and
secure the pipe with the retaining screw (3).
8.4
Maintaining the secondary heat exchanger
• Release the nut (4) on the secondary heat exchanger.
• Release the clamp (1) on the preference changeover
valve.
• Release the clamps (2) and (3) on the secondary heat
exchanger.
• Remove the secondary heat exchanger to the side.
• Flush the secondary heat exchanger thoroughly with
clean water.
• When re-assembling, use new O rings and flat seals,
the part numbers can be obtained from the parts
catalogue.
8.5
Cleaning the condense trap
1
d Danger!
All water conducting components present a
danger of burning and scalding. Only carry out
work on these components once they have
cooled down.
a Caution!
Protect the electronics box turned down
against sprayed water.
Fig. 8.8 Cleaning the condense trap
h
Note!
When removing the secondary heat exchanger,
protect the opening in the appliance from dirt
contamination!
d Danger!
If the device is operated with empty condense
trap, there is risk of poisoning through emitting
flue gases.
Therefore, fill the trap with water again after
each cleaning operation.
1
2
3
4
• Unscrew the lower section (1) of the water condense trap.
• Clean the bottom of the trap by flushing it out with
water.
• Fill the lower section with water until about 10 mm
below the upper edge.
• Fasten the lower section onto the condense trap again.
Fig. 8.7 Cleaning the secondary heat exchanger
• Isolate the appliance from the house electricity circuit
(see Section 8.3) and close the gas supply.
• Close the maintenance cocks -if fitted- and the cold
water inlet valve on the inlet combination, and drain
the appliance.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
39
8 Inspection and maintenance
8.6
8.7
Checking the connection pressure
(gas inlet working pressure)
To check the connection pressure proceed as described
in Section 6.2.3.
Checking the expansion vessel
8.8
1
Checking CO2 content and adjusting if
necessary
To check the air figure proceed as described in
Section 8.1.3.
8.9
Test operation
Always perform the following checks after completing
any inspection/maintenance task:
• Commission the appliance in accordance with the
instructions in the relevant operating manual.
Fig. 8.9 Checking the expansion vessel
h Note!
This check need not be performed every
year - a check every three years is sufficient.
• The maintenance cocks of the central heating system
must be closed.
• Release the pressure from the appliance.
• Remove the valve cover from the filling connection
of the expansion vessel.
• Check that the internal pressure in the expansion
vessel is between 0.75 and 0.9 bar. If the pressure
is less than this, the vessel must be pumped up again
using an air pump.
• Refit the valve cover.
• Re-pressurise the boiler and the heating system.
40
Fig. 8.10 Function check
• Check the appliance for gas and water leaks.
• Check the flue system for leaks and that it is fixed
properly.
• Check over-ignition and that the flame on the burner
is burning evenly.
• Check the function of the heating (see Section 6.3.1)
and the hot water preparation (see Section 6.3.2)
• Document the inspection/maintenance tasks performed in the form provided in the inspection or
maintenance contract.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Troubleshooting 9
9
Troubleshooting
h
Note!
If you wish to contact the Vaillant Service Team,
please refer to the error code displayed (F.xx)
and the appliance status (S.xx) if possible.
Display
Meaning
Heating mode
9.1
Diagnostics
9.1.1
Status codes
The status codes that you can see on the display
provides information about the current operating
condition of the appliance.
S.0
S.1
S.2
S.3
S.4
S.5
S.6
S.7
S.8
No heat required
Fan start
Water pump flow
Ignition
Burner mode
Fan and water pump return water
Fan return flow
Water pump return water
Burner lock after heating mode
Hot water function
S.10
S.11
S.13
S.14
S.15
S.16
S.17
Hot water switch on
Fan start
Ignition
Burner mode
Fan and water pump return water
Fan return flow
Water pump return water
Storage tank charging/heat retention mode
Page 20
S.21
S.23
S.24
S.25
S.26
S.27
S.28
Water pump flow
Fan start
Ignition
Burner mode
Fan and water pump return water
Fan return flow
Water pump return water
Burner lock after recharging/heat retention
(cycle suppression)
Other:
Fig. 9.1 Display of status codes
S.30
The display of the status codes can be viewed as follows:
• Press the "i" button.
The display shows the status code, e.g. S.4 for
"Burner mode - Heating".
The display of the status codes can be ended as follows:
• Press the "i" button or
• Do not press any button for about 4 minutes.
The current filling pressure in the heating system
appears in the display again.
S.31
S.32
S.34
S.36
S.41
S.42
S.53
S.54
S.96
S.97
S.98
Room thermostat blocks heating operation
(terminal 3’-4’ open)
Summer mode active or eBUS controller or timer
blocks heating operation
Heat exchanger antifreeze active, as fan speed
variation is too high. Appliance is within the waiting
time of the operation block function
Antifrost mode active
Target value specification of room thermostat
< 20 °C , i.e. the external regulator is blocking
the heating operation
Water pressure >2.9bar
Exhaust gas diverter return signal blocks burner
operation (only in connection with accessories) or
condensate pump faulty, heat demand is blocked
Appliance is within the waiting period of the
modulation block/operation block function due to
water shortage (flow-return spread too large)
Appliance is within the waiting period of the
operation block function due to water shortage
(temperature gradient)
Return sensor test running, heating demands
are blocked
Water pressure sensor test running, heating
demands are blocked
Flow/return sensor test running, heating
demands are blocked
Table 9.1 Status codes
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
41
9 Troubleshooting
9.1.2 Diagnosis codes
In the diagnosis mode, you can change certain parameters or display more information.
The diagnosis information is divided into two diagnosis
levels. The 2nd diagnosis level can be reached only after
entering a password.
a Caution!
The access to the 2nd diagnosis level may only
be used by a qualified heating engineer.
1st diagnosis level
• Press the "i" and "+" buttons simultaneously.
The display shows "d.0".
• Scroll to the desired diagnosis point of the 1st
diagnosis level using the buttons "+" or "–"
(see Table 9.2).
• Press the "i" button.
The display shows the relevant diagnosis information.
• If necessary, use the "+" or "–" keys to change the
value (display flashes).
• Save the new value by holding down the "i" button for
approx. 5 seconds until the display no longer blinks.
You can end the diagnosis mode as follows:
• Press the "i" and "+"
buttons simultaneously or
• Do not press any button for about 4 minutes.
The current pressure in the heating system appears in
the display again.
2nd diagnosis level
• Scroll as described above in the 1st. diagnosis level to
diagnosis number d.97
• Change the displayed value to 17 (password) and save
this value.
You are now in the 2nd diagnosis level in which all
information from the 1st diagnosis level (see Table 9.2)
and the 2nd diagnosis level (see Table 9.3) is displayed.
Scroll and change values and exit diagnosis mode as
described in the first diagnosis level.
h Note!
If you push the buttons "i" and "+" within
4 minutes of leaving the 2nd diagnosis level,
you can directly access the 2nd diagnosis level
without having to re-enter the password.
42
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Troubleshooting 9
Display Meaning
Display value/adjustable value
d.0
Heating partial load
adjustable heating partial load in kW
d.1
Water pump return time for heating mode
2 - 60 minutes (factory setting: 5)
d.2
Max. blocking time heating at 20°C feed temperature
2 - 60 minutes (factory setting: 20)
d.3
Measured value for the hot water outlet temperature
in °C
d.4
Measured value for the hot start sensor
in °C
d.5
Feed temperature target value (or return temperature target value, if return flow regulation selected)
in °C, max. of the value set in d.71
limited by an eBUS controller, if fitted)
d.6
Set hot water temperature
35 to 65 °C
d.7
Set hot water retention temperature
d.9
Feed target temperature from external analogue
regulator to terminal 7-8-9/eBus
40 to 65 °C
15 °C left, then 40 °C up to value set in d.20 (max. 70 °C)
in °C, minimum from ext. eBus target value and target
value terminal 7
d.10
Status internal heating pump
1 = on, 0 = off
d.11
Status external heating pump
1 to 100 = on, 0 = off
d.12
Cylinder charging pump
0 = off, 1 - 100 = on
d.13
Circulation pump
0 = off, 1 - 100 = on
d.15
Pump speed actual value
Actual value internal pump in %
d.16
Room thermostat 24 V DC on terminal 3‘ and 4‘
0 = Room thermostat open (no heat request)
1 = Room thermostat closed (heat request)
d.22
Hot water demand
1 = on, 0 = off
d.23
Summer mode (heating on/off)
1 = heating on, 0 = heating off (summer mode)
d.25
Storage tank charging /hot water charging via
eBUS controller released
1 = yes, 0 = no
d.30
Control signal for both gas valves
1 = on, 0 = off
d.33
Fan speed target value
in rpm/10,
d.34
Fan speed actual value
in rpm/10,
d.35
Position of the preference changeover valve
0 = heating; 100 = hot water; 40 = centre position
d.36
Through-flow sensor hot water actual value
in l/min
d.40
Flow temperature
actual value in °C
d.41
Return flow temperature
actual value in °C
d.44
Digitalised ionisation voltage
Display range 0 to 102, >80 no flame, <40 good flame display
d.47
External temperature (with weather-controlled
Vaillant controller)
actual value in °C
d.67
Remaining burner locking time
in minutes
d.76
Appliance variant (device specific number)
00 to 99
d.90
Digital regulator status
1 = identified, 0 = unidentified (eBUS Address ≤ 10)
d.91
DCF status with connected external probe with
DCF77 receiver
0 = no reception, 1 = reception, 2 = synchronised, 3 = valid
d.97
Activation of the 2nd diagnosis level
Password: 17
d.98
Telephone installer
Programmable telephone number
d.99
Language variant
Available languages: 0 = German, 1 = English, 2 = Dutch
Table 9.2 Diagnosis codes in the 1st. diagnosis level
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
43
9 Troubleshooting
Display
1)
Meaning
Display value/adjustable value
d.14
Pump speed target value
target value internal pump in % - possible settings:
0=Auto, 1=53, 2=60, 3=70, 4=85, 5=100 % (Factory setting: Auto)
d.17
Heating flow/return regulation changeover
0 = flow, 1 = return (factory setting: 0)
d.18
Pump mode (return flow)
0 = overrun 1 = continuous, 2 = winter (Factory setting: 0)
1 = circulation pump
2 = external pump
3 = storage charging pump
4 = vapour extraction hood
5 = external throttle
6 = external fault signal (without maintenance display)
1 = circulation pump (factory setting)
2 = ext. pump
3 = storage charging pump
4 = flue gas flap/extractor hood
5 = external gas valve
6 = external error message
1 = circulation pump
2 = ext. pump (factory setting)
3 = storage charging pump
4 = Flue gas flap/extractor hood
5 = External gas valve
6 = External error message
d.26
Changeover option relay to electronic
d.27
Changeover relay 1 on the accessories module
d.28
Changeover relay 2 on the accessories module
d.50
Offset for minimum fan speed
in rpm/10, adjustment range: 0 to 300
d.51
Offset for maximum fan speed
in rpm/10, adjustment range: -99 to 0
d.58
Activation solar post-heating
setting range: 0 to 3
0 = solar post-heating deactivated (factory setting)
3 = activation drinking water target value min = 60 °C for
solar post-heating
d.60
Number of temperature limiting shutdowns
amount
d.61
Number of fuel automatic system faults
number of successful ignitions in the last attempt
d.64
Average ignition time
in seconds
d.65
maximum ignition time
in seconds
d.68
Unsuccessful ignitions at the first attempt
number
d.69
Unsuccessful ignitions at the second attempt
number
d.70
Setting the priority changeover valve position
0 = normal mode (factory setting)
1 = centre position
2 = permanent heating position
d.71
Target value max. heating flow temperature
Adjustment range in °C 40 to 85 (Factory setting: 75)
d.72
Pump overrun time after heat retention function
Adjustment range in sec: 0, 10, 20 to 600 (Factory setting: 80)
d.73
Offset for hot start target value
Setting range: -15 K to +5 K (Factory setting: depending upon variant)
d.80
Operating hours heating
in h1)
d.81
Operating hours hot water function
in h1)
d.82
Hystereses in heating mode
number/1001) (3 equals 300)
d.83
Hystereses in hot water function
number/1001) (3 equals 300)
d.84
Maintenance indicator: Number of hours until the
next maintenance
setting range: 0 to 3000h and „-“ for deactivated
factory setting: „-“ (300 corresponds to 3000h)
d.93
DSN appliance variant setting
setting range: 0 to 99
d.96
Default setting
1 = Resetting adjustable parameters to factory setting
In the diagnosis codes 80 to 83 5 digit figure values are stored. When selecting e.g. d.80 only the first two digits of the figure value are displayed
(e.g.10). By pressing the „i“ key, the display switches over to the last three figures (e.g. 947). The operating hours counter of the heating in this case
would be 10947 h. Pressing the „i“ again causes the display to switch back to the diagnosis point that was called up.
Table 9.3 Diagnosis codes in the 2nd diagnosis level
44
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Troubleshooting 9
9.1.3 Error codes
The error codes displace all other displays when errors
occur.
If many errors occur simultaneously, the relevant error
codes are displayed alternately for approx. 2 seconds
each.
You can exit the error memory display as follows:
• Press the "i" button or
• Do not press any button for about 4 minutes.
The current heating flow temperature appears in the
display again.
9.1.4 Error memory
The last ten errors are saved in the appliance error
memory.
• Press the "i" and "-" buttons simultaneously.
• Scroll back in the error memory with the "+" button.
Code
Meaning
F.0
Interruption feed temperature sensor (NTC):
F.1
Interruption return temperature sensor (NTC):
Cause
NTC faulty, NTC cable faulty, faulty plug connection on NTC,
faulty plug connection on the electronics
NTC faulty, NTC cable faulty, faulty plug connection on NTC,
faulty plug connection on the electronics
Sensor plug has mass short to the casing, short-circuit in
wiring loom, sensor faulty
Sensor plug has mass short to the casing, short-circuit in
wiring loom, sensor faulty
Sensor plug has mass short to the casing, short-circuit in
wiring loom, sensor faulty
Flow probe not connected thermally correct or defective,
appliance does not shut down
Too little water in the appliance, water shortage switch defective,
cable to pump or water shortage switch defective, pump blocked
or defective, pump output too low
Pump blocked or defective, pump output too low, flow and return
sensor swapped over
Pump blocked, low output from the pump, air in appliance, system
pressure too low
F.10
Short-circuit in feed temperature sensor
F.11
Short-circuit in return temperature sensor
F.13
Short-circuit on heat retention storage tank sensor
F.20
Safety temperature limiter actuated
F.22
Dry fire
F.23
Water shortage, temperature spread between
flow and return probe too large
F.24
Water shortage, temperature rise too quick
F.25
Interruption in cable harness
Cable harness faulty
F.27
External light:
Gas solenoid valve defective, flame detector defective
Faults in the gas supply such as:
- Gas meter or gas pressure detector defective
- Air in gas
- Gas flow pressure too low
- Main gas cock closed
Faults in the gas fitting, wrong gas setting, igniter (ignition
transformer, ignition cable, ignition plug) defective, ionisation
current stopped (cable, electrode), faulty earthing in appliance,
electronics defective
Gas supply temporarily stopped, ignition transformer has spark
failure, faulty earthing of appliance
Fans blocked, plug not inserted correctly on fan, hall sensor
defective, fault in cable harness, electronics defective
Short-circuit on eBUS input, eBUS overload or two power
supplies with different polarities on the eBUS
Short-circuit to mass in cable harness to the gas valves,
installation fault on gas valve (short-circuit, mass short in the coils)
electronics faulty
F.28
Appliance does not start: Attempts to ignite
during start failed
F.29
Flame goes off during operation and subsequent
ignition attempts failed
F.32
Speed deviation Fan
F.49
eBUS undervoltage
F.61
Gas valve control faulty
F.62
Gas valve shutoff delay defective
Gas fitting leaking, electronics defective
F.63
EEPROM faulty
Electronics defective
F.64
Electronics/sensor fault
Short-circuit in flow or return sensor or electronics defective
F.65
Electronics temperature too high
Electronics too hot due to external effect, electronics defective
F.67
Flame monitor input signal is outside the limits (0 or 5 V)
electronics defective
F.70
No valid appliance variant for display and/or electronics
Spare part case: Display and electronics changed at the same
time appliance variant not re-set
Table 9.4 Error codes
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
45
9 Troubleshooting
Code
Meaning
Cause
F.71
Constant value feed NTC
Feed NTC faulty
F.72
Flow and/or return sensor fault
Signal water pressure sensor in the wrong range
(too low)
Signal water pressure sensor in the wrong range
(too high)
Flow and/or return sensor is faulty (tolerance too great)
Line to water pressure sensor is interrupted or has
a short-circuit to 0V or water pressure sensor faulty
Line to water pressure sensor has a short-circuit at 5V / 24V
or internal fault in water pressure sensor
Water pressure sensor or/and pump defective
Too little water in the appliance; check adjustable bypass;
Connect expansion vessel in return;
Air in the appliance
Cable harness faulty
Condensate pump faulty or return signal from the exhaust
gas flap has responded
Communication fault between the display and the printed
circuit board in the switchgear box
F.73
F.74
F.75
F.76
F.77
con
No sudden change in pressure was detected on
turning on the pump
Interruption in cable harness
Condensate pump or return signal from accessory
module heating
No communication with the printed circuit board
Table 9.4 Error codes (continuation)
9.2
Test programs
Special functions can be triggered in the appliances by
activating various test programs.
These programs are given in detail in the Table 9.5.
• The test programmes P.0 to P.6 will be started when
"Power ON" is turned on and the "+" button is
pressed for 5 seconds simultaneously. The display
shows "P.0".
• Press the "+" key to start counting the test programme number upwards.
• Press the "i" to operate the appliance now and to
start the test programme.
• Press "i" and "+" simultaneously to exit the test programs. You can also exit the test programs by not
pressing any button for 15 minutes.
Display
9.3
Resetting parameter to factory settings
Besides the option to reset individual parameters
manually to the factory settings specified in Tables 9.2
and 9.3, you can also reset all parameters
simultaneously.
• Change the value in the 2nd diagnosis level under
diagnosis point "d.96" to 1 (see Section 9.1.2).
The parameters of all adjustable diagnosis points now
correspond to the factory settings.
Meaning
P.0
Bleeding test program The heating circuit and
the hot water circuit are bled via the automatic
bleeding valve (the cap of the automatic bleeding
valve must be released).
P.1
Test programme where the appliance is operated
in full load after successful ignition.
P.2
Test program where the appliance is operated with
minimum gas volume (ignition gas volume) after
successful ignition.
P.5
Test function for the safety temperature limiter (STL):
The burner is switched on with maximum output,
the temperature controller is switched off so that the
burner heats until the software STL responds by
reaching the STL temperature on the flow or return
sensor.
P.6
Filling/draining programme:
The preference changeover valve moves to the centre
position. The burners and pump are switched off.
Table 9.5 Test programmes
46
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Replacing components 10
10 Replacing components
The tasks listed below in this section may be carried out
only by a heating engineer approved at the time by the
Health and Safety Executive.
• Only use genuine spare parts for repairs.
• Make sure the parts are correctly fitted and that their
original position and alignment are retained.
10.1
• Release the 4 screws (1) on burner, and remove the
burner.
• Mount the new burner with a new gasket. Make sure
that the nose on the burner window grips onto the
gasket in the groove in the burner.
• Install the compact thermo module as described in
Section 8.3.4.
• After completing the work, check for gas leaks and
perform a function check (see Section 6).
Safety instructions
10.3
d
Danger!
Each time the components are replaced, comply
with the safety instructions below for your own
safety and to avoid damage to the appliance.
• Take the appliance out of operation.
h Note!
Isolate the appliance from the electrical mains
Replacing fan or gas fittings
d Danger!
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Disconnect the appliance from the mains as described
in Section 10.1, and close the gas cock in the gas
supply pipe.
by pulling the plug out of the wall plug socket!
1
• Close the gas cock in the gas supply pipe, the maintenance cocks and -if fitted-in- the heating flow and
return.
• Close the cold water inlet valve on the inlet combination.
• Empty the appliance if you want to replace waterbearing components of the appliance!
• Make sure that no water drips on live components
(e.g. electronic box etc.)!
• Use only new gaskets and O-rings!
• After completing the work, check for gas leaks and
perform a function check (see Section 6).
10.2
2
3
4
Replacing burner
d Danger!
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Dismantle the compact thermo module as described in
Section 8.3.1.
1
Fig. 10.2 Dismantling fan with gas valve
• Remove the screw (2) and remove the air inlet pipe (1)
from the inlet spigot on the gas fitting.
• Release the gas supply pipe (4) on the gas valve.
• Pull out the plug from the gas valve.
• Only ecoTEC exclusive 832: Pull out the plug from the
fan printed circuit board.
Only ecoTEC exclusive 838: Open the coupling of the
mains input.
• Release the four screws (3) on the compact thermo
module .
• Remove the complete "gas fitting/fan" unit.
Fig. 10.1 Replacing burner
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
47
10 Replacing components
• Release both fixing screws (5) on the gas fitting and
remove the fan from the gas fitting.
• Replace the defective component.
• Remove the clamps (4) on the trap (3), release the
fittings on the trap and remove the trap from the
primary heat exchanger.
• Remove the adaptor nuts of the trap from the primary
heat exchanger.
• Release the return connection (6) and the feed
connection (5) on the primary heat exchanger.
• Release the three screws (2) on the primary heat
exchanger and remove the primary heat exchanger
from the appliance.
• Mount the new primary heat exchanger in reverse
order and replace the seals.
• Fill and bleed the appliance and if needed, the plant
after installing the new primary heat exchanger.
• After completing the work, check for gas and water
leaks and perform a function check (see Section 6).
a Caution!
Mount the gas valve and the fan in the same
10.5
5
Fig. 10.3 Gas fitting/fan screwed joint
Replacing electronics and display
position as before.
Danger!
d Before replacing the component, comply with
• Screw the fan to the gas fitting. Use the new seals.
• Re-install the complete "gas fitting/fan" unit in
reverse sequence.
• After completing the work, check for gas leaks and
perform a function check (see Section 6).
10.4
the safety instructions in Section 10.1.
• Comply with the assembly and installation manuals
provided with the spare parts.
Replacing display or electronics
If you are replacing only one of the two components,
the parameter adjustment functions automatically. On
turning on the appliance, the new component takes over
the previously set parameters from the components
that are not replaced.
Replacing primary heat exchanger
d Danger!
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Disconnect the appliance from the mains as described
in Section 10.1, and close the gas cock in the gas
supply pipe.
• Close the maintenance cocks - if fitted - in the heating
flow and return and drain the appliance.
• Dismantle the compact thermo module as described
under Section 8.3.1.
The electronics is now set to the appliance type and the
parameters of all adjustable diagnosis points correspond
to the factory settings.
6
5
4
Replacing display and electronics
When replacing both components (spare part case),
after being turned on, the appliance goes to fault and
displays the error message F.70.
• In the second diagnosis level, under the diagnosis
point "d.93" enter the number of appliance variant
according to Table 10.1 (see Section 9.1.2).
1
2
Appliance
Number of the appliance variant
ecoTEC exclusive 832
4
ecoTEC exclusive 838
5
Table 10.1 Numbers of the appliance variants
3
Fig. 10.4 Replacing primary heat exchanger
48
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Vaillant service 11
Recycling and disposal 12
11
Vaillant service
To ensure regular servicing, it is strongly recommended
that arrangements are made for a Maintenance
Agreement. Please contact Vaillant Service Solutions
(0870 6060 777) for further details.
12 Recycling and disposal
Both your Valliant ecoTEC exclusive and its packaging
consist mainly of recyclable raw materials.
The Vaillant ecoTEC exclusive and all accessories and
the packaging must not be disposed of in the household
waste. Make sure that the old appliance and any
accessories and the transport packaging are disposed of
in the proper way.
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
49
13 Technical data
13
Technical data
ecoTEC exclusive
832
838
Unit
Nominal heat output range P at 40/30 °C
11,0 - 29,3
12,1 - 32,4
kW
Nominal heat output range P at 50/30 °C
10,8 - 28,7
11,9 - 31,8
kW
Nominal heat output range P at 60/40 °C
10,5 - 27,9
11,5 - 30,9
kW
Nominal heat output range P at 80/60 °C
10,2 - 27,0
11,2 - 30,0
kW
Hot water output
31,4
37,2
kW
Maximum load in hot water function
32
38
kW
Maximum thermal load on heating-side
27,6
30,6
kW
Minimum thermal load
10,4
11,4
kW
Max. flow temperature
90
90
°C
Setting range max. feed temperature (factory setting: 75°C)
40 - 85
40 - 85
°C
Permissible total over-pressure
3
3
bar
Circulation water volume (with reference to T = 20 K)
Condensate volume approx. (pH value 3,5 - 4,0)
at heating operation 50 °C flow/30 °C return
Residual feed head pump (at nominal circulation water volume)
1161
1290
l/h
2,8
3,1
l/min
250 (300)
250
mbar
Heating
hot water handling
Least water volume
1,5
1,5
l/min
Water volume (at T = 35 K)
12,9
15,2
l/min
Maximum pressure
10
10
bar
Required connection pressure
0,35
0,35
bar
Hot water discharge temperature range
35 - 65
35 - 65
°C
Gas connection
15
15
mm
Heating connection
22
22
mm
Hot and cold water connection
15
15
mm
Exhaust spigot (parallel adaptor)
60/100
60/100
mm
Designation Venturi
051
051
–
Category
II2H 3P
II2H 3P
–
Connection pressure (gas flow pressure) natural gas, G20
20
20
mbar
Connection pressure (gas flow pressure) propane, G31
Connection value at 15 °C and 1013 mbar G20
(if necessary with reference to hot water preparation) G31
Exhaust gas mass flow min./max.
37
3,4
2,49
4,8/14,4
37
4,0
2,95
5,3/17,2
mbar
m3/h
kg/h
g/s
Exhaust gas temperature min./max.
40/78
40/82
°C
Exhaust gas connection approval
C13, C33, C43, C53, C83, B23, B33
C13, C33, C43, C53, C83, B23, B33
–
General
SEDBUK classification
NOx class
Appliance dimensions
Installation weight approx.
E = 91,1 / Class „A“
5
- Height 800
- Width 480
- Depth 450
44
E = 91,1 / Class „A“
–
5
800
480
450
46
–
mm
mm
mm
kg
Electrical connection
230/50
230/50
V/Hz
Built-in fuse
1 x 2 A slow-acting
1 x 2 A slow-acting
–
Electrical power consumption min./max.
40/95
40/110
W
Power consumption at rest
5
5
W
Level of protection
IP x4 D
IP x4 D
–
Test marks/registration number
CF 0085 BR 0308
CF 0085 BR 0308
–
Table 13.1 Technical data
50
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Appendix
Appendix
EC declaration of conformity
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
51
Installation,
Commissioning and
Service Record
52
Installation and maintenance instructions ecoTEC exclusive 0020017768_05
Please affix the label from the
rear cover of the control box
over this area.
SERVICE INTERVAL RECORD
0020008345-06
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below .
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service
as described in the boiler manufacturer’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.
SERVICE 1
SERVICE 2
Date
Energy Efficiency Checklist completed?
Yes
No
Date
Energy Efficiency Checklist completed?
Engineer Name
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
Engineer ID Number
Engineer ID Number
Comments
Comments
Signature
Signature
SERVICE 3
SERVICE 4
Date
Energy Efficiency Checklist completed?
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
Engineer ID Number
Engineer ID Number
Comments
Comments
Signature
Signature
SERVICE 6
Date
Energy Efficiency Checklist completed?
Yes
No
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
Engineer ID Number
Engineer ID Number
Comments
Comments
Signature
Signature
SERVICE 8
Date
Energy Efficiency Checklist completed?
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
Engineer ID Number
Engineer ID Number
Comments
Comments
Signature
Signature
Yes
No
Yes
No
Yes
No
SERVICE 10 Date
Date
Energy Efficiency Checklist completed?
No
Date
Engineer Name
SERVICE 9
Yes
Date
Energy Efficiency Checklist completed?
Engineer Name
SERVICE 7
No
Date
Engineer Name
SERVICE 5
Yes
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
Engineer ID Number
Engineer ID Number
Comments
Comments
Signature
Signature
0020017768_05 GBIE 062010 — Subject to alterations