Vaillant ecoTEC plus 837 Technical data

Installation and maintenance instructions
For the competent person
Installation and maintenance instructions
ecoTEC plus
VU
VUW
GB, IE
Table of Contents
i
BEFORE PROCEEDING - ENSURE BOILER IS
CORRECT FOR GAS GROUP SUPPLIED!
Table of Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Notes on the documentation .....................................4
Storing documents ..........................................................4
Symbols used ....................................................................4
Applicability of the instructions ...................................4
Identification plate...........................................................4
CE label...............................................................................4
Benchmark.........................................................................4
Type overview ...................................................................5
2
2.1
2.1.1
2.1.2
2.2
2.3
2.4
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.5.8
2.5.9
2.5.10
Safety .................................................................................6
Safety and warning information ..................................6
Classification of warnings ..............................................6
Structure of warnings .....................................................6
Intended use......................................................................6
Basic safety instructions ................................................6
Important information regarding
propane-fired boilers....................................................... 7
General requirements .....................................................8
Related documents ..........................................................8
Installation site .................................................................8
Gas supply .........................................................................9
Air supply ...........................................................................9
Compartment ventilation ...............................................9
Electrical supply ...............................................................9
Water supply Combination boilers...............................9
Water circulation system................................................9
Pressure relief valve...................................................... 10
Venting ............................................................................. 10
3
Description of the appliance ......................................11
4
4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.2.3
4.3
4.4
4.4.1
Installation ......................................................................12
Accessories .......................................................................12
Controller ..........................................................................12
Installation and operation.............................................12
Scope of delivery ............................................................12
Unpacking the boiler ......................................................12
Checking the scope of delivery....................................12
Disposing of the packaging ..........................................13
Transporting the appliance ..........................................13
Requirements for the installation site .......................15
Required minimum clearances/installation
clearances .........................................................................15
Using installation templates .........................................16
Dimension drawing and connection
measurements .................................................................17
Wall-mounting the boiler ............................................ 18
Removing/fitting the front casing ............................. 18
Removing/fitting the side panel .................................19
4.4.2
4.5
4.6
4.7
4.8
2
5
5.1
5.2
Gas installation ............................................................ 20
Preparing for installation ............................................ 20
Connecting the gas pipe ............................................. 20
6
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.5
6.6
6.7
Hydraulic installation ..................................................21
Preparing for installation ..............................................21
Connecting the hot and cold water (VUW boiler) ..22
Connecting the domestic hot water cylinder ..........22
Connecting the heating flow and heating return...22
VUW boiler .......................................................................22
VU boiler ..........................................................................22
Low loss header .............................................................23
Connecting the condensate discharge pipework ...23
Connecting the discharge pipe to the expansion
relief valve on the boiler ..............................................23
7
7.1
7.2
Flue gas installation ...................................................25
Air/flue gas duct.............................................................25
Flue termination .............................................................26
8
8.1
8.2
8.3
8.4
8.4.1
8.4.2
8.5
8.5.1
8.7
Electrical installation .................................................28
Preparing for installation .............................................28
Opening/closing the electronics box .........................28
Establishing the mains connection ............................28
Connecting the controller ............................................29
Fitting the controller .....................................................29
Connecting controllers to the electronic system .. 30
Connecting additional components ........................ 30
Connecting the auxiliary relay (grey connector
on PCB) ............................................................................ 30
Connect VR 40 – "2 from 7" multi-functional
module ..............................................................................31
Actuating the circulation pump demandcontrolled ..........................................................................31
Connection diagrams ....................................................32
9
9.1
9.2
Operation ........................................................................36
Calling up the installer level .......................................36
Overview of the menu structure ................................37
10
10.1
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
10.2.8
10.2.9
10.2.10
10.2.11
10.3
10.4
10.5
10.6
Commissioning ..............................................................39
Switching on the boiler.................................................39
Installation assistant .....................................................39
Language .........................................................................39
Filling mode .....................................................................39
Purging .............................................................................39
Target feed temperature ............................................. 40
Hot water temperature ................................................ 40
Comfort mode ................................................................ 40
Heating partial load...................................................... 40
Auxiliary relay and multi-functional module.......... 40
Competent person telephone number..................... 40
Terminating the installation assistant ..................... 40
Restarting the installation assistant ........................ 40
Appliance configuration and diagnosis menu........ 40
Using test programs ..................................................... 40
Preparing the heating water ........................................41
Read off the filling pressure ........................................41
8.5.2
8.6
Installation and maintenance instructions ecoTEC plus 0020116700_06
Table of Contents
10.7
10.7.1
10.7.2
10.7.3
10.8
10.8.1
10.9
10.10
10.11
10.11.1
10.11.2
Filling and purging the heating installation ............41
Filling the heating installation .................................. 42
Purging the heating system ....................................... 42
Flushing the system for the first time ("cold") ..... 42
Avoiding low water pressure ...................................... 43
Top up VUW boilers using a filling device ............... 43
Fill and purge the hot water system ........................ 43
Filling the condensate siphon .................................... 43
Checking the gas setting............................................. 44
Factory setting ............................................................... 44
Checking for tightness of the flue gas
installation and flue gas recirculation ..................... 45
10.11.3 Checking the gas flow rate ..................................... 45
10.11.4 Checking the gas inlet working pressure ................ 45
10.12
Carrying out a full function test.................................47
10.12.1 Checking the heating mode ........................................47
10.12.2 Checking hot water generation
(VUW boilers only) .........................................................47
10.12.3 Checking hot water generation
(VU boilers only).............................................................47
10.13
Final flush of the heating system ("hot") ............... 48
11
11.1
11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
11.1.6
11.1.7
11.1.8
11.2
12
12.1
12.1.1
12.1.2
12.1.3
12.1.4
12.1.5
12.2
12.2.1
12.2.2
12.2.3
12.3
12.3.1
12.4
12.4.1
12.4.2
12.4.3
12.4.4
12.4.5
Adapting the boiler to the heating
installation .................................................................... 48
Diagnosis codes – Overview ....................................... 48
Setting the heating partial load .................................52
Setting pump overrun time and pump
operating mode .............................................................52
Setting the maximum flow temperature ..................53
Setting the return flow temperature control ..........53
Burner anti-cycling time...............................................53
Setting the maintenance interval ............................ 54
Setting the pump output............................................. 54
Setting the by-pass valve ............................................ 54
Handing over the boiler to the operator................. 55
Inspection and maintenance ................................... 56
Inspection and maintenance intervals ..................... 56
General inspection and maintenance
instructions..................................................................... 56
Safety instructions ........................................................57
Checking the CO/CO2 ratio and the CO2
concentration ..................................................................57
Adjusting the CO2 concentration (or the air
ratio) ................................................................................. 58
Performing the gas family check .............................. 59
Inspection and maintenance work steps................. 60
Filling the boiler and the heating installation ..........61
Draining the boiler .........................................................61
Draining the entire heating installation ...................61
Using the function menu ..............................................61
Carrying out electronics self-tests .............................61
Carrying out maintenance work..................................61
Removing the compact thermal module...................61
Cleaning the heat exchanger ......................................63
Checking the burner .....................................................63
Cleaning the condensate siphon ................................63
Clean the filter in the cold water inlet
(VUW boilers only) ........................................................ 64
12.4.6
12.4.7
12.5
12.5.1
13
13.1
13.2
13.2.1
13.2.2
13.2.3
13.2.4
13.2.5
13.2.6
13.2.7
13.2.8
13.3
13.4
13.5
14
14.1
14.1.1
14.1.2
14.2
14.3
14.4
14.5
14.6
14.7
14.8
14.8.1
14.8.2
Installing the compact thermal module .................. 64
Checking the charge pressure of the expansion
vessel ............................................................................... 65
Checking the gas flow pressure ................................ 65
Checking CO2 content .................................................. 65
Troubleshooting ........................................................... 66
Contact Vaillant Service Solutions
(0870 6060 777) .......................................................... 66
Performing diagnostics ............................................... 66
Call up Live Monitor (status codes) .......................... 66
Status codes – Overview ............................................. 66
Service messages ..........................................................67
Calling up diagnosis levels ...........................................67
Reading off the fault codes .........................................67
Querying the fault memory .........................................67
Reset fault memory .......................................................67
Overview of fault codes............................................... 68
Using the function menu .............................................70
Running test programs .................................................70
Resetting parameters to factory settings ................70
Replacing components ................................................71
Preparing for and completing replacement work ...71
Preparing for replacement work .................................71
Completing replacement work.....................................71
Replacing the burner .....................................................71
Replacing the fan ...........................................................72
Replacing the gas valve................................................73
Replacing the venturi including the mass flow
sensor ............................................................................... 74
Replacing the expansion vessel..................................75
Replacing the heat exchanger ....................................75
Replacing the PCB and/or the display ......................76
Replacing either the display or the PCB ..................77
Replacing the PCB and the display at the same
time ...................................................................................77
15
15.1
15.2
15.3
Decommissioning .........................................................78
Temporarily shutting down the boiler ......................78
Taking the boiler permanently out of service ........78
Disposing of the boiler .................................................78
16
16.1
16.2
Guarantee and customer service............................78
Factory guarantee..........................................................78
Vaillant Service ...............................................................78
17
Technical data ...............................................................79
18
Glossary .......................................................................... 81
Benchmark Commissioning and Servicing Section......... 82
Index
Installation and maintenance instructions ecoTEC plus 0020116700_06
.......................................................................................... 86
3
1 Notes on the documentation
1
Notes on the documentation
Article
number
Gas
Council
Number
ecoTEC plus 612 (VU GB 126/5-5)
0010011677
41-044-60
ecoTEC plus 615 (VU GB 156/5-5)
0010011678
41-044-61
ecoTEC plus 618 (VU GB 186/5-5)
0010011679
41-044-62
Boiler
The following instructions are intended to guide you
throughout the entire documentation. Further documents
apply in combination with these installation and maintenance instructions.
We accept no liability for any damage caused by nonobservance of these instructions.
Type designation
ecoTEC plus
Other applicable documents
> Follow all installation instructions for the various parts
and components of the system without exception when
installing the ecoTEC plus.
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.
618 (VU GB 186/5-5)
(LPG)
ecoTEC plus 624 (VU GB 246/5-5)
0010011681
ecoTEC plus 630 (VU GB 306/5-5)
0010011682 41-044-64
630 (VU GB 306/5-5)
(LPG)
0010011683 41-044-67
ecoTEC plus
ecoTEC plus 637 (VU GB 376/5-5)
Storing documents
ecoTEC plus
> Pass these installation instructions and all other applicable documents and, if necessary, any required aids to the
system operator.
The operator will store the instructions and aids so that
they are available when required.
1.2
41-044-63
0010011684 41-044-65
ecoTEC plus 824 (VUW GB 246/5-5) 0010011685 47-044-40
ecoTEC plus 831 (VUW GB 316/5-5)
1.1
0010011680 41-044-66
831 (VUW GB 316/5-5)
(LPG)
0010011686 47-044-41
0010011687 47-044-46
ecoTEC plus 837 (VUW GB 376/5-5) 0010011688 47-044-42
1.1 Appliance types, article numbers and Gas Council Number
The article number of the boiler can be found on the identification plate.
Symbols used
1.4
Identification plate
The symbols used in the text are explained below:
i
>
1.3
Symbol that denotes useful tips and information
Symbol for a required action
The identification plate of the Vaillant ecoTEC plus is
attached to the underside of the boiler in the factory.
The article number of the gas fired wall hung boiler can be
found in the serial number. The seventh to sixteenth numbers constitute the article number.
The serial number can also be found on the lift out badge
located behind the front flap at the bottom of the boiler.
The serial number can also be shown on the display of the
boiler (¬ Operating instructions).
Applicability of the instructions
These installation instructions are only valid for boilers with
the following article numbers:
1.5
CE label
The CE label shows that the boilers comply
with the basic requirements of the applicable
directives as stated on the identification plate.
The declaration of conformity can be viewed at the manufacturer’s site.
1.6
Benchmark
Vaillant Ltd. supports the Benchmark Initiative.
You will find the Benchmark Logbook on the last pages of
this instruction manual. It is very important that this document be filled out properly when installing, commissioning,
4
Installation and maintenance instructions ecoTEC plus 0020116700_06
Notes on the documentation 1
and fully explained at hand over to the operator of the
installation. Installers should point out also the service
record section for completion following service calls to this
appliance.
Vaillant Ltd. is a licensed member of the Benchmark
Scheme which aims to improve the standards of installation
and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimize safety, efficiency and performance. Benchmark is
managed and promoted by the Heating and Hot water
Industry Council.
> For more information visit www. centralheating .co .uk
i
1.7
Vaillant supply a special self adhesive sticker on
top of the boiler for use in entering the serial
number details straight onto the commissioning
checklist found in the last pages of this document.
Type overview
Appliance type
ecoTEC plus
Designated country
(designation in
accordance with
ISO 3166)
Approval
category
612 (VU GB 126/5-5)
GB (Great Britain)
IE (Ireland)
I2H
615 (VU GB 156/5-5)
GB (Great Britain)
IE (Ireland)
I2H
618 (VU GB 186/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
624 (VU GB 246/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
630 (VU GB 306/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
637 (VU GB 376/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
824 (VUW GB 246/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
831 (VUW GB 316/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
837 (VUW GB 376/5-5)
GB (Great Britain)
IE (Ireland)
II2H3P
1.2 Type overview
Installation and maintenance instructions ecoTEC plus 0020116700_06
5
a
a
2 Safety
2
Safety
2.1
2.2
Safety and warning information
> When installing the ecoTEC plus, take account of the
general safety instructions and the warning notes that
appear before all of the actions.
2.1.1
Classification of warnings
The warning notes are classified in accordance with the
severity of the possible danger using the following warning
signs and signal words:
Warning
sign
Signal
word
a
e
a
b
Danger!
Explanation
Immediate danger to life or
risk of severe personal
injury
Danger!
Risk of death from electric
shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental damage
2.1 Classification of warnings
There is a risk of injury or death to the user or others, or of
damage to the product and other property in the event of
improper use or use for which it is not intended.
This boiler is not designed to be used by persons (including
children) with limited mental and sensory capabilities or by
persons who do not have enough experience and/or knowledge, unless they are supervised by a person who is responsible for their safety or they have been instructed by him/
her about how to use the boiler.
Children must be supervised to ensure that they do not
play with the boiler.
The boiler is intended as a heater for closed hot water/central heating installations and for hot water generation.
The use of the ecoTEC plus in vehicles, such as mobile
homes and caravans, is not classed as intended use. Units
that are not classed as vehicles are those that are installed
in a fixed and permanent location and that do not have any
wheels (fixed installation).
Any other use, or use beyond that specified, shall be considered as improper use. Any direct commercial or industrial use is also deemed to be improper.
The manufacturer or supplier is not liable for any damage
resulting from such use. The user alone bears the risk.
Intended use includes the following:
– observance of accompanying operating, installation and
maintenance instructions for Vaillant products as well as
for other parts and components of the system
– installing and fitting the appliance in accordance with the
boiler and system approval
– complying with all of the inspection and maintenance
conditions listed in the instructions.
Caution.
Any improper use is forbidden.
2.3
2.1.2
Intended use
Basic safety instructions
Structure of warnings
> Observe the following safety instructions at all times.
Warning signs are identified by an upper and lower separating line. and are laid out according to the following basic
principle:
a
6
Signal word!
Type and source of danger!
Explanation of the type and source of danger
> Measures for averting the danger
European installation directive
Installation and maintenance of the appliance should only
be undertaken by a competent person (referred to in these
instructions as “competent person” or “skilled trade company” and thereby indicating male and female persons)
approved at the time by the Health and Safety executive
and in accordance with the gas safety (installation and use)
regulations 1998. The existing regulations, rules and guidelines must be observed when doing so. The competent person is also responsible for inspection, maintenance and
repairs to the unit, as well as alterations to the gas volume
setting.
Only 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 installing electrical equipment must also be observed.
Installation and maintenance instructions ecoTEC plus 0020116700_06
a
Safety 2
Installation and settings
In the following cases, the boiler must be operated only
with the front casing fitted and closed and with a completely mounted air/flue gas duct:
– starting up
– test purposes
– continuous operation,
Otherwise, under unfavourable operating conditions, injury,
death or material damage may occur.
Exclusively for test purposes such as gas working pressure
testing the boiler may be operated with the front casing
removed for short durations ONLY but must have a completely mounted air/flue gas duct.
What to do if you smell gas
Installation errors, damage, manipulation, an unauthorised
installation site or similar can cause gas to escape and
result in a risk of poisoning and explosion. If there is a smell
of gas in the building, proceed as follows:
> Avoid rooms that smell of gas.
> If possible, open doors and windows fully and ensure air
is circulating.
> Avoid the use of naked flames (e.g. lighters, matches).
> Do not smoke.
> Do not use any electrical switches, plugs, doorbells, telephones or other communication systems in the building.
> Close the gas meter isolator device or the main isolator
device.
> If possible, close the gas stop cock on the unit.
> Warn the occupants in the building by knocking or calling.
> Leave the building.
> If you can actually hear gas leaking, leave the building
immediately and ensure that no third parties enter the
building.
> Alert the police and fire brigade when you are outside
the building.
> Use a telephone outside the building to inform the gas
supply company or National Grid Transco 0800 111999.
Material damage due to improper use and/or
unsuitable tools
The use of unsuitable tools or improper use thereof may
cause damage, such as gas or water leaks.
> When tightening or loosening threaded connections,
always use suitable open-end spanners, but do not use
pipe wrenches, extensions, etc.
2.4
Important information regarding
propane-fired boilers
Purging the liquid gas tank when installing the system:
> Before installing the boiler, make sure that the gas tank
has been purged.
The liquid gas supplier is responsible for proper ventilation
of the tank. Ignition problems can result if the tank is not
purged properly.
> In such cases, first contact the person in charge of filling
the tank.
> Also observe the information on conversion to liquid gas
in (¬ section 10.11) of this manual.
Using the correct gas group
Using the wrong gas group may cause a fault shutdown on
the boiler. Furthermore, ignition and combustion noise may
occur in the boiler.
> Only use propane gas G31.
Affix tank sticker
Affix the enclosed tank sticker (propane quality) to the tank
where it will be clearly visible, or on then cylinder cabinet
near the filler nozzle if possible.
What to do if you smell exhaust fumes
Installation errors, damage, manipulation, unauthorised
installation sites or the like can cause flue gas to escape
and result in a risk of poisoning. If there is a smell of
exhaust fumes in the building, proceed as follows:
> If possible, open doors and windows fully and ensure
adequate ventilation.
> Switch the boiler off.
> Check the flue gas route in the boiler and the flue gas
pipes.
Material damage caused by corrosion
To prevent corrosion on the boiler and also on the air/flue
gas duct, note the following:
> Do not use sprays, solvents, chlorinated cleaning agents,
paint, adhesives or similar substances in the vicinity of
the boiler.
Under unfavourable circumstances, these substances may
cause corrosion.
Installation and maintenance instructions ecoTEC plus 0020116700_06
7
a
a
a
2 Safety
2.5
General requirements
2.5.1
Related documents
To ensure the safe installation and continued satisfactory
operation of your appliance, all works shall be carried out
by a competent installer fully conversant with the required
current and up to date, acts standards, laws and regulations
relevant for this range of equipment at the time of installation. In addition any special requirements of Local Authorities, gas undertakings or insurers must be complied with.
Installers shall carryout a full site risk assessment and put
into place all necessary steps and procedures to comply
with Health and safety at work act and ensure safety of
themselves and others with regard to manual handling and
working at height requirements.
Attention shall be paid to (but not restricted to) the following:
– Gas Safety (Installation and Use) regulations.
– All Building Regulations 2000 for England and Wales,(as
amended).
– (Includes Approved Codes of Practice and Approved Documents for building regulations e.g. L1, L1A, L1B, L8.)
– The Building Standards, Scotland, and any requirements
determined by the local authorities within.
– The current Version of I.S.813 „Domestic Gas Installations“ and the current Building Regulations for IE.
– The current ETCI Regulations for installing electrical
equipment for IE.
– BS 7671 Requirements for electrical installations. IEE
Wiring Regulations
– The Electricity at Work Regulations.
– The Water supply (water fittings) regulations 1999.
– BS 5854 Code of practice for flues and flue structures
in buildings.
– BS EN 12828 Design of water-based heating systems.
– BS EN 806 parts 1 - 5
– BS 8558
– BS 6880 Code of practice for low temperature heating
systems with outputs greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
– BS 6981 Installation of low pressure gas pipework of up
to 35 mm in domestic premises.
– BS 4814 Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water and heating systems.
– BS 7074 Application, selection and installation of expansion vessels and ancillary equipment for sealed water
systems.
Part 1 Code of practice for domestic heating and hot
water.
Part 2 Code of practice for low and medium temperature
hot water systems.
– BS 7593 Code of practice for treatment of water in
domestic hot water central heating systems
8
– BS EN 13831 Closed expansion vessels with built in diaphragm
– BS EN 14336 Heating systems in buildings. Installation
and commissioning of water based heating systems.
– BS 5440 – 1 Installation of flues and ventilation for gas
appliances of rated input not exceeding 70 kW*
– BS 5440 – 2 Flueing and ventilation for gas appliances
of rated input not exceeding 70 kW*
* 1st 2nd and 3rd family gases.
– BS EN 6798 Installation & maintenance of gas fired hot
water boilers of rated input not exceeding 70 kW net
Institute of Gas Engineers Publications:
– IGE/UP/1B (Edition 2) Tightness testing and direct purging of small natural gas installations.
– IGE/UP/ 7 (Edition 2) Gas in timber and light steel
framed buildings.
– I.S. 813 - Domestic Gas Installations - 2nd edition (Ireland)
– BS 5482 - Part 1 Domestic butane and propane gas
burning installations
2.5.2
Installation site
The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location must
also provide adequate space for servicing and air circulation around the boiler.
Before commencement of any works the installer should
carry out a full risk assessment in accordance with Health
and Safety executive regulations.
The boiler may be installed in any room, although particular
attention is drawn to the requirements of BS 7671 (IEE Regulations), the electrical provisions of the Building Regulations (Scotland) and in IE the current edition of IS 813 and
the current ETCI rules, in respect of the installation of a
boiler in a room containing a bath or shower.
In case of installation of the boiler in an unusual location,
special procedures may be necessary and BS 5546 and
BS 6798 give detailed guidance on this aspect. The boiler
must be mounted on a flat, vertical wall, which must be sufficiently robust to take the weight of the boiler.
The boiler may be installed on a combustible wall, subject
to the requirements of the Local Authorities and Building
Regulations. A compartment used to enclose the boiler
must be designed and constructed specifically for this purpose. (An existing cupboard or compartment may be used
provided that it is modified for the purpose). Details of
essential features of cupboard/compartment design including airing cupboard installations are given in BS 6891. In IE
the current edition of IS 813.
i
If the boiler is to be installed in an airing
cupboard it is not required to separate the
boiler with a non-combustible partition. However
installation and servicing clearances must be
maintained, and the boiler kept clear of any
clothing.
Installation and maintenance instructions ecoTEC plus 0020116700_06
a
Safety 2
b
Caution.
Risk of damage caused by aggressive
vapours and dust.
Aggressive vapours and dust in the installation room may cause corrosion damage to
the boiler and to the flue gas installation.
> Ensure that the boiler is room sealed if
the air in the installation room contains
aggressive vapours or dust.
> Observe the following when choosing the installation site
and operating the boiler,
– Do not install the boiler in rooms prone to frost.
– Do not install the boiler in rooms in which the combustion air contains chemical substances, e.g. fluoride,
chlorine, sulphur, dust, etc. (e.g. sprays, solvents,
cleaning agents, paint, adhesives).
> Please ensure that the boiler is room sealed or in a separate installation room if
– the combustion air supply contains the aforementioned substances,
– you install the boiler in hairdresser salons, painter's or
joiner's workshops, cleaning businesses or similar.
> Do not route the combustion air through an old oil furnace chimney, as this can also cause corrosion.
2.5.3 Gas supply
An existing gas meter should be checked to ensure that it is
capable of passing the rate of gas supply required.
Installation pipes should be fitted in accordance with
BS 6891, in IE in accordance with the current issue of IS 813.
Pipework from the meter to the boiler must be of an adequate size.
Do not use pipes of a smaller size than the boiler gas connection. The complete installation must be tested and
purged in accordance with:
– IGE/UP /1B for systems up to 0.035 m3 capacity
– for larger systems IGE/UP/1A and
– for LPG installations refer to BS 5482 - 1 or
– IGE/UP1 Edition 2 for larger volume installations.
2.5.4 Air supply
Detailed recommendations for air supply are given in
BS 5440: Part 2. It is not necessary to have an air vent in
the room or internal space in which the boiler is installed.
2.5.5 Compartment ventilation
The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during
operation is very low. Compartment ventilation is required
if the flue used is not concentric and air is supplied from
the room or compartment the boiler is installed in.
2.5.6 Electrical supply
a
Danger!
Risk of death from electric shock.
If the appliance is not earthed, it may hold
voltage if a defect occurs.
> Earth the appliance.
A 230 V, ~ 50 Hz single phase electricity supply fused to 3
Amp. must be provided in accordance with the latest edition
of BS 7671 (IEE Wiring Regulations) and any other local regulations that may apply. In IE reference should be made to
the current edition of the ETCI rules. The method of connection to the mains electricity supply must provide a
means of completely isolating the boiler and its ancillary
controllers. Isolation is preferably by the use of a fused
three pin plug and unswitched shuttered socket outlet, both
complying with the requirements of BS 1363. Alternatively, a
3 Amp. fused doublepole switch with a 3 mm contact opening on both poles may be used.
2.5.7 Water supply Combination boilers
Designers and installers must ensure that all pipe work and
fittings connected to the ecoTEC complies with the necessary water fittings regulations. See related documents
above (ref BS 6700 and new BSEN 806 parts 1 - 5 plus BS
8558) For combination boilers the incoming water supply
should be checked to ensure that sufficient pressure and
flow rate are available to suite the intended use, see the
technical data at the back of this manual.
All mains water heated by the ecoTEC combination boiler
will be classed as Category 2 fluid and small expansion volumes created during warm up must be allowed to flow back
into the supply pipe. No back flow prevention is necessary
with this appliance as the very small expansion volume is
unlikely to heat the incoming service pipe above 25 Deg C.
Note that where back flow prevention devices are fitted
(this may include water meters) these can prevent the permitted expansion into the cold supply. This along with the
effects of pumping and / or water hammer can result in a
pressure build-up that may cause damage to the boiler (and
other household devices such as showers). Vaillant cannot
accept responsibility for damage caused to the boiler or its
surroundings where an appliance has been fitted to supplies with mechanical back flow prevention. In these cases
the requirement would be that a competent installer correctly installs a suitable shock arrestor / mini-expansion
vessel adjacent to the boiler in the cold water supply pipe.
2.5.8 Water circulation system
Detailed recommendations concerning the water circuit system can be taken from BS 6798 and BS 5449, Part 1 (for
Installation and maintenance instructions ecoTEC plus 0020116700_06
9
a
a
a
2 Safety
"Small Bore" and "Micro Bore" central heating installations). Lines which do not form part of the usable heating
surface should be insulated to prevent heat losses and possible freezing up, especially where the lines run under
rooves and ventilated cellar rooms. The drain connections
must be easily-accessible, so that the entire system including the boiler and hot water system can be drained. The
drain connections should be at least 1/2 " (BSP nominal
size) and must be in accordance with BS 2879.
The boiler is suitable for Minibore and Microbore systems.
Water lines are to be copper pipes in accordance with
BS 2871, Part 1. These must be thoroughly cleaned, especially when connecting a new boiler to an existing system.
Provided the national regulations and technical standards
do not stipulate more stringent requirements, the following
applies:
> You must condition the heating water in the following
cases:
– If the entire filling and supplementary water quantity
during the operating life of the system exceeds three
times the nominal volume of the heating installation
or
– If the limit values shown in the tables are not
observed.
Total heating
output
Overall hardness at smallest boiler heating
surface2)
20 l/kW
> 20 l/kW
< 50 l/kW
> 50 l/kW
mol/m3
(mg/l CaCO3)
mol/m3
(mg/l CaCO3)
mol/m3
(mg/l CaCO3)
2
(200)
0.02
(2.0)
1.5
(150)
0.02
(2.0)
0.02
(2.0)
0.02
(2.0)
0.02
(2.0)
0.02
(2.0)
Risk of damage if the heating water is treated with
unsuitable frost or corrosion protection agents.
Frost and corrosion protection agents can cause changes to
seals, noise during heating mode and may lead to
other consequential damage.
> Do not use any unsuitable frost or corrosion protection
agents.
Mixing additives with the heating water can result in material damage. However no incompatibility with Vaillant boilers has been detected with proper use of the following
products over a long period.
> When using additives, follow the manufacturer's instructions without exception.
Vaillant accepts no liability for the compatibility of any additive or its effectiveness in the rest of the heating installation.
Additives for cleaning measures
(subsequent flushing required)
– Fernox F3
– Sentinel X 300
– Sentinel X 400
Additives intended to remain permanently in the
system
–
–
–
–
Fernox F1
Fernox F2
Sentinel X 100
Sentinel X 200
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 if you
have used these additives.
> Inform the operator about the required measures for
frost protection.
Permissible water hardness
> Observe all valid national and technical regulations when
conditioning filling and supplementary water.
10
kW
< 50
> 50 to £ 200
>200 to £ 600
> 600
No requirement or
< 31)
< (300)1)
2
(200)
1.5
(150)
0.02
(2.0)
1) on systems with circulation water heaters and for systems with
electric heating elements
2) from the specific system volume (nominal capacity in litres/heating
output; for multiple boiler systems, the lowest individual heating
output should be used). This data only applies up to 3 times the
system volume for filling and top-up water. If 3 times the system
volume figure is exceeded, the water must be treated in exactly the
same way as if the limits quoted in table 2.2 were exceeded
(softening, desalination, hardness stabilisation or desludging).
2.2 Guideline values for heating water: water hardness
2.5.9 Pressure relief valve
The boiler is equipped with a pressure relief valve. This
safety device is required for all sealed central heating systems, is preset to 3 bar and is fitted with a 15 mm compression connection for the discharge pipe, whose diameter
must not be less than 15 mm. The pressure relief valve must
not be used for draining purposes.
For situations where the discharge cannot be easily routed
Vaillant have a remote pressure relief valve mounting kit
available which can be used to provide a suitable way to
achieve this.
2.5.10 Venting
The boiler is fitted with an automatic air vent. Other measures need to be taken to allow the heating system to be
either automatically or manually vented during filling and
during commissioning.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Description of the appliance 3
3
Description of the appliance
Design
5
4
5
6
6
7
7
4
8
9
3
9
3
10
11
2
1
8
10
11
2
12
1
13
12
13
14
14
15
15
19
18
16
17
3.1 Functional elements of the VU system boiler
3.2 Functional elements of the VUW combination boiler
Key
1 Gas valve
2 Water pressure sensor
3 Venturi with mass flow sensor
4 Heat exchanger
5 Connection for the air/flue gas duct
6 Expansion vessel
7 Air intake pipe
8 Compact thermal module
9 Ignition electrode
10 Fan
11 Automatic air vent
12 Pressure gauge
13 Internal pump
14 By-pass valve
15 Expansion relief valve
16 Electronics box
Key
1 Gas valve
2 Water pressure sensor
3 Venturi with mass flow sensor
4 Heat exchanger
5 Connection for the air/flue gas duct
6 Expansion vessel
7 Air intake pipe
8 Compact thermal module
9 Ignition electrode
10 Fan
11 Automatic air vent
12 Pressure gauge
13 Internal pump
14 By-pass valve
15 Expansion relief valve
16 Electronics box
17 Diverter valve with bypass
18 Impeller sensor (hot water)
19 Secondary heat exchanger
Installation and maintenance instructions ecoTEC plus 0020116700_06
16
11
4 Installation
4
Installation
i
i
BEFORE PROCEEDING - ENSURE BOILER IS
CORRECT FOR GAS GROUP SUPPLIED!
4.2
The work described in this section must only be carried out
by a competent person.
The pipes can be routed upwards behind the
boiler in front of the wall (surface installation)
using the spacer frame. Which means the distance between the wall and the boiler increases
by 65 mm.
Scope of delivery
The Vaillant ecoTEC plus is delivered pre-mounted in a
packaging unit.
4.1
Accessories
4.1.1
Controller
4.2.1
Unpacking the boiler
> Remove the boiler from its box.
> Remove the protective film from all parts of the boiler.
To control the ecoTEC, Vaillant offers various controller versions for connecting to the switching rail or for plugging
into the operator control screen.
4.2.2 Checking the scope of delivery.
Room Thermostats
> Check that all parts have been delivered and are intact
(¬ fig. 4.1 and ¬ table 4.2 or ¬ fig. 4.2 and ¬ table 4.3).
VRT 30 – Room Thermostat (230 V)
VRT 50 – Room Thermostat eBUS
8
Timers / Programmers
1
timeSWITCH 150 – mechanical clock
timeSWITCH 160 – 7 day programmer
2
Digital Room Temperature Controls
VRT 350 – Programmable Room Control
VRT 392f – RF Programmable Room Control *
VRT 350f – RF Programmable Room Control
7
Weather Compensating Controls
VRC 470 – Weather Compensator
VRC 470f – RF Weather Compensator
3
Communication
6
vrnetDIALOG
comDIALOG
4
Accessories
5
VR 65 – Control Centre
VR 66 – Control Centre
VR 61/2 – Two Zone Wiring Centre
VR 81/2 – Remote Control Unit
VR 68/2 – Solar Module
4.1 Controller accessories
* Note 392f RF transmitter wired external to boiler
4.1 Scope of delivery for ecoTEC plus VU boiler
4.1.2
Installation and operation
Optional accessories are available for use in conjunction
with the installation and operation of the ecoTEC.
The current price list shows the complete range of hydraulic
accessories for the ecoTEC plus series.
12
Installation and maintenance instructions ecoTEC plus 0020116700_06
Installation 4
Item Qty
1
1
2
1
3
1
4
4
5
3
6
1
7
1
8
3
1
Description
Wall bracket
Boiler
Lower cover
Supply pipes (gas, heating, expansion relief valve)
Service valves
Installation template
Enclosure documentation
Bags with parts
Additional for propane boilers: sticker for tank
4.2.3 Disposing of the packaging
> Dispose of the cardboard packaging used on the ecoTEC plus at a cardboard recycling site.
> Dispose of the plastic film and plastic filling at an appropriate plastic recycling site.
> Observe national regulations.
4.3
Transporting the appliance
4.2 Scope of delivery for ecoTEC plus VU boiler
Important:
1
8
2
7
3
6
4
With regards to the Manual Handling 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
5
4.2 Scope of delivery for ecoTEC plus VUW boiler
Item Qty
1
1
2
1
3
1
Description
Wall bracket
Boiler
Lower cover
4
6
Supply pipes (gas, heating, water, expansion relief
valve)
5
6
7
8
4
1
1
3
1
Service valves
Installation template
Enclosure documentation
Bags with parts
Additional for propane boilers: sticker for tank
4.3 Scope of delivery for ecoTEC plus VUW boiler
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.
Installation and maintenance instructions ecoTEC plus 0020116700_06
13
4 Installation
> 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 climbing steps and stairs.
> Always use assistance if required.
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 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 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.
14
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.
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.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Installation 4
> 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.
flooring, lighting and other factors, and appropriate
measures taken.
4.4
Requirements for the installation site
4.4.1
Required minimum clearances/installation
clearances
Positioning of Appliance for Final Installation –
within compartment etc. restricting installation.
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
A
> When using accessories, observe the minimum clearances/installation clearances (¬ fig. 4.3).
C
C
B
> 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.
4.3 Recommended minimum clearances/installation clearances
Key
A 165 mm (air/flue gas duct Æ 60/100 mm)
246 mm (air/flue gas duct Æ 80/125 mm)
B 180 mm
C 5 mm; optimum approx. 50 mm
500 mm in front of the boiler to enable easy access for
servicing (may be provided by an opening door).
Clearance at the side is not required, but the side panels
can also be removed if there is adequate side clearance (at
least approx. 50 mm) in order to facilitate maintenance or
repair work (¬ section. 4.8).
It is not necessary to ensure sufficient clearance between
the boiler and combustible materials or components as the
temperature of the boiler will always be less than the maximum permissible temperature of 85 °C due to its nominal
heat output.
Installation and maintenance instructions ecoTEC plus 0020116700_06
15
4 Installation
4.4.2 Using installation templates
An installation template is supplied with the boiler to aid
wall mounting.
The template shows the following:
– The position of the fixing holes for the hanging bracket.
– The position of the connections.
– The position of the wall breakthrough of the air/flue gas
duct.
Position the installation template vertically over the installation site.
> Attach the template to the wall, using tacks for example.
> Mark the drill holes for the hanging bracket on the wall.
> If necessary, mark the position for the wall breakthrough
for the air/flue gas duct.
> Remove the installation template from the wall.
> Drill 2 holes Æ 10 mm for the hanging bracket in the wall.
> If necessary, cut the wall breakthrough for the air/flue
gas duct.
16
Installation and maintenance instructions ecoTEC plus 0020116700_06
Installation 4
4.5
Dimension drawing and connection
measurements
8
440
A
125
1
624
720
2
3
4
5
6
7
11
20
35
100
180
125
B
3
4
5
6
7
35
100
9
10
4.4 Connection measurements in mm
Key
1 Wall breakthrough for air/flue gas duct
2 Hanging bracket
3 Heating flow (Æ 22 x 1.5)
4 Hot water connection (Æ 15 x 1.5), only for VUW boilers
5 Gas connection (Æ 15 x 1.5; ecoTEC 837: Æ 22 x 1.5)
6 Cold water connection (Æ 15 x 1.5), only for VUW boilers
7 Heating return (Æ 22 x 1.5)
8 Air/flue gas duct connection
9 Condensate siphon
10 Condensate discharge connection, Æ 19 mm
11 Heating expansion relief valve discharge pipe connection,
Æ 15 mm
Minimum dimension from wall bracket to
center line of air/flue gas duct wall breakthrough
Dimension A
[mm]
60/100 with elbow 87°, PP
80/125 with elbow 87°, PP
175
223
ecoTEC plus installation depth
612 (VU GB 126/5-5)
615 (VU GB 156/5-5)
618 (VU GB 186/5-5)
624 (VU GB 246/5-5)
824 (VUW GB 246/5-5)
831 (VUW GB 316/5-5)
630 (VU GB 306/5-5)
637 (VU GB 376/5-5)
837 (VUW GB 376/5-5)
Dimension B
[mm]
338
372
406
4.5 Dimension B for installation depth on VU and VUW boilers
4.4 Dimension A for air/flue gas duct wall breakthrough with
VU and VUW boilers
Installation and maintenance instructions ecoTEC plus 0020116700_06
17
4 Installation
4.6
Wall-mounting the boiler
a
4.7
Removing/fitting the front casing
Danger!
Risk of death if the load-bearing capacity
of the fixing elements used is insufficient!
If the fixing elements or wall do not have
sufficient load-bearing capacity, the boiler
can come loose and fall down. This may
also cause leaks in the gas line, which is
potentially fatal.
> When fitting the boiler, ensure that the
fixing elements and the wall have a sufficient load-bearing capacity.
> Check the quality of the wall.
2
1
1
4.6 Removing the front casing
Removing the front casing
2
3
4.5 Wall-mounting the boiler
> Mount the hanging bracket (1) on the wall using the wall
plugs and screws (2) provided with the unit.
> Hang the boiler (3) on the hanging bracket from above
using the hanging bracket.
18
> Loosen the screw (1) on the bottom of the boiler using a
screwdriver or small spanner.
> Push in both retaining clips (2) on the bottom of the
boiler so that the front casing is released.
> Pull the front casing forwards using the bottom edge.
> Lift the front casing upwards from the bracket.
Fitting the front casing
> Place the front casing on the upper brackets.
> Push the front casing onto the boiler so that until both
retaining clips (2) snap into place at the front casing.
> Fasten the front casing by screwing in the bolt (1) on the
underside of the boiler.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Installation 4
4.8
Removing/fitting the side panel
You can also remove a side panel for installation or maintenance purposes.
b
Caution.
Risk of damage caused by mechanical
tension.
Removing both side panels may cause
mechanical distortion in the boiler, which
can cause damage to the piping and potentially result in leaks.
> Always only remove one side panel,
never both side panels at the same time.
> Fold the electronics box (1.) forwards.
> Unscrew the two screws (2.) from the top and bottom of
the side panel.
> Hold onto the side panel (3.) when doing this.
> Swivel the side panel outwards and remove it from below
by pulling it downwards (4.).
> Install the side panel in reverse order.
2.
3.
1.
4.
4.7 Removing/fitting the side panel
b
Caution
Risk of damage to the side panel.
Unscrewed side panels that are merely suspended from the back wall can fall down.
> Hold onto the side panel when you are
unscrewing it, and always remove it from
the boiler.
Installation and maintenance instructions ecoTEC plus 0020116700_06
19
5 Gas installation
5
Gas installation
5.2
Connecting the gas pipe
The work described in this section must only be carried out
by a competent person.
5.1
Preparing for installation
a
Danger!
Risk of death from incorrectly installed
gas system!
An incorrect gas installation can result in
leaks and an explosion.
> During installation, the legal directives
and the local regulations for gas supply
companies must be observed.
a
Danger!
Risk of death from incorrectly installed
gas system!
Tension in the gas line can result in leaks or
an explosion.
> Make sure there are no stresses in the
gas lines when it is installed.
5.1 Fitting the gas connection (example: VUW boiler)
> Make the gas connection as shown.
b
Caution.
Risk of damage caused by incorrect gas
installation.
Excess test pressure or operating pressure
can cause damage to the gas valve.
> When the entire gas installation is tested
for leaks, the maximum pressure at the
gas valve must not exceed 0.75 kPa
(75 mbar).
b
Caution.
Risk of damage caused by contaminated
lines.
Foreign bodies such as welding remnants.
sealing residue or dirt in the connection
lines for gas can cause damage to the
boiler.
> Blow the gas line clean prior to installation.
b
Caution.
Risk of damage caused by using the
wrong gas type.
Using the wrong gas type can cause a fault
shutdown on the boiler. Furthermore, ignition and combustion noise may occur in the
boiler.
> Only use propane gas for propane-fired
boilers in accordance with BS 4250: Part
1 (1987).
20
Installation and maintenance instructions ecoTEC plus 0020116700_06
Hydraulic installation 6
6
Hydraulic installation
The work described in this section must only be carried out
by a competent person.
6.1
b
Caution.
Risk of damage caused by heat transfer
when soldering.
Heat that is transferred during soldering
can cause damage to the seals in the service valves.
> Do not solder the connection pieces if
the connection pieces are screwed to the
service valves.
i
Seals made of rubber-like materials may be subject to plastic deformation, which can lead to
pressure losses. We recommend using seals
made of a paste-like fibre material.
Preparing for installation
a
b
b
a
Danger!
Risk of death caused by an incorrectly
installed system!
Heating water that leaks from the discharge
pipe of the expansion relief valve can cause
severe burns.
> Install the expansion relief valve and its
discharge pipe work termination ensuring that there is no danger to persons in
or about the building. This may be outside or to a suitable open drain in the
installation room.
> Make sure that the drain is visible.
Caution.
Risk of damage caused by contaminated
lines.
Foreign bodies such as welding remnants,
sealing residue or dirt in the water lines can
cause damage to the boiler.
> Flush the heating installation thoroughly
prior to installation.
The Vaillant ecoTEC boiler is equipped with a 10 l expansion
vessel with a gas-side filling pressure of 0.075 MPa
(0.75 bar), which is suitable for a closed heating system
with a maximum water volume of 100 litres.
> Before installing the boiler, check whether the volume of
the installed expansion tank is sufficient.
> If the volume of the expansion vessel is insufficient, then
install an additional expansion vessel connected as close
to the boiler as possible into the boiler return pipe.
i
Caution.
Risk of damage from corrosion.
If non-diffusion-tight plastic pipes are used
in the heating installation, this may cause
air to enter the heating water and corrosion
of the heat generator circuit and the boiler.
> If using non-diffusion-tight plastic pipes
in the heating installation, separate the
system by installing an external heat
exchanger between the boiler and the
heating installation.
Danger!
Risk of scalding and/or damage due to
incorrect installation leading to leaking
water.
Stresses in the supply line can cause leaks.
> Make sure there are no stresses in the
supply lines when they are installed.
When using an external expansion vessel
together with a VUW boiler, it is advisable to
install a non-return valve in the outlet (boiler
flow) or take the internal expansion vessel out of
service.
Otherwise, the warm start function may be more
frequently activated because of backflow, which
causes unnecessary energy loss.
Vessel volume (in l)
Initial system pressure (in bar)
Expansion relief valve setting
(in MPa (bar))
With system volumes greater than 100 l,
multiply the volume by the adjacent factor.
1.0
1.5
0.3 (3.0)
0.109
0.156
6.1 Size of an additional expansion vessel
Installation and maintenance instructions ecoTEC plus 0020116700_06
21
6 Hydraulic installation
6.2
Connecting the hot and cold water
(VUW boiler)
6.4
Connecting the heating flow and heating
return
6.4.1
VUW boiler
6.1 Fitting the hot and cold water connection
> Make the domestic hot and cold water connections as
shown.
> Ensure correct water pressure and flow requirements
and that any expansion can be accommodated with the
cold supply pipe work (¬ section 2.5.7).
6.2 Fitting the heating flow and heating return (VUW boiler)
> Make the water connections as shown.
6.4.2 VU boiler
6.3
Connecting the domestic hot water cylinder
> When connecting the domestic hot water cylinder to the
ecoTEC plus, follow the installation instructions for the
domestic hot water cylinder.
6.3 Fitting the heating flow and heating return (VU boiler)
> Make the water connections as shown.
22
Installation and maintenance instructions ecoTEC plus 0020116700_06
Hydraulic installation 6
6.5
Low loss header
A low loss header disconnects the boiler from the heating
system. The system is no longer dependent on the remaining feed head of the boiler. In conjunction with the boiler
circulation pump, the low loss header ensures that a sufficiently high minimum quantity of water is always circulating
through the boiler. No electrical accessories are required in
order to use a low loss header.
6.6
Connecting the condensate discharge
pipework
Danger!
Risk of death from flue gases!
Due to an empty or insufficiently filled condensate trap, flue gases may escape into
the room air.
> Make sure that the condensate water
siphon is filled with water when switching
on the boiler.
a
i
> During installation remove all burs from inside of cut
pipe work and avoid excessive adhesive which may trap
small pockets of water close to the pipe wall which can
freeze and build into a larger ice plug.
> As with other pipe work insulate the condensate discharge pipe to minimise any risk of freezing and beware
when crossing cavities that the fall is maintained and the
pipe sleeved.
> The condensate discharge pipework must terminate in a
suitable location.
Further information can be obtained from "BS 6798 Specification for installation of gas–fired boilers of rated input not
exceeding 70 kW net". The condensate siphon (2) must be
filled with water as described in the relevant section before
the boiler is commissioned.
6.7
The ecoTEC plus boilers are equipped with a condensate
siphon. (The filling height is 145 mm). The siphon collects
the condensate that has formed in a vessel with a capacity
of approx. 200 ml, and intermittently deposits the contents
to the discharge pipe. This minimises the risk of the discharge pipe freezing up.
The condensate discharge pipework must have a
continuous fall (45 mm per metre) and should
whenever possible terminate at a suitable discharge point within the heated envelope of the
building that will remain frost free under long
periods of low external temperatures.
Connecting the discharge pipe to the
expansion relief valve on the boiler
The expansion relief valve for the heating installation is
integrated in the boiler.
> Install the discharge pipe for the expansion relief valve
so that it does not interfere with the removal and fitting
of the condensate trap.
i
We recommend not to shorten the discharge
pipe supplied.
> Leave an installation space of at least 180 mm beneath
the condensate siphon.
1
2
3
4
a
d
c
b
6
3
Internal
stackpipe
3
5
Internal
discharge system
7
Gulley
min.
180
Soakaway
2
3
6.4 Condensate discharge pipework
> Connect the condensate discharge (1) of the boiler to a
condensate discharge pipework (3) which has a minimum
internal diameter of 19 mm (22 mm outside diameter for
all external pipes) and is made from an acid-resistant
material (e.g. plastic overflow pipe).
1
6.5 Fitting the discharge pipe to the expansion relief valve
(example: VUW boiler)
Installation and maintenance instructions ecoTEC plus 0020116700_06
23
6 Hydraulic installation
> Insert a seal (1) in the cap nut (2).
> Screw the discharge pipe (3) onto the expansion relief
valve.
> Make the discharge line routing as short as possible and
sloping away from the boiler.
> Allow the line to terminate in such a way that nobody
can be injured and no cable or other electrical components can be damaged if water or steam is ejected.
> Note that the end of the line must be visible.
> If the pipe cannot fall to a safe discharge point then the
Vaillant remote pressure relief valve mounting kit can be
used to provide a suitable way to achieve this.
> Ensure the discharge pipe work is installed, routed and
terminated correctly to minimise the risk of freezing up.
24
Installation and maintenance instructions ecoTEC plus 0020116700_06
Flue gas installation 7
Air/flue gas duct
The CE mark is valid only if the appliance is operated with
Vaillant air/flue gas ducts.
All ecoTEC plus boilers feature a 60/100 mm diameter air/
flue gas connection as standard. Selecting the most suitable system depends on the individual installation and application conditions.
48
Danger!
Risk of death and risk of damage from
use of non-approved air/flue gas ducts!
Vaillant boilers are system-certified only in
combination with genuine Vaillant air/flue
gas ducts. The use of other accessories can
cause personal injury and material damage
as well as operating faults.
> Only use genuine Vaillant air/flue gas
ducts.
901
a
542
7.1
Flue gas installation
1456
7
7.2 Scope of delivery of vertical air/flue gas duct
Article number 0020060570 and 0020065937
Optional 125 mm air/flue gas duct
A concentric air/flue gas duct with an outer diameter of
125 mm is available that can be extended depending on the
boiler output range. The flues gas spigot Ø 80/125 (with 2
measuring apertures) Art. No.: 0020147469 will be required.
You can also get a vertical system. For more information
refer to the ¬ installation manual for the air/flue gas
duct.
Standard 100 mm air/flue gas duct
87
1020
48
15
65
74
667
7.1 Scope of delivery of horizontal air/flue gas duct
Article number 303933
70
30
70
7.3 Scope of delivery of horizontal air/flue gas duct
Article number 303209
70
1430
A concentric air/flue gas duct with an outer diameter of
100 mm that can be extended depending on the boiler output range is available.
You can also get a vertical system. For more information
refer to the ¬ installation manual for the air/flue gas
duct. 87° elbows and 45° elbows are also available for
greater flexibility during installation.
7.4 Scope of delivery of vertical air/flue gas duct
Article number 303200
Installation and maintenance instructions ecoTEC plus 0020116700_06
25
7 Flue gas installation
7.2
Flue termination
The following details refer to all flue systems.
a.
The terminal must be positioned such that the products of combustion can disperse freely at all times.
b.
A plume of water vapour will sometimes be visible
from the flue terminal. Positions where this could be a
nuisance should be avoided.
c.
If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people
have access then a suitable terminal guard must be
provided and fitted (contact Tower Flue Components,
Tonbridge, TN9 1TB).
i
Vertical flues must not terminate within 600 mm
of an openable window, air vent or any other
ventilation terminal.
The flue system shall be so placed or shielded as to prevent
ignition or damage to any part of the building.
P
I
Q
Q
T
Q
S
Q
R
F
Q
D, E
G
O
C
A
I
M
B
L
N
N
H
H
M
J
K
7.5 Termination of the air/flue gas duct
26
Installation and maintenance instructions ecoTEC plus 0020116700_06
Flue gas installation 7
Location
A
Minimum
dimensions
Directly below an opening, air brick, opening win300 mm
dows, etc.
B Above an opening, air brick, opening window, etc. 300 mm
C
Horizontally to an opening, air brick, opening win300 mm
dow, etc.
D
Below temperature-sensitive building components
75 mm
e.g. plastic gutters, soil pipes or drain pipes
E
F
G
H
I
J
K
Below eaves
Below balconies or car port roof
From a vertical drain pipe or soil pipe
From an internal or external corner
Above ground, roof or balcony level
From a surface facing the terminal
From a terminal facing the terminal
200 mm
200 mm
150 mm
200 mm
300 mm
600 mm
1200 mm
L
From an opening in the car port (e.g. door, window) into the dwelling
1200 mm
M
N
O
P
Q
Vertically from a terminal on the same wall
Horizontally from a terminal on the same wall
From the wall on which the terminal is mounted
From a vertical structure on the roof
Above intersection with roof
1500 mm
300 mm
0 mm
N/A
300 mm
R
Horizontally to a window or opening on pitched or
600 mm
flat roofs
S
Above a window or opening on pitched or flat
roofs
600 mm
T
Below a window or opening on pitched or flat
roofs
2000 mm
7.6 Termination of air/flue gas duct under balcony or eaves
7.1 Position of the termination in a fan-assisted air/flue gas
duct
BS 5440–1 It is recommended that the fanned flue terminal
should be positioned as follows:
a)
at least 2 m from an opening in the building directly
opposite, and
b)
so that the products of combustion are not straightly
directed to discharge across a boundary.
1)
Dimensions D, E, F and G:
These clearances may be reduced to 25 mm without
affecting the performance of the boiler. In order to
ensure that the condensate plume does not affect
adjacent surfaces the terminal should be extended as
shown in ¬ fig. 7.6.
2)
Dimension H:
This clearance may be reduced to 25 mm without
affecting the performance of the boiler. However, in
order to ensure that the condensate plume does not
affect adjacent surfaces a clearance of 300 mm is preferred. For IE, recommendations are given in the current edition of IS 813.
For 1 and 2 above you can use the Variable Termination Kit
to move the termination point away from the building fabric.
Article numbers:
0020060584 - White
0020060585 - Black
Installation and maintenance instructions ecoTEC plus 0020116700_06
27
8 Electrical installation
8
8.1
Electrical installation
Preparing for installation
e
Danger!
Risk of death from electric shock!
Touching live connections can cause serious personal injury.
> Switch off the power supply.
> Secure the power supply against being
switched on again.
e
Danger!
Risk of electrocution as a result of an
improper electrical connection!
An improper electrical connection may negatively affect the operational safety of the
boiler and result in material damage or personal injury.
> The electrical connection must be carried out by a suitably qualified competent person who is responsible for complying with the existing standards and
guidelines.
> Connect the boiler in accordance with
BS 7671 (IEE Regulations).
> For IE: Please observe the latest edition
of the ETCI regulations (Electro-Technical
Council for Ireland).
> Earth the boiler.
8.2
Opening/closing the electronics box
Opening the electronics box
> Remove the front casing from the boiler
(¬ section 4.7).
28
3
1
4
2
8.1 Opening the back wall of the electronics box
> Fold the electronics box (1) forwards.
> Undo the 4 clips of the rear cover (2) of the electronics
box from the brackets (3) at the rear and sides of the
electronics box.
> Fold up the cover.
Closing the electronics box
>
>
>
>
Close the rear panel on the electronics box.
Push in the panel until it clicks into place in the clips.
Fold up the electronics box.
Push the right and left clips of the box against the side
panels on the boiler until they click into place.
> Replace the front casing on the boiler
(¬ section 4.7).
8.3
Establishing the mains connection
e
Danger!
Risk of death from electric shock!
Mains connection terminals L and N remain
live even if the continuous on/off switch is
turned off!
> Before establishing a mains connection,
switch off the power supply.
b
Caution.
Risk of damage from erroneous connected voltage.
At mains voltages greater than 253 V and
less than 190 V, the functions may be
impaired.
> Make sure that the rated voltage of the
mains is 230 V.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Electrical installation 8
b
Caution.
Risk of damage caused by incorrect
installation.
A mains voltage at the incorrect plug terminals on the ProE system can destroy the
electronics.
> Only connect the mains connection cable
to the terminals marked for the purpose.
b
Caution.
Risk of damage caused by incorrect
installation.
Connecting wires that have been stripped
too far can cause short circuits and damage
the electronics if a strand accidentally
comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits.
> Lay the lines correctly.
> Use strain reliefs.
i
If you install the boiler in safety area 2, it can
only be operated if it is room sealed. Installation
method B53P is not permitted in this case.
Please pay attention to the latest edition of the
"IEE Wiring Regulations – BS7671, Requirements
for Electrical Installation".
In IE, reference should be made to the current edition of
the ETCI (Electro-Technical Council for Ireland) rules.
The boiler is supplied for connection to 230 V, ~ 50Hz supply fused at 3 A rating. Connection to the mains supply shall
be made via a fused 3 pin plug to an unswitched shuttered
socket, both complying with the requirements of BS 1363.
(Alternatively, connection may be made via a 3 A fused
double pole isolator having a contact opening of at least
3 mm in all poles and supplying the boiler and controllers
only). The point of connection to the mains supply must
allow complete electrical isolation of the boiler and its ancillary controllers. It should be readily accessible and adjacent
to the boiler. A flexible cord fulfilling BS6500 or comparable standard, conductor diameter between 0,75 and 1,5 mm2
and an allowed temperature range including 90 °C should
be used.
The nominal voltage of the mains must be 230 V; at mains
voltages greater than 253 V and less than 190 V the functions may be impaired.
> Open the electronics box (¬ section 8.2).
> Use a normal commercial mains connection cable that is
compliant with standards.
> Route the mains connection cable through the left cable
duct (¬ fig. 8.1, pos. 4) on the base of the unit.
1
2
3
8.2 Cable routing of the mains connection cable
> Use the strain reliefs (1).
> Shorten the mains connection cable as necessary.
> Only strip the outer sheathing of flexible cables for a
maximum of 3 cm.
> Ensure inner conductor insulation is not damaged during
stripping of outer sheathing.
> Only strip inner conductors sufficient to make good
sound connections.
> Crimp pin terminals to ensure a secure connection free
from loose strands to prevent short circuits.
> Take the turquoise ProE plug (2) for the mains connection out of the bracket in the electronics box and connect the plug professionally to the mains connection
cable.
> Insert the ProE plug into the corresponding PCB slot
(L, N and earth) (3).
> Lay the lines correctly.
> Secure the cable in the electronics box using the strain
reliefs.
> Close the electronics box (¬ section 8.2).
i
Make sure that the connection cables are
securely fastened to the plug terminals.
8.4
Connecting the controller
8.4.1
Fitting the controller
> Fit the controllers in accordance with the relevant operating and installation instructions.
Installation and maintenance instructions ecoTEC plus 0020116700_06
29
8 Electrical installation
> If you connect a weather compensator or room temperature control via eBUS, then bridge input 24 V = RT (X100
or X106) if no bridge exists.
> I If using low voltage (24 V) controls connect these in
place of the bridge marked RT 24 V (X100 or X106).
> Close the electronics box (¬ section 8.1).
> In order to achieve pump operating mode "Comfort"
(continuously running pump) for multi-circuit controllers,
change diagnosis code D.018 Pump operating mode from
"Eco" (intermittent pump) to "Comfort" (¬ section 11.1.2).
8.4.2 Connecting controllers to the electronic
system
b
b
i
Caution.
Risk of damage caused by incorrect
installation.
Connecting wires that have been stripped
too far can cause short circuits and damage
the electronics if a strand accidentally
comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits.
> Lay the lines correctly.
> Use strain reliefs.
i
Caution.
Risk of damage from incorrect installation.
A mains voltage at the incorrect plug terminals on the ProE system can destroy the
electronics.
> Do not connect a mains voltage to the
eBUS terminals (+/-).
8.5
30
Connecting additional components
b
Make sure that the conductors are securely fastened to the plug terminals of the ProE plug.
> Open the electronics box (¬ section 8.2).
> Lead the supply lines of the components to be connected
(e.g. external controllers, external sensors) through the
left cable duct (¬ fig. 8.1, pos. 4) on the underside of the
boiler.
> Use the strain reliefs provided.
> Shorten the supply lines as necessary.
> Only strip the outer sheathing of the supply lines for a
maximum of 3 cm.
> Ensure inner conductor insulation is not damaged during
stripping of outer sheathing.
> Only strip inner conductors sufficient to make good
sound connections.
> Fit the stripped ends of the conductors with crimp pin
terminals to ensure a secure connection free from loose
strands to prevent short circuits.
> Connect the ProE plug to the supply lines of the controller using a screwdriver.
> Insert the ProE plug into the associated PCB slot
(¬ figs. 8.3 and 8.4).
> Lay the lines correctly.
> Secure the cable in the electronics box using the strain
reliefs.
> If you connect a 230 V AC time and temperature control
to the boiler, then remove the bridge at input 24 V = RT
(X100 or X106) if a bridge exists.
Please note that the bridge at the ProE plug
(Burner off) must be removed when connecting
a maximum thermostat (contact thermostat) for
underfloor heating.
Caution.
Risk of damage caused by incorrect
installation.
Connecting wires that have been stripped
too far can cause short circuits and damage
the electronics if a strand accidentally
comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits.
> Lay the lines correctly.
> Use strain reliefs.
You can actuate an additional component with the aid of
the auxiliary relay that is installed in the ecoTEC plus (only
ecoTEC 637/837), and two other components with the multifunctional module.
The following components can be actuated:
– Circulation pump
– External pump
– Cylinder charging pump
– Extractor hood
– External solenoid valve
– External fault signal
– Solar pump (not active)
– eBUS remote control (not active)
– Legionella protection pump (not active)
– Solar valve (not active)
8.5.1
Connecting the auxiliary relay (grey
connector on PCB)
i
You can connect the additional component to
the integrated auxiliary relay using the grey plug
on the PCB.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Electrical installation 8
> Perform the wiring in the same way as in ¬ section 8.4.
> To start up the connected components, select the components using diagnosis code "D.026" at installer level
(¬ section 11.1).
8.5.2 Connect VR 40 – "2 from 7" multifunctional module
You can connect additional components to the ecoTEC plus
using the Vaillant multi-functional module 2 in 7 (accessories).
> Fit the components in accordance with the corresponding operating and installation instructions.
> Select diagnostics code "D.027" to actuate relay 1 on the
multi-functional module at installer level (¬ section 11.1).
> Select diagnostics code "D.028" to actuate relay 2 on the
multi-functional module at installer level (¬ section 11.1).
8.6
Actuating the circulation pump
demand-controlled
You can actuate the circulation pump for a domestic hot
water cylinder demand-controlled using the ecoTEC plus.
b
Caution.
Risk of damage caused by incorrect
installation.
Connecting wires that have been stripped
too far can cause short circuits and damage
the electronics if a strand accidentally
comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits.
> Lay the lines correctly.
> Use strain reliefs.
> Perform the wiring in the same way as in ¬ section 8.4.
> Connect the supply line of the external button with terminals X41/1 (0) and X41/6 (FB) of the PCB (¬ fig. 8.3
and 8.4).
i
The edge connector required for this is included
with your controller.
Installation and maintenance instructions ecoTEC plus 0020116700_06
31
8 Electrical installation
8.7
Connection diagrams
X51
Display
Connection
X22
8
7
2
1
5
3
X25 11
white 10
+
Holding magnet
1
2
3
4
5
6
4
X2
Pump PWM signal
Gas valve
+
9
6
12
8
17
7
18
14
13
11
Stepper motor
+
1
2
3
4
5
6
Mass flow
sensor
Diverter
valve *
M
1
3
4
Water pressure
sensor
blue
X100
white
X16
grey
X18
J
Flow sensor
blue
J
Return sensor
Coding resistor, gas group
6FB
AF
RF
DCF
1
+
pink
red
Coding resistor, output range
Bus
24 V
230 V~
Cylinder contact "C1-C2"
Safety fuse
0
0
Burner RT
off
24
blue
white
L
N
L
N
Circulation pump remote control
External sensor
External temperature sensor
DCF connection
Earth
Earth
Contact thermostat/burner off
24 V DC room thermostat
Bus connection
(Controller/room th. digital)
1 2
4 5
PWM
Earth
X41
Edge
connector
J Cylinder sensor (optional)
white
+ 24 V
Hall signal
4
12
1
16
5
7
8
7
12
X20 13
pink
2
15
16
4
3
17
X24 3
white
17
Fan
Auxiliary relay *
(Selection by D.026)
Internal pump *
green
Ignition
transformer
X1
turquoise
RT
L
N
No function *
230 V AC room thermostat *
Mains connection
Appliance earth
Ignition
electrode
* ... variant-dependent
8.3 Connection diagram for electronics box ecoTEC plus 612,
615, 618, 624, 630
32
Installation and maintenance instructions ecoTEC plus 0020116700_06
Electrical installation 8
X51
Display
Connection
X22
8
7
2
1
5
3
X25 11
white 10
+
Holding magnet
1
2
3
4
5
6
4
X2
Pump PWM signal
Gas valve
+
9
6
12
8
17
7
18
14
13
11
Stepper motor
+
1
2
3
4
5
6
Mass flow
sensor
Diverter
valve *
M
1
3
4
Water pressure
sensor
blue
4
12
1
16
5
7
8
7
12
X20 13
pink
2
15
16
4
3
17
X24 3
white
17
white
blue
J
Return sensor
DCF
1
0
0
X16
L
N
X11
L
N
grey
blue
X18
L
N
Circulation pump remote control
External temperature sensor
Flow sensor (optional)
DCF connection
Earth
Earth
Contact thermostat/burner off
24 V DC room thermostat
Bus connection
(Controller/room th. digital)
Auxiliary relay *
(Selection by D.026)
1 2
4 5
PWM
Earth
AF
RF
+
pink
Flow sensor
+ 24 V
Hall signal
6FB
Bus
24 V
230 V~
J
Coding resistor, gas group
Burner RT
off
24
X100
red
Coding resistor, output range
Edge
connector
white
Cylinder contact "C1-C2"
Safety fuse
X41
blue
J Cylinder sensor (optional)
white
Fan
N L
Internal pump *
green
Ignition
transformer
X1
turquoise
RT
L
N
No function *
230 V AC room thermostat *
Mains connection
Appliance earth
Ignition
electrode
* ... variant-dependent
8.4 Connection diagram for electronics box ecoTEC plus 637
Installation and maintenance instructions ecoTEC plus 0020116700_06
33
8 Electrical installation
X22
8
7
2
1
5
3
X25 11
white 10
9
6
12
8
17
7
18
14
13
X2 113
blue
2
6
4
12
5
1
5
7
8
7
12
X20 13
pink
2
15
16
4
3
17
X24 3
white
17
Mass flow
sensor
Diverter
valve
M
Water pressure
sensor
Impeller
sensor
orange
J
Warm start sensor
violet
J
Hot water sensor
red
J
Flow sensor
blue
J
Return sensor
Coding resistor, output range
6FB
AF
RF
DCF
1
0
0
X16
grey
X18
Circulation pump remote control
External sensor
External temperature sensor
DCF connection
Earth
Earth
Contact thermostat/burner off
24 V DC room thermostat
+
Bus connection
(Controller/room th. digital)
L
N
Auxiliary relay *
(Selection by D.026)
L
N
1 2
4 5
PWM
Earth
Coding resistor, gas group
Bus
pink
+
Safety fuse
Burner RT
off
24
24 V
230 V~
Holding magnet
1
3
4
1
2
3
Edge
connector
X100
+
Stepper motor
1
2
3
4
5
6
X41
white
Gas valve
1
2
3
4
5
6
4
blue
Pump PWM signal
+
+ 24 V
Hall signal
X51
Display
Connection
Fan
Internal pump *
green
Ignition
transformer
X1
turquoise
RT
L
N
No function *
230 V AC room thermostat *
Mains connection
Appliance earth
Ignition
electrode
* ... variant-dependent
8.5 Connection diagram for electronics box ecoTEC plus 824,
831
34
Installation and maintenance instructions ecoTEC plus 0020116700_06
Electrical installation 8
X22
white
X41
Edge
connector
X100
white
6FB
AF
RF
DCF
1
X11
L
N
X18
Diverter
valve
M
Water pressure
sensor
Impeller
sensor
orange
J
Warm start sensor
violet
J
Hot water sensor
red
J
Flow sensor
blue
J
Return sensor
Coding resistor, gas group
L
N
blue
Mass flow
sensor
Coding resistor, output range
X16
grey
+
Safety fuse
+
pink
Holding magnet
1
3
4
1
2
3
Bus
24 V
230 V~
+
Stepper motor
1
2
3
4
5
6
0
0
Burner RT
off
24
blue
Gas valve
1
2
3
4
5
6
4
9
6
12
8
17
7
18
14
13
X2 113
blue
2
6
4
12
5
1
5
7
8
7
12
X20 13
pink
2
15
16
4
3
17
3
X24
white
17
Pump PWM signal
+
L
N
Circulation pump remote control
External sensor
External temperature sensor
DCF connection
Earth
Earth
Contact thermostat/burner off
24 V DC room thermostat
Bus connection
(Controller/room th. digital)
Auxiliary relay *
(Selection by D.026)
1 2
4 5
PWM
Earth
X25
8
7
2
1
5
3
11
10
+ 24 V
Hall signal
X51
Display
Connection
Fan
N L
Internal pump *
green
Ignition
transformer
X1
turquoise
RT
L
N
No function *
230 V AC room thermostat *
Mains connection
Appliance earth
Ignition
electrode
* ... variant-dependent
8.6 Connection diagram for electronics box ecoTEC plus 837
Installation and maintenance instructions ecoTEC plus 0020116700_06
35
9 Operation
9
Operation
The Vaillant ecoTEC plus boiler is fitted with a digital information and analysis system (DIA). If additional settings are
required, which have not been configured using the installation assistant, you can view and modify further parameters
using the DIA.
The operating concept and operation of the boiler is
described in the ¬ operating instructions of the boiler. The
read-off and setting facilities of the operator level are also
described in the ¬ operating instructions.
The following overview shows the read-off and setting facilities of the installer level.
9.1
Calling up the installer level
b
Caution.
Risk of damage caused by incorrect handling.
Incorrect settings at installer level can
cause damage to the heating installation.
> You should only access installer level if
you are an approved competent person.
Installer level is secured against unauthorised access with a
password, as incorrect parameter settings at this level can
cause functional faults and damage to the heating installation.
and right selection buttons
> Press the left
("i") simultaneously
The following menu appears on the display.
or the plus but> Scroll using the minus button
until the menu point "installer level"
ton
appears.
to select the
> Press the right selection button
menu point.
"Enter code" and the value "00" appear in the display.
> Select the value 17 (code) using the minus button
or the plus button
.
to confirm
> Press the right selection button
the entered code.
The installer level appears with a selection of menu points.
i
In the following, a path specification at the
beginning of an action instruction specifies how
to access this function in the installer level, e.g.
Menu ¬ Installer level ¬ Test programs ¬
Test programs.
i
If you exit the installer level and then access it
again within 15 minutes, you do not have to
enter the code again.
36
Installation and maintenance instructions ecoTEC plus 0020116700_06
Operation 9
9.2
Overview of the menu structure
Menu
Information
Reset burner off time
Installer level
Back
Select
Installer level
Fault list
Test programmes
Appliance config.
Enter code
17
Back
Ok
Back
Select
Installer level
Fault list
Test programmes
Appliance config.
Back
Select
F.00
F.75
Interruption
Flow Fehler
sensor
Pumpe/Wassermangel
Test programmes
Gas type check
Test programmes
Function menu
Back
Select
Test programmes
Gas type check
Test programmes
Function menu
Back
Select
Test programmes
Gas type check
Function menu
Self test Electronics
Back
Select
Test programmes
Gas type check
Function menu
Self test Electronics
Back
Installer level
Test programmes
Appliance config.
Diagnosis menu
Back
Select
Select
Appliance config.
Language
Target flow temp.
DHW temperature
Back
Select
Appliance config.
Language
Target flow temp.
DHW temperature
Back
Select
Appliance config.
Language
Target flow temp.
DHW temperature
Back
Select
Gas type check
Select
gas type
LPG
Back
Select
P.00 Exhaust
P.00 Pump
Entlüftung
run
Pumpe
Clockedwird
taktend
angesteuert
Back
Select
Back
Select
T.01
T.01
internal pump
interne Pumpe
Back
Back
Select
Select
Self test
Self diagnosis
of the electronics
Back
Select
Language
02 English
Cancel
Ok
Target flow temp.
41
Cancel
Ok
DHW temperature
35
Cancel
Ok
9.1 Overview of the menu structure for installer level part 1
Installation and maintenance instructions ecoTEC plus 0020116700_06
37
9 Operation
Appliance config.
Target flow temp.
DHW temperature
Comfort mode
Back
Select
Appliance config.
DHW temperature
Comfort mode
Auxiliary relay
Back
Select
Appliance config.
Comfort mode
Auxiliary relay
Accessory relay 1
Back
Select
Appliance config.
Auxiliary relay
Accessory relay 1
Accessory relay 2
Back
Select
Appliance config.
Accessory relay 1
Accessory relay 2
Heating partial load
Back
Select
Appliance config.
Accessory relay 2
Heating partial load
Contact data
Back
Select
Appliance config.
Heating partial load
Contact data
Factory setting
Back
Installer level
Testprogramme
Appliance config.
Diagnosis menu
Back
Select
Installer level
Appliance config.
Diagnosis menu
Start inst. assistant
Back
Select
Select
Comfort operation
Comfort on
Cancel
Ok
D.026
D.026
Auxiliary relay
Zusatzrelais
Circulation pump
externe Pumpe
Back
Cancel
Ok
D.027
D.027
Accessory relay 1
Zubehörrelais 1
Circulation pump
externe Pumpe
Back
Cancel
Ok
D.028
D.028
Accessory relay 2
Zubehörrelais 2
Circulation pump
externe Pumpe
Back
Cancel
Ok
D.000
Heating partial load
0
Cancel
Ok
Contact data
Phone number
Back
D.096
Reset to
factory settings?
Cancel
Ok
D.000
D.001 partial load
Heating
Pumpennachlauf
Heizung
auto
0
Back
Back
To start the
Competent Installer
press OK
Cancel
Ok
9.2 Overview of the menu structure for installer level part 2
38
Installation and maintenance instructions ecoTEC plus 0020116700_06
Commissioning 10
10
Commissioning
At the time of commissioning, complete all relevant sections of the benchmark checklist found within the back
pages of this document.
Ensure that the filling and purging programs P.06 and P.00
have been allowed to run fully before the boiler is ignited
for the first time.
a
i
Danger!
Risk of poisoning and burns caused by
escaping hot flue gas!
Hot flue gas can escape and cause poisoning and burns if the boiler is operated with
an incompletely mounted or open air/flue
gas duct or if the boiler is operated with
internal leaks with the front casing open.
> Operate the boiler
- for commissioning
- for testing purposes
- in continuous operation
only when the front casing is fitted and
closed and the air/flue gas duct is completely mounted.
> Exclusively for test purposes such as gas
working pressure testing the boiler may
be operated with the front casing
removed for short durations ONLY but
must have a completely mounted air/flue
gas duct.
The automatic air vent cap must be loosened
before filling the heating circuit or recharging
circuit and during operation.
Purge the heating circuit and the recharging circuit using the purging program P.00
(¬ section 10.4).
installing the boiler. The installation assistant is displayed
whenever the boiler is switched on until it has been successfully completed.
You must confirm the start of the installation assistant.
Once confirmed, all of the heating and hot water demands
from the boiler are blocked. This status remains until the
installation assistant is completed or cancelled.
If you do not confirm the start of the installation assistant,
it will be closed 10 seconds after being switched on and the
basic display will appear. The next time the boiler is
switched on using the on/off button, the installation assistant will be started again.
10.2.1 Language
> Select the required language using the minus or plus
button.
> Press the right selection button to confirm the selected
language.
The language change must be confirmed a second time in
order to avoid an unintentional change.
i
If you unintentionally select a language that you
cannot understand, you can change it again as
described below.
> Press the right selection button and the plus button
simultaneously and hold them down.
> Press the fault clearance key for a short time.
> Keep the right selection button and the plus button
pressed until the option for changing the language
appears on the display.
> Select the language of your choice using the minus key
or the plus key.
> Confirm the change by pressing the right-hand selection
button ("OK").
Auxiliary service equipment:
10.2.2 Filling mode
The following test and measuring equipment is required for
commissioning:
– CO2 measuring instrument
– Digital or U-tube manometer
Filling mode (test program P.06) is activated automatically
in the installation assistant for as long as it appears on the
display. (¬ section 10.4).
10.1
10.2.3 Purging
Switching on the boiler
> Press the on/off button (¬ Operating instructions).
The basic display appears on the display.
10.2
Installation assistant
The installation assistant is launched when switching on the
boiler for the first time. It provides easy access to the most
important test programs and configuration settings for
> Start test program P.00 to purge the system
(¬ section 10.4).
Unlike the way in which it is started in the test programs
menu, the purge program P.00 is started in the installation assistant by pressing the minus button or the plus
button.
In order to change the circuit that is being purged, you
can press the right selection button.
Installation and maintenance instructions ecoTEC plus 0020116700_06
39
10 Commissioning
10.2.4 Target feed temperature
10.2.11 Restarting the installation assistant
Use the minus button and the plus button to set the target
feed temperature. Confirm your setting with OK.
You can restart the installation assistant any time by calling
it up manually in the menu.
Menu ¬ Installer level ¬ Installation assistant
10.2.5 Hot water temperature
10.3
Use the minus button and the plus button to set the hot
water temperature. Confirm your setting with OK.
10.2.6 Comfort mode
Use the minus button and the plus button to enable or disable comfort mode. Confirm your setting with OK.
Appliance configuration and diagnosis menu
If you have already filled and purged the heating installation and have terminated the installation assistant, but wish
to set the most important system parameters again, you
can also call up the "Appliance configuration" menu point.
Menu ¬ Installer level ¬ Appliance configuration
All of the setting options for more complex systems can be
found in the diagnosis menu (¬ section 11).
Menu ¬ Installer level ¬ Diagnosis menu
10.2.7 Heating partial load
10.4
The heating partial load of the Vaillant ecoTEC plus boiler is
factory set to "auto". This means that the boiler independently determines the optimum heating output depending on
the current heat demand of the system. A setting is normally no longer required.
The setting can also be changed later using diagnostics
point D.000.
i
If you have activated return control under D.17,
the automatic heating output determination
function is not active. If you set d.00 to "auto"
anyway, the boiler operates with the maximum
possible heating partial load.
Using test programs
As well as the installation assistants, you can also call up
the test programs for commissioning.
Menu ¬ Installer level ¬ Test programs
As well as the function menu (¬ section 12.3), an electronics self test facility (¬ section 12.3.1) and the gas family
check (¬ section 12.1.5), you will also find the test programs
here.
Menu ¬ Installer level ¬ Test programs -> Test programs
If you activate different test programs, you can trigger special functions on the boiler.
The following four test programs are available:
10.2.8 Auxiliary relay and multi-functional module
Additional components that are attached to the boiler can
be adjusted directly here.
This setting can be changed using diagnostics codes D.026,
D.027 and D.028.
10.2.9 Competent person telephone number
You can store telephone numbers in the menu.
The operator can display these in the information menu.
The telephone numbers can be up to 16 digits long and
must not contain any spaces. If the telephone number is
shorter, end the entry after the last digit by pressing the
right selection button.
All of the digits to the right will be deleted.
10.2.10 Terminating the installation assistant
If you have successfully run through and confirmed the
installation assistant, it will not start up automatically next
time the unit is switched on.
40
Installation and maintenance instructions ecoTEC plus 0020116700_06
Commissioning 10
Display
Meaning
P.00 1)
Purging test program
The heating circuit and the hot water circuit are purged
using the automatic air vent (the cap of the automatic
air vent must be released).
1 x right selection button: Start heating circuit purging
2 x right selection button (" ->
"): Start purging
hot water circuit
3 x right selection button ("
-> "): Restart heating
circuit purging
1 x left selection button ("Cancel"): Exit purging program
The internal pump is cyclically actuated.
Note: The purge program runs 7.5 min per circuit.
P.01
Maximum load test program:
The boiler is operated at maximum heat input after successful ignition.
P.02
Minimum load test program:
The boiler is operated at minimum heat input after successful ignition.
P.06
Filling mode test program:
The diverter valve (VUV) is moved to the mid-position.
The burner and pump are switched off (to fill or drain
the boiler).
10.1 Overview of the test programs
1)
Purging the heating circuit:
Diverter valve in heating position, actuation of internal pump
for 9 cycles: 30 s on, 20 s off. Display: "Active heating circuit".
Purging the hot water circuit:
After the above-mentioned cycles have run or the right selection button has been pressed again: Diverter valve in the hot
water position, actuation of the internal pump as above. Display:
"Active hot water circuit".
i
If you do not press a button for more than
15 minutes. the test programs are stopped automatically. The boiler switches to normal operating mode.
To terminate the test programs, you can press the left
selection button ("Cancel") at any time.
P.00 Exhaust
Heating circuit
1,0 bar
Cancel
10.1 Boiler in error condition
i
10.5
If the boiler is in error condition, you cannot
start any test programs. You can detect an error
condition by the fault symbol shown in the left
bottom corner of the display. You must first
reset.
Preparing the heating water
Pay attention to the specifications concerning heating
water preparation in (¬ section 2.5.7).
10.6
Read off the filling pressure
The boiler is equipped with an analogue pressure gauge
(¬ fig. 3.1 and 3.2) and also has a symbolic bar display for
the filling pressure of the heating installation and a digital
pressure and temperature display.
You can see the pressure gauge once you have removed
the front casing of the boiler.
Press the right selection button twice to read off the digital
filling pressure value.
10.7
Filling and purging the heating installation
b
Caution.
Risk of damage caused by contaminated
lines.
Foreign bodies such as welding remnants.
sealing residue or dirt in the water lines can
cause damage to the boiler.
> Flush the heating installation thoroughly
prior to commissioning.
The system is filled via a customer-installed filling connection, which must be attached in a suitable position in the
heating circuit. This connection must be removed again
after the filling process is complete. If the local Water
Authority regulations do not allow temporary connection a
sealed system filler pump with break tank must be used.
The heating system will not be filled automatically from the
domestic hot water side. (Alternative methods of filling
sealed systems are given in BS 5449). The ecoTEC plus
combination boilers can be filled via the built in filling lopp
under the boiler (¬ fig. 10.3).
To ensure the correct operation of the heating installation,
the indicator on the pressure gauge must point to the
upper half of the grey area or in the middle of the bar
graph display (marked by the dashed limit value) when the
heating installation is cold. This corresponds to a filling
pressure of between 0.1 MPa and 0.2 MPa (1.0 bar and
2.0 bar).
You can display the exact filling pressure (¬ section 10.6).
Installation and maintenance instructions ecoTEC plus 0020116700_06
41
10 Commissioning
> Purge the lowest radiator until water flows out of the
purging valve without bubbles.
> Purge all other radiators until the entire heating system
has been filled with water. Close all purging valves.
> Use the display to monitor the rising filling pressure in
the heating installation.
> Top up with water until the pressure gauge display is in
the middle of the grey area and the required filling pressure appears on the display.
> After filling, close the stop valve at the filling line and the
cold water valve.
> Check all connections and the entire system for leaks.
If the heating installation extends over several storeys,
higher filling pressures may be required to avoid air entering the heating installation.
> Remove the front casing from the boiler
(¬ section 4.7).
1
10.7.2 Purging the heating system
> To purge the heating installation, select test program
P.00 (¬ section 10.4).
The boiler does not start up, the internal pump operates
intermittently and, as an option, purges the heating circuit
or the hot water circuit. The display shows the filling pressure of the heating installation.
10.2 Automatic air vent
> The filling pressure of the heating installation must not
fall below 0.08 MPa (0.8 bar) when purging is in progress
as, otherwise, this will not be carried out properly.
> Release the cap of the automatic air vent (1) by up to
two rotations.
> Open all thermostatic radiator valves.
i
The test program P.00 runs for 7.5 minutes per circuit.
At the end of the filling procedure, the filling pressure of
the heating installation should be at least 0.02 MPa (0.2 bar)
above the counterpressure of the expansion vessel
(PInstallation ³ PExp + 0.02 MPa (0.2 bar)).
The ecoTEC plus purges the heating circuit independently during continuous operation via the
automatic air vent.
> Only for VUW boilers: Select test program P.06
(¬ section 10.4).
> If there is still too much air in the heating installation at
the end of test program P.00, repeat the test program.
> Check all connections for leaks.
The diverter valve moves to the central position, the pumps
do not run and the boiler does not switch to heating mode.
10.7.1
10.7.3 Flushing the system for the first time
("cold")
Filling the heating installation
i
i
Ensure that the filling and drainage cock on the
heating installation is connected to a cold water
valve as per standard.
> In order to fill the heating installation, first open the cold
water valve.
> Open all thermostatic radiator valves.
> Check that both service valves on the boiler are open.
> Slowly open the stop valve on the filling line so that the
water flows into the heating system.
i
42
If the water pressure in the heating system is
too low, the display switches between fault message F.22 and the display of the current pressure
when the boiler is switched on.
The entire heating system must be flushed
through completely at least twice: once cold and
once hot, in accordance with the following
instructions.
> Check whether all thermostatic radiator valves and both
service valves on the boiler are open.
> Connect a hose to the drain valve that is located at the
lowest position in the heating system.
> Open the drain cocks and all the purging 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 installation out
of the heating system before the boiler is started up.
> Close the drain cocks.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Commissioning 10
> Refill the heating system with water, as described in
(¬ section 10.7).
> Check that the expansion relief valve of 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 the filling valve and the cold water valve.
10.8
Avoiding low water pressure
To prevent damage to the heating installation caused by
low water pressure, the ecoTEC plus is fitted with a water
pressure sensor.
If the water pressure falls below 0.08 MPa (0.8 bar), the
boiler indicates low pressure by displaying a flashing pressure value.
If the water pressure falls below 0.05 MPa (0.5 bar), the
boiler switches off.
The fault message F.22 appears in the display.
> Top up the water and switch the boiler on again.
A flashing pressure value appears on the display until a
pressure of 1.1 bar or higher has been reached.
i
If you notice frequent drops in pressure, then
determine and eliminate the cause, i.e water
leaks in the system. Failure to do so along with
frequent topping up will result in system corrosion and subsequent failures.
10.8.1 Top up VUW boilers using a filling device
The VUW boilers are equipped with a filling device.
> Insert the double non-return valve (1) of the filling line
into the cold water stop valve and secure the valve with
the spring clip (2).
> To fill, first open the stop valve (3).
> Open the stop valve (4) so that the water flows into the
heating system. Fill the heating system as described in
¬ section 10.7.
> After filling, close both stop valves and disconnect the
filling device by pulling the double non-return valve from
the cold water stop valve.
i
10.9
Both stop valves must be closed during the
operation of the heating system and the filling
line must be removed from the double nonreturn valve again.
Fill and purge the hot water system
> Open the cold water stop valve on the boiler (only for
VUW boilers).
> Fill the hot water system by opening all the hot water
draw-off points until water comes out.
As soon as water comes out of all the hot water draw-off
points, the hot water circuit is filled completely and also
purged.
10.10
Filling the condensate siphon
a
4
Danger!
Risk of poisoning from escaping flue gas!
An empty or insufficiently filled condensate
siphon may allow flue gas to escape into
the room air.
> Fill the condensate siphon with water
before starting up the boiler.
3
1
2
10.3 Filling the VUW boiler using a filling device
Installation and maintenance instructions ecoTEC plus 0020116700_06
43
10 Commissioning
Gas valves with gas pressure regulators (1) are not installed
in all boilers. There are also versions without gas pressure
regulators.
10.11.1 Factory setting
b
1
10.4 Filling the condensate siphon
> Remove the lower part (1) of the condensate siphon by
turning the bayonet fitting anti-clockwise.
> Fill the lower section with water until about 10 mm below
the upper edge.
> Re-attach the lower section to the condensate siphon.
Caution!
An incorrect gas group setting can cause
operating faults or a reduction in the
working life of the boiler.
If the boiler version does not correspond to
the local gas group, 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 gas group specified on
the identification plate with the gas
group supplied at the installation site.
If the boiler version corresponds to the local gas
family:
> Proceed as described below.
10.11
Checking the gas setting
b
If the boiler version does not correspond to the
local gas family:
Caution.
Risk of damage caused by a not permissible setting.
Modifications to the gas pressure regulator
on the gas valve can destroy the gas valve
and cause operating faults on the boiler.
> Never modify the factory setting for the
gas pressure regulator of the gas valve.
1
> Call Vaillant Service Solutions (0870 6060 777); Gas
conversions must only be carried out by Vaillant Service
Solutions.
> You must not start up the boiler yourself.
i
If a gas conversion to liquid gas has been carried
out by Vaillant Service Solutions, the smallest
possible partial load is higher than is shown in
the display. The current values can be found in
the technical data (¬ section 17).
The combustion of this boiler has been checked, adjusted
and preset at the factory for operation on the gas group
defined on the identification plate. No measurement of the
combustion is necessary to set up the boiler.
Do not adjust the 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.
10.5 Gas pressure regulator
To further validate the integrity of the flue system and confirm correct operation of the boiler it is possible to conduct
44
Installation and maintenance instructions ecoTEC plus 0020116700_06
Commissioning 10
flue gas and air measurements on this boiler - for details
see section ¬ section 10.11.2.
Proceed to put the boiler into operation as follows:
> Check the maximum gas flow rate as detailed in
¬ section 10.11.3.
> Check the gas inlet working pressure as detailed in
¬ section 10.11.4.
> 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.
10.11.2 Checking for tightness of the flue gas
installation and flue gas recirculation
> Check the integrity off the flue gas installation according
to TB 008.
> Should the flue gas installation be longer than 2 m we
strongly recommend to check the system for flue gas
recirculation as described below.
> Start the boiler by activating the test program P.01 as
described in ¬ section 10.4.
> In addition, ensure that maximum heat can be dissipated
into the heating system by turning up the room thermostat.
> Alternatively, for VUW-boilers: 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 10.2.
If the measured gas flow rate lies outside the tolerance limits specified in ¬ table 10.2, do not operate the boiler and
inform the Vaillant Service Solutions (0870 6060 777).
If the measured gas flow rate is within the tolerance limits
shown in ¬ table 10.2, then proceed as follows:
> Take the boiler out of operation by
– terminating test program P.01 as described in
¬ section 10.4.
– Only for VUW-boilers: Allow the boiler to cool down
by turning off water taps and allow pump overrun
to operate for a minimum of two minutes.
1
> Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
Nominal net
heat
output in kW
2
10.6 Flue gas and air measure points
Legend:
1 Flue gas measure point
2 Air measure point
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.
10.11.3 Checking the gas flow rate
The boiler is fitted with an electronic gas air system 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:
Gas flow rate (as per BS EN 483)
Propane in kg/h
Natural gas in m3/h
nominomi+ 5 % - 10 %
+ 5 % - 10 %
nal
nal
12
1.31
1.38
1.18
0.96
1.01
0.86
15
1.64
1.72
1.48
1.20
1.26
1.08
18
1.97
2.07
1.77
1.44
1.51
1.30
24
2.61
2.74
2.35
1.92
2.02
1.73
30
3.27
3.43
2.94
2.40
2.52
2.16
37
4.03
4.23
3.63
2.96
3.11
2.66
24
2.61
2.74
2.35
1.92
2.02
1.73
31
3.30
3.47
2.97
2.42
2.54
2.18
37
4.15
4.36
3.74
3.05
3.20
2.75
10.2 Gas flow rates
10.11.4 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 (¬ section 4.7).
> Close the gas isolation valve of the boiler.
Installation and maintenance instructions ecoTEC plus 0020116700_06
45
10 Commissioning
1
>
>
>
>
>
>
>
>
2
10.7 Measuring the gas inlet working pressure
> Undo the sealing screw of the measuring nipple (1)
(lower screw) at the gas valve using a screwdriver.
> Connect a digital pressure gauge or U-tube manometer
(2) to the measuring nipple (1).
> Open the gas isolation valve of the boiler.
> Start the boiler by activating the test program P.01 as
described in ¬ section 13.4.
> In addition, ensure that maximum heat can be dissipated
into the heating system by turning up the room thermostat.
> Alternatively, for VUW-boilers: 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 10.3.
> Should the pressure recorded at the reference test point
in the boiler be lower than indicated (¬ table 10.3) check
if there is any blockage in the pipework or if the pipework is undersized.
– terminating test program P.01 as described in
¬ section 10.4.
– Only for VUW-boilers: 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 retighten the sealing
screw (1) for the measuring nipple.
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.
If the gas inlet working pressure is within the permissible
range, proceed as follows:
> Take the boiler out of operation by
– terminating test program P.01 as described in
¬ section 10.4.
– Only for VUW-boilers: 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 retighten the sealing
screw (1) for the measuring nipple.
> 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 boiler gas inlet working pressure (kPa
resp. mbar) in the Benchmark gas boiler commissioning
checklist.
Natural gas (G20)
Boiler
LPG (G31)
Minimum
Maximum
Minimum
Maximum
pressure at pressure at pressure at pressure at
reference
reference
reference
reference
test point in test point in test point in test point in
kPa (mbar) kPa (mbar) kPa (mbar) kPa (mbar)
612/
615/
618/
624/
630/
824/
831
1.3 (13)
2.3 (23)
2.3 (23)
4.3 (43)
637/
837
1.3 (13)
2.3 (23)
2.3 (23)
4.3 (43)
10.3 Gas inlet working pressure at the reference test point
If the supply pressure is out of tolerance contact your
Emergency Service Provider.
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 (0870 6060 777) and proceed as follows:
> Take the boiler out of operation by
46
Installation and maintenance instructions ecoTEC plus 0020116700_06
Commissioning 10
10.12
Carrying out a full function test
> After completing the installation and the gas setting, perform a complete function check of the boiler before starting up the boiler and handing it over to the operator.
> Start up the boiler in accordance with the relevant operating instructions.
If you have still not successfully completed the installation
assistant and subsequently confirmed this, it will be
restarted when you switch on the boiler. Before continuing,
complete the installation assistant (¬ section 10.2).
10.12.1 Checking the heating mode
> Switch on the boiler.
> Make sure that there is a heat requirement.
> Activate the Live monitor (¬ section 13.2.1).
S.04
Heating mode
Burner on
Back
10.9 Live monitor – display during heating mode
If the boiler is operating correctly, the display will show status code "S.04". The status code displayed will also be
explained by the plain text display "Heating mode: Burner
on".
10.12.2 Checking hot water generation
(VUW boilers only)
10.8 Checking for leaks
b
> Switch on the boiler.
> Open a hot water valve all the way.
> Activate the Live monitor (¬ section 13.2.1).
If hot water generation is working correctly, the display
shows "S.14". The displayed status code is also explained by
the plain text display "DHW mode: Burner on".
S.14
Caution!
Malfunction or shortened life expectancy!
The leak detection spray can damage the
heating device.
> Do not spray the leak detection spray on
the cover cap on the filter of the Venturis (3, ¬ fig. 3.1 and 3.2).
> Check the gas supply line, the flue gas installation, the
heating installation and the hot water pipes for leaks.
> Check the air/flue gas duct for correct installation.
> Make absolutely sure that the front casing is properly fitted.
> Check the heating mode (¬ section 10.12.1)
> Check the operation of the hot water generation
(¬ section 10.12.2 and 10.12.3)
You can display the current operating condition of the
boiler in the "Live monitor" on the boiler display
(¬ section 13.2.1).
Menu ¬ Live monitor
DHW mode
Burner on
Back
10.10 Display during hot water generation (VUW boilers only)
10.12.3 Checking hot water generation
(VU boilers only)
> Switch on the boiler.
> Switch on the connected domestic hot water cylinder.
> Make sure that the cylinder thermostat is requesting
heat.
> Activate the Live monitor (¬ section 13.2.1).
If the cylinder is being charged correctly, status code "S.24"
appears in the display. The status code that is displayed is
Installation and maintenance instructions ecoTEC plus 0020116700_06
47
11 Adapting the boiler to the heating installation
11
also explained by the plain text display "DHW mode: Burner
on".
S.24
The installation assistant is started when the boiler is
switched on for the first time (¬ section 10.2).
DHW mode
Burner on
If you have already filled the heating installation and terminated the installation assistant, but wish to set the most
important system parameters again, you can also call up
the "Appliance configuration" menu point.
Menu ¬ Installer level ¬ Appliance configuration
Back
10.11 Display during cylinder charging (VU boilers only)
> If you have connected the controller for the heating
installation using a two-wire eBUS line, then set the hot
water temperature at the boiler to the maximum possible
temperature (¬ table 11.1).
> Adjust the target temperature for the connected domestic hot water cylinder to the controller.
10.13
Final flush of the heating system ("hot")
> Operate the appliance until the boiler and the heating
system are up to temperature.
> Check the heating system for leaks.
> Connect a hose to the drain valve located at the lowest
position of the heating system.
> Shut off the boiler, open the drain valve and all purging
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.
> Fill the heating system again with water as described in
¬ section 10.7.3.
> Re-fill the system until the system design pressure of
0,1 MPa (1,0 bar) is attained. (The actual reading on the
digital pressure gauge should ideally be 0,05 MPa (0,5
bar) plus an additional pressure corresponding to the
highest point of the system above the base of the boiler
– 10 m head equals an additional 1 bar reading on the
pressure gauge. The minimum pressure should not be
less than 0,1 MPa (1 bar) in any installation.) If the system
is to be treated with an inhibitor it should be applied 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 Fernox, Alpha–
Fry technologies. Tel: 0870 8700362.
> Refit the boiler casing (¬ section 4.7).
> 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 the
appliance. It may be necessary to adapt the bottom
cover by removing the easy break sections.
48
Adapting the boiler to the heating
installation
All of the settings for more complex systems can be found
in the diagnosis menu.
Menu ¬ Installer level ¬ Diagnosis menu
11.1
Diagnosis codes – Overview
Menu ¬ Installer level ¬ Diagnosis menu
With the use of the parameters that are marked as adjustable in ¬ table 11.1, you can adapt the boiler to the heating
installation and the needs of the customer:
i
You can enter your settings in the last column
after setting the system-specific parameters.
or the plus button
> Press the minus button
to switch between the displayed diagnosis
codes.
With modifiable parameters:
("Selection")
> Press the right selection button
to select the parameter to make a change.
or the plus button
> Press the minus button
to change the current setting.
("Ok") to
> Press the right selection button
confirm the change.
The change is saved.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Adapting the boiler to the heating installation 11
Factory
setting
Auto
Your own
setting
Code
Parameters
Adjustable values
D.000
Heating partial load
Adjustable heating partial load in kW
Auto: Boiler automatically adjusts max. partial load to current system demand
D.001
Overrun time of internal pump for
heating mode
1 - 60 min
5 min
D.002
Max. burner anti-cycling time heating
at 20 °C flow temperature
2 - 60 min
20 min
D.003
Outlet temp. actual value
In °C
Not
adjustable
D.004
Measured value of hot water sensor
In °C
Not
adjustable
D.005
Flow temperature target value
(or return target value)
In °C, max. of the value set in d.71, limited by an eBUS controller if connected)
Not
adjustable
D.006
Hot water temperature target value
(VUW boilers only)
35 to 65 °C
Not
adjustable
D.007
Warm start temperature target value
(only with VUW boilers)
Cylinder temperature target value
(only with VU boilers)
40 to 65 °C
15 °C frost protection, then 40 to 70 °C;
(max. temperature can be adjusted under D.020)
Not
adjustable
D.008
Room thermostat at terminal RT
Room thermostat open (no heat requirement)
Room thermostat closed (heat requirement)
Not
adjustable
D.009
Target value from external eBus controller
In °C
Not
adjustable
D.010
Status of internal pump
On, Off
Not
adjustable
D.011
Status of external heating pump
On, Off
Not
adjustable
D.012
Status of cylinder charge pump
On, Off
Not
adjustable
D.013
Status of hot water circulation pump
On, Off
Not
adjustable
D.014
Target pump speed
(high-efficiency pump)
Not relevant
Not
adjustable
D.015
Actual pump speed
(high-efficiency pump)
Not relevant
Not
adjustable
D.016
Room thermostat 24 V DC open/
closed
Heating mode Off/On
Not
adjustable
D.017
Heating flow/return regulation
changeover
Control type: flow, return
Flow
D.018
Pump operating mode setting
Comfort (continuously operating pump)
Eco (intermittently operating pump)
Eco
D.019
Operating mode of 2-stage pump
Setting for operating mode of 2-stage pump:
0 = Burner operation = stage 2, Flow/overrun = stage 1;
1 = Heating + Overrun = stage 1, Hot water = stage 2,
2 = Like 1, but rotational speed during heating mode
depending on heating partial load,
3 =always stage 2
4 = Rotational speed during heating mode depending on
heating partial load, otherwise always stage 1
2
D.020
D.022
Max. setting for cylinder target value
Hot water requirement via C1/C2,
impeller or APC
Setting range: 50 °C - 70 °C (actoSTOR 65 °C)
On, Off
65 °C
D.023
Summer/winter operating mode
(heating on/off)
Heating on, heating off (summer mode)
Not
adjustable
D.025
Hot water generation enabled by
eBUS controller
On, Off
Not
adjustable
Not
adjustable
11.1 Diagnosis codes
Installation and maintenance instructions ecoTEC plus 0020116700_06
49
11 Adapting the boiler to the heating installation
Factory
setting
External
pump
Your own
setting
Code
Parameters
Adjustable values
D.026
Auxiliary relay control
Circulation pump
External pump
Cylinder charging pump
Extractor hood
External solenoid valve
External fault message
Solar pump (not active)
eBUS remote control (not active)
Legionella protection pump (not active)
Solar valve (not active)
D.027
Switching of relay 1 on the "2 in 7" multi- Circulation pump
functional module VR 40
External pump
Cylinder charging pump
Extractor hood
External solenoid valve
External fault message
Solar pump (not active)
eBUS remote control (not active)
Legionella protection pump (not active)
Solar valve (not active)
External
pump
D.028
Switching of relay 2 on the "2 in 7"
multi-functional module VR 40
Circulation pump
External pump
Cylinder charging pump
Extractor hood
External solenoid valve
External fault message
Solar pump (not active)
Remote control eBUS (not active)
Legionella protection pump (not active)
Solar valve (not active)
External
pump
D.033
Fan speed target value
In rpm
Not adjustable
D.034
Fan speed actual value
In rpm
Not adjustable
D.035
Position of the diverter valve
Heating mode
Parallel operation
DHW mode
Not adjustable
D.036
Hot water flow quantity (impeller sensor)
In l/min
Not adjustable
D.039
Solar feed temperature
Actual value in °C
Not adjustable
D.040
Flow temperature
Actual value in °C
Not adjustable
D.041
Return temperature
Actual value in °C
Not adjustable
D.044
Digitised ionisation value
Display range 0 to 1020,
> 800 no flame
< 400 good flame
Not adjustable
D.046
Pump type
Disable via relay
Disable via PWM
D.047
Outside temperature (with weather-con- Actual value in °C
trolled Vaillant controller)
D.050
Offset for minimum speed
In rpm, setting range: 0 to 3000
Nominal value
set in factory
D.051
Offset for maximum speed
In rpm, setting range: -990 to 0
Nominal value
set in factory
D.058
Activation of solar post-heating for VUW Solar post-heating mode deactivated
boilers;
DHW activation target value minimum 60 °C
Switch hot water mode
Disable via
relay
Not adjustable
Solar postheating mode
deactivated
11.1 Diagnosis codes (continued)
50
Installation and maintenance instructions ecoTEC plus 0020116700_06
Adapting the boiler to the heating installation 11
Code
Parameter
Adjustable values
D.060
Number of temperature limiter shutdowns
Number of shutdowns
Your own
setting
Not adjustable
D.061
Number of ignition device cutoffs
Number of unsuccessful ignitions in the last attempt
Not adjustable
D.064
Average ignition time
In seconds
Not adjustable
D.065
Maximum ignition time
In seconds
Not adjustable
D.067
Remaining burner anti-cycling time
In minutes
Not adjustable
D.068
Unsuccessful ignitions at 1st attempt
Number of unsuccessful ignitions
Not adjustable
D.069
Unsuccessful ignitions at 2nd attempt
Number of unsuccessful ignitions
Not adjustable
D.070
Setting diverter valve position
Normal operating mode
Mid-position (parallel operation)
Continuous heating adjustment
Normal operating mode
D.071
Target value maximum heating flow
temperature
40 to 80 °C
75 °C
D.072
Internal pump overrun after cylinder
charging
Adjustable from 0 - 10 minutes in increments of 1
minute
2 mins
D.073
Warm start target offset
Adjustable from -15 K to 5 K
0
D.075
Max. charging time for domestic hot
20 - 90 min
water cylinder without independent control system
D.076
Device specific number
1 = VU 612
3 = VU 615
4 = VU 618
9 = VU 624
14 = VU 630
20 = VU 637
6 = VUW 824
10 = VUW 831
17 = VUW 837
D.077
Limit on cylinder charging output
in kW
Limit on cylinder charging output
in kW
D.078
Limit on cylinder charging temperature
in °C
55 °C - 80 °C
Note: The chosen value must be at least 15 K or 15 °C
above the set cylinder target value.
D.080
Operating hours, heating
In hours (h)
Not adjustable
D.081
Operating hours, hot water generation
In hours (h)
Not adjustable
D.082
Number of burner start-ups in heating
mode
Number of start-ups
Not adjustable
D.083
Number of burner start-ups in hot water Number of start-ups
mode
Not adjustable
D.084
Maintenance indicator: Number of hours Setting range: 0 to 3000 hrs and "---" for deactivated
until the next maintenance
"---"
D.088
Start delay for hot water draw-off detec- 1.5 l/min and no delay,
tion via impeller (VUW boilers only)
3.7 l/min and 2 s delay
1.5 l/min and
no delay
D.090
Status of digital controller
recognised, not recognised
Factory
setting
45 mins
Not adjustable
75 °C
Not adjustable
11.1 Diagnosis codes (continued)
Installation and maintenance instructions ecoTEC plus 0020116700_06
51
11 Adapting the boiler to the heating installation
Code
Parameter
Adjustable values
D.091
Status DCF with external sensor connected
No reception
Reception
Synchronised
Valid
D.093
Setting of device specific number (DSN)
Setting range: 0 to 99
D.094
Delete fault history
Delete fault list
D.095
Software version of PeBUS components
PCB (BMU)
Display(AI)
actoSTOR(APC)
HBI/VR34
D.096
Factory setting
Reset all adjustable parameters to factory setting
D.098
Value of coding resistors for gas group
and output range
Display xx.yy
xx = Coding resistor 1 in cable harness for output
range:
08 = VU 612, VU 615, VU 618, VUW 824
09 = VU 624, VUW 831
10 = VU 630
11 = VU 637, VUW 837
Factory
setting
Your own
setting
Not adjustable
Not adjustable
Not adjustable
yy = Coding resistor 2 on PCB for gas group:
02 = P-Gas
03 = H-Gas
11.1 Diagnosis codes (continued)
11.1.1
Setting the heating partial load
The heating partial load of the Vaillant ecoTEC plus boiler is
factory set to "auto". This means that the boiler independently determines the optimum heating output depending on
the current heat demand of the system. A setting is normally no longer required. If you still want to set a fixed
maximum heating partial load, you can set a value under
diagnosis code "D.000", which equates to the boiler output
in kW.
11.1.2
Setting pump overrun time and pump
operating mode
The pump overrun time for the heating mode is set at the
factory to a value of 5 minutes. You can set the pump overrun time under diagnosis code "D.001" within the range of
1 minute to 60 minutes. You can set a different pump operating mode under diagnosis code "D.018". Here you have
the choice between Eco and Comfort.
Comfort (continuously operating pump)
The internal pump is switched on when the heating flow
temperature is not at "Heating off"(¬ Operating instructions) and the heating requirement is enabled via an external controller.
52
Installation and maintenance instructions ecoTEC plus 0020116700_06
Adapting the boiler to the heating installation 11
Eco (intermittently operating pump)
11.1.5
Pump operating mode Eco is the factory setting. This pump
operating mode is useful for removing residual heat after
hot water generation when the heat demand is extremely
low and large temperature spreads exist between the hot
water generation and heating mode target values. This prevents living rooms from being under-supplied. If there is a
heat demand, the pump is switched on every 25 minutes for
5 minutes once the overrun time has elapsed.
11.1.3
Setting the maximum flow temperature
The maximum flow temperature for the heating is set at the
factory to 75 °C. This can be set to a value in the range of
40 °C to 80 °C under diagnosis code "D.071".
11.1.4
Setting the return flow temperature control
If the boiler is connected to an underfloor heating system,
the temperature control can be changed from flow temperature regulation (factory setting) to return flow temperature control under diagnosis code "D.017".
Burner anti-cycling time
Setting the burner anti-cycling time
To prevent frequent switching on and off of the burner and
therefore energy loss, an electronic restart lockout is activated for a specific period each time the burner is switched
off. You can adjust the burner anti-cycling time to the conditions of the heating installation.
The burner anti-cycling time is only activated for the heating mode.
Hot water handling during a burner anti-cycling time does
not affect the timer.
You can set the maximum burner anti-cycling time at
installer level under diagnosis code "D.002" within the
range 2 minutes to 60 minutes (factory setting: 20 min).
The effective burner anti-cycling time depends on the current target flow temperature and the maximum burner anticycling time set.
The effective burner anti-cycling times with respect to the
target flow temperature and the maximum set burner anticycling time can be found in the following table.
i
The remaining burner anti-cycling time following
a regular shutdown in heating mode can be
called up under diagnosis code "d.067".
Set maximum burner anti-cycling time [min]
TFeed (target)
[°C]
1
5
10
15
20
25
30
35
40
20
2.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
25
2.0
4.5
9.2
14.0
18.5
23.0
27.5
32.0
36.5
41.0
30
2.0
4.0
8.5
12.5
16.5
20.5
25.0
29.0
33.0
37.0
35
2.0
4.0
7.5
11.0
15.0
18.5
22.0
25.5
29.5
40
2.0
3.5
6.5
10.0
13.0
16.5
19.5
22.5
45
2.0
3.0
6.0
8.5
11.5
14.0
17.0
50
2.0
3.0
5.0
7.5
9.5
12.0
14.0
55
2.0
2.5
4.5
6.0
8.0
10.0
60
2.0
2.0
3.5
5.0
6.0
7.5
65
2.0
1.5
2.5
3.5
4.5
5.5
70
2.0
1.5
2.0
2.5
2.5
75
2.0
1.0
1.0
1.0
1.0
45
50
55
60
50.0
55.0
60.0
45.0
50.0
54.5
41.0
45.0
49.5
33.0
36.5
40.5
44.0
26.0
29.0
32.0
35.5
38.5
19.5
22.5
25.0
27.5
30.5
33.0
16.5
18.5
21.0
23.5
25.5
28.0
11.5
13.5
15.0
17.0
19.0
20.5
22.5
9.0
10.5
11.5
13.0
14.5
15.5
17.0
6.5
7.0
8.0
9.0
10.0
11.0
11.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
11.2 Effective burner anti-cycling times
Installation and maintenance instructions ecoTEC plus 0020116700_06
53
11 Adapting the boiler to the heating installation
Reset remaining burner anti-cycling time
You have two options to reset the remaining burner anticycling time:
1st option
Menu ¬ Reset burner anti-cycling time
The current burner anti-cycling time appears in the display.
> Confirm the reset of the burner anti-cycling time by
("Select").
pressing the right selection button
2nd option
> Press the fault clearance key (¬ Operating instructions).
11.1.6
Setting the maintenance interval
You can define maintenance intervals for the ecoTEC plus.
Using this function, the message that the boiler must be
serviced appears in the display after a defined, configurable
number of burner operating hours.
After the expiry of the set burner operating hours, the
(open-end spanner) appears next to
maintenance symbol
the current flow temperature. The display on the eBUS controller (accessory) shows the information "Maintenance"
"MAIN".
Heat demand
Burner operating hours until the
Number of
next inspection/service
persons
(depending on the system type)
5.0 kW
1-2
2-3
1,050 h
1,150 h
10.0 kW
1-2
2-3
1,500 h
1,600 h
15.0 kW
2-3
3-4
1,800 h
1,900 h
20.0 kW
3-4
4-5
2,600 h
2,700 h
25.0 kW
3-4
4-6
2,800 h
2,900 h
> 27.0 kW
3-4
4-6
3,000 h
3,000 h
11.1.7
Setting the pump output
The ecoTEC plus boiler is equipped with a 2-stage pump.
The output of the two-stage pump can be adjusted to the
requirements of the heating installation.
> If necessary, change the setting of the pump speed
according to the operating mode under diagnostic point
"D.019" (Setting options ¬ table 11.1).
D.019 Pump operating mode of 2-stage pump, settings:
0
Burner mode stage 2,
pump flow/overrun stage 1
1
Heating mode and pump flow/overrun stage 1,
DHW mode stage 2
2
Automatic heating mode,
pump flow/overrun stage 1,
DHW mode, stage 2
3
Stage 2
4
Rotational speed during heating mode depending on
heating partial load, otherwise always stage 1
11.1.8
Setting the by-pass valve
The boilers have a by-pass valve.
The pressure is adjustable in the range between 17.0 MPa
(170 mbar) and 35.0 MPa (350 mbar). Approx. 25.0 MPa
(250 mbar) is pre-set (mid-position). The pressure changes
by approx. 1.0 MPa (10 mbar) each time the adjusting screw
is rotated. By turning right, the pressure increases and turning left decreases it.
1
11.3 Guideline values for operating hours
> Set the operating hours until the next service using diagnosis code "d.084".
Guideline values for the setting can be found in ¬ table 11.3.
The values stated correspond to an average boiler operating time of one year.
You can set the operating hours in increments of ten from
0 to 3,000 h.
If you do not enter a figure under diagnosis code "D.084"
but instead enter the symbol "–", then the "Maintenance
display" function is not active.
i
54
On completion of the set operating hours, you
must set the maintenance interval again in diagnosis mode.
11.1 Adjusting the by-pass valve
> Regulate the pressure using the setting screw (1).
Installation and maintenance instructions ecoTEC plus 0020116700_06
Adapting the boiler to the heating installation 11
Position of the
setting screw
Pressure
in MPa
(mbar)
Right-hand stop
(turned all the way
down)
If the radiators do not get
properly hot in the factory
setting.
35.0 (350)
Note: In this case, you must
set the pump to the maximum
stage.
Mid-position (5 turns
to the left)
5 further turns to the
left from the mid-position
Notes/application
25.0 (250) Factory setting
17.0 (170)
>
>
>
>
>
>
If noises in the radiators or
radiator valves are produced
>
11.4 Setting value for the by-pass valve (feed head)
>
11.2
Handing over the boiler to the operator
>
a
Danger!
Risk of poisoning and burns caused by
escaping hot flue gas!
Hot flue gas can escape and cause poisoning and burns if the boiler is operated with
an incompletely mounted or open air/flue
gas duct or if the boiler is operated with
internal leaks with the front casing open.
> Operate the boiler
- for commissioning
- for testing purposes
- in continuous operation
only when the front casing is fitted and
closed and the air/flue gas duct is completely mounted.
> Exclusively for test purposes such as gas
working pressure testing the boiler may
be operated with the front casing
removed for short durations ONLY but
must have a completely mounted air/flue
gas duct.
>
>
>
>
guarantee (Note: Your legal rights remain unaffected by
this.)
Handover the boiler to the operator.
Explain the basic operation of the heating installation to
the operator.
Provide the operator with all relevant instructions and
boiler documentation.
Go through the operating instructions with the operator
Reply to his questions if necessary.
Make the operator aware of the need to keep the instructions in a handy location near the boiler, but not in or on
the boiler.
Draw special attention to the safety instructions, which
the operator must follow.
Instruct the operator that no changes or adaptations
must be made to the flue system or combustion air supply. These must both terminate outside of the building
and be constructed only from approved components.
Explain to the operator how he should monitor the water
level/filling pressure of the system.
Explain to the operator which measures are required to
top up and purge the heating installation if required.
Explain to the operator how to correctly set the temperatures, the controllers and the thermostatic radiator
valves (economically).
Complete and sign off the Benchmark commissioning
check list.
Complete and sign off the guarantee documentation.
> After completing the installation, stick the 835593
sticker in the user's language to the front of the unit.
The sticker is delivered with the boiler.
You must brief the operator of the boiler on the handling
and function of the ecoTEC plus.
> Explain the importance of regular maintenance by a
competent specialist company to the operator.
It is strongly recommended that a maintenance contract
be taken out to ensure regular maintenance. Important
information is available from Vaillant Service Solutions
(0870 6060 777).
> Fully complete the Benchmark gas boiler commissioning
checklist which will be found at the back of this manual.
If this boiler is not installed and commissioned in accordance with manufacturer's instructions, this may void the
Installation and maintenance instructions ecoTEC plus 0020116700_06
55
12 Inspection and maintenance
12
Inspection and maintenance
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.
After servicing, complete the relevant Service Record section of the Benchmark Checklist located on the inside back
pages of this document.
12.1
Inspection and maintenance intervals
a
a
This normally is done by cleaning, adjustment and, if necessary, replacing individual components that are subject to
wear.
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.
You must carry out an annual inspection of the Vaillant
ecoTEC.
The annual inspection can be effectively performed without
removing components by requesting data from the DIA system, carrying out the simple visual checks indicated in
¬ table 12.3 and performing a flue gas measurement.
The maintenance intervals 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 12.3.
a
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 BS 7927 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.
56
12.1.1
Danger!
Risk of poisoning and burns caused by
escaping hot flue gas!
Hot flue gas can escape and cause poisoning and burns if the boiler is operated with
an incompletely mounted or open air/flue
gas duct or if the boiler is operated with
internal leaks with the front casing open.
> Operate the boiler
- for commissioning
- for testing purposes
- in continuous operation
only when the front casing is fitted and
closed and the air/flue gas duct is completely mounted.
> Exclusively for test purposes such as gas
working pressure testing the boiler may
be operated with the front casing
removed for short durations ONLY but
must have a completely mounted air/flue
gas duct.
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 0870 6060 777.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Inspection and maintenance 12
During any inspection and maintenance or after change of
parts of the combustion circuit, the following must be
checked:
– The boiler 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 (paying particular attention to the burner
door seal).
– The gas inlet working pressure at maximum rate as
described in ¬ section 10.11.4.
– The gas flow rates as described in ¬ section 10.11.3.
– 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.
12.1.2 Safety instructions
a
i
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.
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.
> Open the cold water stop valve if necessary.
> Reconnect the boiler to the power mains.
> Switch on the boiler using the on/off switch.
> Fill the heating circuit of the boiler to a pressure of
between 0,1 and 0,2 MPa (1,0 and 2,0 bar) if required.
> If you have topped up with water, purge the heating
installation using test program P.00 (¬ section 10.7.2).
> Open the gas isolation valve.
> Check the boiler for gas and water leaks.
> Replace the front casing to the boiler (¬ section 4.7).
> If you have worked on the gas route, carry out a gas
family check (¬ section 12.1.5).
> Carry out a functional check of the boiler (¬ section 10.12).
> Always check earth continuity, polarity and resistance to
earth with a multimeter after any service work and after
replacing any electrical component.
> If necessary, refill and re-purge the heating installation.
> Complete the benchmark gas boiler commissioning service record on the back pages of these instructions.
12.1.3 Checking the CO/CO2 ratio and the CO2
concentration
a
Danger!
Danger of explosion, fire or poisoning
caused by incorrect flue gas value
adjustment.
Safe combustion can only be verified by
measuring CO/CO2 ratio.
> Make sure that the CO/CO2 ratio does not
exceed the value shown in ¬ table 12.1.
i
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.
Installation and maintenance instructions ecoTEC plus 0020116700_06
57
12 Inspection and maintenance
1
1
2
12.1 Measuring the CO2 concentration
i
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 (¬ section 4.7).
> Start the testing program P.01 (¬ section 10.4).
> Wait at least 5 minutes until the boiler reaches its operating temperature.
> Measure the CO2 concentration at the flue gas analysis
point (1). Compare the measured value with the corresponding value in ¬ table 12.1.
> If all these points are as required, proceed as described
in ¬ section 12.2.
> If one of the flue gas values is greater than the acceptable values in ¬ table 12.1, then proceed as described in
the following ¬ section 12.1.4.
12.1.4 Adjusting the CO2 concentration (or the air
ratio)
a
58
Danger!
Increased risk of poisoning due to incorrect settings!
If one of the flue gas values is greater than
the acceptable values in ¬ table 12.1 then:
> Check the integrity of the complete flue
gas installation.
> Check the integrity of the combustion
circuit seals.
> Check the gas inlet working pressure.
> Check the gas flow rate.
12.2 Removing the covering cap for the air ratio setting adjusting screw (gas setting) and making the air ratio setting
If the flue gas value needs to be adjusted, proceed as follows.
The adjusting screw for making the air ratio setting is
located beneath a covering cap (1), which is easy to
unscrew.
> To do this, push a small slotted screwdriver through the
covering cap at the mark and unscrew it.
> Set the relevant CO2 value (value with removed front
casing ¬ table 12.1) by turning the screw (2). To do this,
use a small slotted screwdriver or a 2.5 mm Allen key.
– Turn to the left: higher CO2 concentration,
– Turn to the right: lower CO2 concentration.
i
Natural gas: Only perform the adjustment in
increments of 1 turn and wait approximately
1 minute after each adjustment until the value
stabilises.
i
Liquid gas: Only perform the adjustment in small
increments (approximately 1/2 turns), and wait
approximately 1 minute after each adjustment
until the value stabilises.
> Press the "Cancel" selection button once the settings
have been adjusted.
> When the adjusting work is complete, screw the covering
cap back in again.
> Put the front casing back on (¬ section 4.7).
Installation and maintenance instructions ecoTEC plus 0020116700_06
Inspection and maintenance 12
Unit
Settings
Natural gas (H)
Result
Propane
CO2 after 5 minutes full
load mode with
boiler front casing fitted
Vol.–%
7.8 - 10.2
9.7 - 10.7
CO2 after 5 minutes full
load mode with boiler
front casing removed
Vol.–%
7.6 - 10.0
9.5 - 10.5
Set for Wobbe index Ws
kWh/m3
15
22.5
CO value with full load
CO/CO2
ppm
< 250
< 0.0031
< 250
< 0.0026
F.92 Coding The coding
resistor fault resistor on the
PCB does not
match the
entered gas
family
"successful" Combustion
quality is good.
Appliance configuration
matches the
specified gas
family.
"Warning"
12.1 Factory gas setting
a
Meaning
Danger!
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 12.1, call
the Vaillant Service Solutions (0870
6060 777).
> Do not start up the boiler!
F.93 Gas
group fault
Response
> Check the coding resistor,
repeat the gas family check
and enter the correct gas family.
None
> Start test program P.01 and
Combustion
adjust the CO2 value with the
quality insuffiadjusting screw in the venturi
cient. CO2 value
and CO/CO2
¬ section 12.1.4.
ratio are incor- > If the correct CO2 value cannot
rect.
be set:
Check the gas restrictor for
correctness (yellow: H-gas,
grey: liquid gas) and damage.
> Repeat gas family check.
Combustion
> Damaged or incorrect gas
quality outside
restrictor (yellow: H-gas, grey:
the permitted
liquid gas), wrong gas group,
range
internal pressure measuring
point in venturi blocked (do not
use lubricants on O-ring in venturi.), recirculation, faulty seal.
> Resetting the boiler.
> Set correct CO2 value using
test program P.01 (adjusting
screw in venturi)
¬ section 12.1.4.
> Repeat the gas family check.
12.1.5 Performing the gas family check
12.2 Results and measures after gas family check
a
Danger!
Risk to life due to poisoning!
CO is an extremely toxic gas. Risk to life
due to excessive CO concentrations. Fault
codes F.92 or F.93 may occur as result of
the gas family check.
> Correct the failure unconditionally before
starting up the boiler for continuous
operation.
Menu ¬ Installer level ¬ Test programs ¬Gas family
check
The gas family check checks the boiler setting with regard
to combustion quality.
> Perform the gas family check:
– as part of regular boiler maintenance
– after replacing components or working on the gas
route.
i
No CO/CO2 or CO2 measurement is possible during the gas family check.
Installation and maintenance instructions ecoTEC plus 0020116700_06
59
12 Inspection and maintenance
12.2
Inspection and maintenance work steps
No. Activity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
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.
Carry out a general inspection of the boiler for dirt and dust and clean as necessary.
Visually inspect the complete heat engine for its general condition and for signs of corrosion,
sooting or other forms of damage (paying particular attention to the burner door seal). If damage is evident proceed to column 2.
Measure the gas flow rate during operation with maximum load (¬ section 10.11.3). If the gas
flow rate complies to the ¬ table 10.2 continue with column 1, if not proceed to column 2.
Check the gas inlet working pressure (¬ section 10.11.4) operation with maximum load. If the gas
inlet working pressure complies to the ¬ table 10.3 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 12 proceed to maintenance column 2. You must not proceed with the maintenance if a new burner door seal kit is not available.
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.
Close the gas isolation valve and the service valves.
Drain 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.
Only with VUW boilers with actoSTOR: Check the charge pressure in the expansion vessel of the
layered storage tank. Correct the pressure if necessary.
Remove the compact thermal module.
Check the integrity of all combustion circuit seals, especially the burner door seal. Ensure any
damage found is repaired before proceeding.
Clean the heat exchanger (¬ section 12.4.2).
Check whether the burner is dirty and clean it if necessary.
Check the condensate siphon in the boiler, clean and fill. Flush through all discharge pipe work
(ensure route and termination are correct and it is unlikely to freeze up in severe weather).
Install the compact thermal module. Caution: Use new seals and nuts!
For VUW boilers:
Replace the hot water heat exchanger if the volume of water is insufficient or the output temperature is not reached
For VUW boilers:
Remove the impeller sensor, clean the filter in the cold water inlet of the sensor and refit the
sensor.
Service the domestic hot water cylinder (see note below).*
Open the gas isolation valve, reconnect the boiler with the power mains and switch on the boiler.
Open the service valves and fill up the boiler/appliance to approximately 0,1 - 0,2 MPa (1,0 - 2,0
bar) (depending on the static height of the system). Start the purging program P.00.
Perform a test operation of the boiler and heating installation, including hot water generation
and purge again if necessary.
Perform the gas family check (¬ section 12.1.5).
Check visually the ignition and burner performance.
Check the boiler for leaks of any kind (gas, flue gas, water, condensate) and rectify as necessary.
If you had problems with the CO, CO2, CO/CO2-values in Step 6 before the maintenance, check
them again now (¬ table 12.1). If they are outside of the tolerances of ¬ table 12.1 make an
adjustment, see ¬ section 12.1.4.
Complete the Benchmark gas boiler commission service record on the back pages of this manual.
Column 1
Inspection
must be carried out each
year
Column 2
Maintenance
must be carried out at
regular intervals
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
12.3 Inspection and maintenance steps
* Additional checks and procedures will be required where the
boiler is used with a cylinder or solar thermal system. These are
not covered in this manual.
60
Installation and maintenance instructions ecoTEC plus 0020116700_06
Inspection and maintenance 12
12.2.1 Filling the boiler and the heating
installation
Display
Test programs
Action
T.01
A description of how to fill the boiler and the heating installation is provided in ¬ section 10.7.
Check internal
pump
You can switch the internal pump on
and off.
T.02
Check 3-way
valve
You can move the diverter valve to
the heating position or to the hot
water position.
12.2.2 Draining the boiler
T.03
Check fan
You can switch the fan on and off.
The fan runs at maximum speed.
> Close the service valves of the boiler.
> Start test program P.06 (diverter valve mid-position)
(¬ section 10.7).
> Open the drain valves on the service valves.
> Make sure that the cap of the automatic air vent on the
internal pump is open so that the boiler can be drained
fully.
T.04
Check cylinder
charge pump
You can switch the cylinder charging
pump on and off.
T.05
Check circulation You can switch the circulation pump
pump
on and off.
T.06
Check external
pump
You can switch the external pump on
and off.
T.08
Check burner
The boiler starts, carries out the necessary self-test and switches to minimum load.
The flow temperature is shown in the
display.
12.2.3 Draining the entire heating installation
> Attach a hose to the draining device on the system.
> Bring the open end of the hose to an appropriate drain
point.
> Start test program P.06 (diverter valve mid-position)
(¬ section 10.7).
> Make sure that the service valves on the boiler and the
cap of the automatic air vent on the internal pump is
open.
> Open the drain cock.
> Open the purging valves of the radiators.
Start from the highest radiator and then work from top
to bottom.
> Once the water has drained off, close the purging valves
of the radiators and the drain cock.
12.4 Self tests in the function menu
12.3.1 Carrying out electronics self-tests
Menu ¬ Installer level ¬ Test programs ¬ Electronics
self-test
In case service is required you should use the electronic
self-test to check the PCB in advance.
12.4
Carrying out maintenance work
12.4.1 Removing the compact thermal module
12.3
Using the function menu
You can use the function menu to service the ecoTEC plus
as it allows you to actuate and test individual components
of the heating installation.
a
Menu ¬ Installer level ¬ Test programs ¬ Function menu
or the plus button
> Use the minus button
to go to the components of the heating
installation.
> Confirm your selection using the right selection button
("Select").
Cancelling the function test
> Press the left selection button
stop the function test.
("Cancel") to
You can test the operation of the heating installation components listed below using the self tests in the function
menu.
Danger!
Risk of being burned or scalded by hot
components!
There is danger of being burned or scalded
at the compact thermal module and at all
water-carrying components.
> Only carry out work on these components if they have cooled down.
The compact thermal module consists of five main components:
1.
Speed-regulated fan
2.
Gas valve including support plate
3.
Venturi including mass flow sensor and gas supply
pipe
4.
Burner door
5.
Premix burner
> Switch off the boiler using the on/off switch.
> Close the gas isolator cock on the boiler.
Installation and maintenance instructions ecoTEC plus 0020116700_06
61
12 Inspection and maintenance
> Close the service valves on the boiler.
> Remove the front casing from the boiler
(¬ section 4.7).
> Fold the electronics box forwards (¬ section 8.2).
8
1
2
1
7
2
6
3
3
4
5
4
12.4 Removing the compact thermal module
12.3 Remove the air intake pipe
> Unscrew the retaining screw (2, ¬ fig. 12.3) and detach
the air intake pipe (1, ¬ fig. 12.3) from the intake stub.
b
Caution.
Risk of damage to the gas pipe.
The corrugated gas pipe may become damaged.
> Do not suspend the compact thermal
module on the flexible corrugated gas
pipe.
> Do not suspend any loads from the corrugated gas pipe.
> Either unscrew the cap nut (3,
¬ fig. 12.3) from the gas valve or the cap nut (4,
¬ fig. 12.3) between the corrugated gas pipe and the
fixed gas pipe.
62
i
The plugs at the fan motor and the venturi have
latching lugs with which they engage in the slot.
You have to push in the latching lug to pull off
the plug.
> Remove the plug of the ignition line (7, ¬ fig. 12.4) and
the ground connection (6, ¬ fig. 12.4) from the ignition
electrode.
> Remove the plug (4, ¬ fig. 12.4) from the fan motor.
> Remove the three plugs from the gas valve (5,
¬ fig. 12.4).
> Remove the plug from the venturi (3, ¬ fig. 12.4).
> Release the cable harness from the clip on the gas valve
retainer.
> Unscrew the four nuts (8, ¬ fig. 12.4).
> Remove the entire compact thermal module (2,
¬ fig. 12.4) from the heat exchanger (1, ¬ fig. 12.4).
> Once removed, check the burner and the heat exchanger
for damage and dirt.
> If necessary, clean the components according to the following sections.
> Check the burner flange insulation on the module. If
signs of damage, other than small cracks, are apparent
you must replaced it (article number 193 595).
Installation and maintenance instructions ecoTEC plus 0020116700_06
Inspection and maintenance 12
12.4.2 Cleaning the heat exchanger
b
12.4.3 Checking the burner
Caution.
Risk of damage from water spray.
If you fail to protect the electronics box
adequately, water can penetrate the box
during cleaning and may damage the electronics.
> Protect the folded down electronics box
against sprayed water.
1
> Remove the compact thermal module (¬ section 12.4.1).
2
3
12.6 Checking the burner
As the burner (1) is maintenance-free, it does not require
cleaning.
> Check the surface of the burner for damage.
> If necessary, replace the burner.
1
4
12.4.4 Cleaning the condensate siphon
12.5 Cleaning the heat exchanger
b
Caution.
Risk of damage to heat exchanger.
> You should neither loosen nor tighten
the four screws (1).
a
> Clean the heating coil (3) of the heat exchanger (4)
using water or if required commercially-available white
vinegar.
> Allow the vinegar to act on the heat exchanger for 20
minutes.
> Rinse away any loose dirt with a sharp jet of water or
use a plastic brush.
> Do not point the water jet directly at the insulating surface (2) on the back of the heat exchanger.
The water flows out of the heat exchanger through the condensate siphon.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Danger!
Risk of death caused by improper maintenance.
If you operate the boiler with an empty
condensate siphon, flue gas can escape into
the room air.
> Top up the condensate siphon after each
cleaning session.
63
12 Inspection and maintenance
> Drain the hot water from the boiler.
> Undo the nut (1, ¬ fig. 12.8) of the cold water supply line
from the casing of the boiler.
1
1
12.7 Cleaning the condensate siphon
> Remove the lower part (1) of the condensate siphon by
turning the bayonet fitting anti-clockwise.
> Clean the bottom of the siphon by flushing it out with
water.
> Fill the lower section of the siphon with water up to
about 10 mm below the upper edge.
> Re-fit the lower part of the condensate siphon.
> Flush through all discharge pipe work (ensure route and
termination are correct and it is unlikely to freeze up in
severe weather).
12.4.5 Clean the filter in the cold water inlet
(VUW boilers only)
There is a filter in the cold water inlet of the boiler which
must be cleaned during maintenance work.
1
2
12.9 Removing the pipe with the cold water filter
>
>
>
>
>
Fold the electronics box forwards (¬ section 8.2).
Detach the clamp (1, ¬ fig. 12.9) from the flow sensor.
Pull off the cold water pipe from the flow sensor.
Remove the pipe (2, ¬ fig. 12.9) from the boiler.
Rinse the filter under a jet of water holding against the
direction of flow.
> Refit the pipe with the cleaned filter in the reverse order.
> Always use new seals.
12.4.6 Installing the compact thermal module
a
Danger!
Risk of death and risk of damage caused
by hot flue gas!
If you do not renew the seal and the selflocking nuts on the burner door, hot flue
gases may escape and cause personal
injury and material damage.
> Replace the seal each time you open the
burner door.
> Replace the self-securing nuts each time
you open the burner door.
> If the burner flange insulation on the
module shows signs of damage other
than small cracks it must be replaced
(article number 193 595).
12.8 Removing the filter from the cold water inlet
> Close the cold water stop valve.
64
Installation and maintenance instructions ecoTEC plus 0020116700_06
Inspection and maintenance 12
1
9
2
8
3
7
4
5
> Open the gas isolator cock on the boiler and ensure
there are no leaks.
> Check that the sealing ring in the air intake pipe is positioned correctly in the seal seat.
> Insert the air intake pipe (1, ¬ fig. 12.3) back into the
intake stub.
> Attach the air intake pipe using the retaining screw (2,
¬ fig. 12.3).
12.4.7 Checking the charge pressure of the
expansion vessel
6
12.10 Installing the compact thermal module
> Attach the compact thermal module (2, ¬ fig. 12.10) to
the heat exchanger (1, ¬ fig. 12.10).
> Tighten the four nuts (9, ¬ fig. 12.10) crosswise until the
burner door fits closely and uniformly onto the mating
surfaces (If a torque spanner is available, set at 6 Nm).
> Attach the plug of the ignition line (7, ¬ fig. 12.10) and
the ground connection (8, ¬ fig. 12.10) to the ignition
electrode.
> Attach the plug (4, ¬ fig. 12.10) to the fan motor.
> Attach the three plugs to the gas valve (5, ¬ fig. 12.10).
> Attach the cable to the venturi (3, ¬ fig. 12.10).
1
12.12 Checking the charge pressure of the expansion vessel
The service valves of the boiler must be closed.
> Measure the charge pressure of the expansion vessel at
the testing nozzle (1) of the vessel with the boiler depressurised.
> Top up the expansion vessel at a pressure of less than
0.75 bar in accordance with the static height of the heating installation, ideally with nitrogen, otherwise with air.
Ensure drain valve on boiler is open during topping up.
> If water escapes from the measuring stub pipes (1) of the
expansion vessel, you must replace the expansion vessel.
12.5
Checking the gas flow pressure
> Check the gas flow pressure (¬ section 10.11.4).
12.5.1 Checking CO2 content
12.11 Tightening the cap nuts on the gas valve
> Check the CO2 content (¬ section 12.1.3).
> Connect the gas supply (6, ¬ fig. 12.10) to the gas valve
with a new seal.
When the cap nuts are being screwed to the gas valve,
counterhold the opposite side of the gas valve or tighten
both of the gas valve cap nuts simultaneously.
Installation and maintenance instructions ecoTEC plus 0020116700_06
65
13 Troubleshooting
13
13.1
Troubleshooting
Contact Vaillant Service Solutions
(0870 6060 777)
> If you contact Vaillant Service Solutions (0870 6060
777) or your Vaillant service partner, if possible, please
mention
– the fault code displayed (F.xx),
– the boiler status that is displayed (S.xx) in the "Live
Monitor" (¬ section 13.2.1).
13.2
Performing diagnostics
You can use the function menu to control and test individual components of the boiler in the fault diagnosis.
Menu ¬ Installer level ¬ Test programs ¬ Function menu
> Use the function menu for fault diagnosis
(¬ section 12.3).
13.2.1 Call up Live Monitor (status codes)
Menu ¬ Live monitor
You can call up the boiler status codes in the display which
provide information on the current operating status of the
boiler.
S.04
Heating mode
Burner on
Back
13.1 Status code display view
13.2.2 Status codes – Overview
Display Meaning
Heating mode
S.00
Heating, no heat demand
S.01
Heating mode fan start-up
S.02
Heating mode pump flow
S.03
Heating mode, ignition
S.04
Heating mode, burner on
S.05
Heating mode, pump/fan overrun
S.06
Heating mode, fan overrun
S.07
Heating mode, pump overrun
S.08
Heating mode, burner anti-cycling time
DHW mode (VUW boiler)
S.10
Hot water demand via impeller sensor
S.11
DHW mode, fan start-up
S.13
DHW mode, ignition
S.14
DHW mode, burner on
S.15
DHW mode, pump/fan overrun
S.16
DHW mode, fan overrun
S.17
DHW mode, pump overrun
DHW mode, (VU boiler with cylinder or VUW comfort mode warm
start)
S.20
DHW demand
S.21
DHW mode, fan start-up
S.22
DHW mode, pump running
S.23
DHW mode, ignition
S.24
DHW mode, burner on
S.25
DHW mode, pump/fan overrun
S.26
DHW mode, fan overrun
S.27
DHW mode, pump overrun
S.28
Hot water burner anti-cycling time
Special cases
S.30
Room thermostat (RT) is blocking heating mode
S.31
Summer mode active or no heat requirement from eBUS
controller
S.32
S.34
S.39
Waiting period because of fan speed deviation
Frost protection mode active
"Burner off contact" has triggered (e.g. contact thermostat or condensate pump)
S.40
Comfort safety mode is active: Boiler running with limited heating comfort (¬ section 13.2.3)
S.41
S.42
Water pressure > 2.8 bar
Flue non-return flap return signal blocks burner operation (only in connection with VR40 accessory) or condensate pump faulty, heat requirement is blocked
S.46
S.53
Comfort safety mode, flame loss at minimum load
Boiler is in waiting period of modulation block/operation
block function due to water shortage (supply-return
spread too large)
S.54
Boiler is in waiting period of operation blocking function
as a result of water shortage (temperature gradient)
S.57
S.58
S.61
Waiting period, comfort safety mode
Modulation limitation due to noise/wind
Gas family check unsuccessful: The coding resistor on
the PCB does not match the entered gas family (see also
F.92).
13.1 Status codes
66
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Troubleshooting 13
Display Meaning
S.62
Gas family check unsuccessful: CO/CO2 values at limit.
Check combustion.
S.63
Gas family check unsuccessful: Combustion quality outside permissible range (see also F.93).
S.76
S.96
System pressure too low; top up water
Return temperature sensor test running, heating
demands are blocked
S.97
Water pressure sensor test running, heating demands
are blocked
S.98
Flow/return temperature sensor test running, heating
demands are blocked
13.1 Status codes (continuation)
Fault codes have priority over all other displays. If a fault
occurs, the display no longer shows the current heating
flow temperature of the heating installation.
If multiple faults occur at the same time, the display shows
the corresponding fault codes for two seconds each in
sequence.
> Remedy the fault.
> To restart the boiler, press the reset button (¬ Operating
instructions).
> If you are unable to remedy the fault and the fault reoccurs despite having carried out several resets, contact
Vaillant customer service Vaillant Service Solutions
(0870 6060 777).
13.2.3 Service messages
13.2.6 Querying the fault memory
If the
"open-end spanner" maintenance symbol appears
on the display, a service message is present. The maintenance symbol appears if you have set a maintenance interval, for example, (¬ section 11.1.6) and it has elapsed. The
boiler is not in fault mode but continues to operate.
To obtain more information about the service message:
> Call up the "Live Monitor" (¬ section 13.2.1).
If status code S.40 is displayed as well as the maintenance
symbol, the boiler is in comfort protection mode. This
means that the boiler continues to operate with restricted
comfort after it has detected a fault (e.g. because of a
severe storm).
> In this case, read out the fault memory in order to determine whether a boiler component is defective
(¬ section 13.2.5).
If no fault message is present, the boiler will automatically
switch back to normal operation after a certain time. Comfort safety mode may then have been triggered by a severe
storm, for example.
Menu ¬ Installer level ¬ Fault list
The boiler has a fault memory.
Here you can query the last ten faults that occurred in
chronological order.
The display shows:
– the number of faults that have occurred
– the fault currently selected with fault number F.xx.
– a plain text display explaining the fault
> You can display the last 10 faults that occurred using the
or the plus button
.
minus button
13.2.7 Reset fault memory
You can delete the entire fault list.
(“Delete”).
> Press the right selection button
> Confirm the deletion of the fault memory by pressing the
(“OK”).
right selection button again
13.2.4 Calling up diagnosis levels
Menu ¬ Installer level ¬ Diagnosis menu
You can use the diagnosis menu to inspect parameters and
modify certain parameters. An overview of the diagnosis
codes can be found in ¬ table 11.1.
13.2.5 Reading off the fault codes
If a fault develops in the boiler, the display shows a fault
code F.xx.
A plain text display explains the displayed fault code.
Example F.10: "Flow temperature sensor short circuit".
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67
13 Troubleshooting
13.2.8 Overview of fault codes
Code
Meaning
Cause
F.00
Flow temperature sensor interruption
NTC plug not plugged in or has come loose, multiple plug on the PCB
not plugged in correctly, interruption in cable harness, NTC defective
F.01
Return temperature sensor interruption
NTC plug not plugged in or has come loose, multiple plug on the PCB
not plugged in correctly, interruption in cable harness, NTC defective
F.02
Interruption cylinder charging sensor actoSTOR
(NTC) only in combination with F.91
NTC defective, NTC cable defective, defective plug connection on NTC,
defective plug connection on actoSTOR electronics
F.03
Interruption cylinder sensor actoSTOR (NTC)
only in combination with F.91
NTC defective, NTC cable defective, defective plug connection on NTC,
defective plug connection on actoSTOR electronics
F.10
Flow NTC short circuit
NTC defective, short circuit in cable harness, cable/casing
F.11
Return NTC short circuit
NTC defective, short circuit in cable harness, cable/casing
F.12
Short circuit at cylinder charging sensor (NTC)
only in combination with F.91
NTC defective, short circuit in cable harness, cable/casing
F.13
VU-/VUW boiler: Short circuit warm start sensor/
cylinder sensor
VUW boiler with actoSTOR: Short circuit cylinder
sensor (NTC) only in combination with F.91
NTC defective, short circuit in cable harness, cable/casing
F.20
Safety switch-off: temperature limiter
Incorrect earth connection between cable harness and boiler, flow or
return NTC defective (loose connection), black discharge via ignition
cable, ignition plug or ignition electrode
F.22
Safety switch-off: low water pressure
No or to low water pressure in the boiler, water pressure sensor defective, cable to pump or water pressure sensor loose/not connected/defective
F.23
Safety switch-off: Temperature difference too great
Pump blocked, insufficient pump output, air in boiler, flow and return
NTC interchanged
F.24
Safety switch-off: Temperature rise too fast
Pump blocked, poor pump performance, air in boiler, system pressure
too low, non-return valve blocks/incorrectly installed
F.25
Safety switch-off: Flue gas temperature too high
Break in plug connection for optional flue gas safety thermostat (STB),
break in cable harness
F.26
Fault: Gas valve without function
Gas valve stepper motor not connected, multiple plug on the PCB not
plugged in correctly, interruption in cable harness, gas valve stepper
motor defective, electronics defective
F.27
Safety switch-off: Flame simulation
Moisture on the electronics, electronics (flame monitor) defective, gas
solenoid valve leaking
F.28
Failure during start-up: ignition unsuccessful
Gas meter defective or gas pressure regulator has triggered, air in gas,
gas flow pressure too low, thermal isolator device (TAE) has triggered,
condensate duct blocked, incorrect gas restrictor, incorrect ET gas valve,
fault on the gas valve, multiple plug on PCB incorrectly plugged in, break
in cable harness, ignition system (ignition transformer, ignition cable,
ignition plug, ignition electrode) defective, ionisation current interrupted
(cable, electrode), incorrect earthing of boiler, electronics defective
F.29
Failure during operation: Re-ignition unsuccessful
Gas supply temporarily stopped, flue gas recirculation, condensate duct
blocked, faulty earthing of boiler, ignition transformer has spark failure
F.32
Fan fault
Plug at fan not correctly plugged in, multiple plug on PCB not correctly
plugged in, break in cable harness, fan blocked, Hall sensor defective,
electronics defective
F.35
Air/flue gas duct fault
Air/flue gas duct blocked
F.42
Coding resistor fault (possible in combination with
F.70)
Short circuit/interruption in coding resistor output range (in cable harness at heat exchanger) or gas group resistor (on PCB)
13.2 Fault codes
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Troubleshooting 13
Code
Meaning
Cause
F.49
eBUS fault
Short circuit on eBUS, eBUS overload or two power supplies with different
polarities on the eBUS
F.52
Mass flow sensor connection fault
Mass flow sensor not connected/disconnected, plug not connected or
incorrectly connected
F.53
Mass flow sensor fault
Mass flow sensor faulty, filter below venturi filter cap wet or blocked, gas
flow pressure too low
F.54
F.56
F.57
F.61
Gas pressure fault (in combination with F.28/F.29)
Fault: Mass flow sensor regulation
Fault during comfort safety mode
Fault: Gas valve regulation
No or too little gas supply pressure, gas valve closed
Gas valve defective, cable harness to gas valve defective
Ignition electrode highly corroded
- Short circuit/short to earth in cable harness for the gas valve
- Gas valve defective (coils shorted to earth)
- Electronics defective
F.62
Fault: Gas valve switch-off delay
- Delayed shutdown of gas valve
- Delayed extinguishing of flame signal
- Gas valve leaking
- Electronics defective
F.63
F.64
F.65
F.67
F.68
EEPROM error
Electronics/NTC fault
Electronic temperature fault
Electronics/flame fault
Unstable flame signal fault
Electronics defective
Supply or return NTC short circuited, electronics defective
Electronics overheating due to external influences, electronics defective
Implausible flame signal, electronics defective
Air in gas, gas flow pressure too low, wrong air ratio, condensate route
blocked, wrong gas restrictor, ionisation flow interruption (cables, electrodes), flue gas recirculation, condensate route
F.70
Invalid device specific number (DSN)
Spare part case: Display and PCB replaced at same time and DSN not set,
wrong or missing output range coding resistor
F.71
Flow NTC fault
Flow temperature sensor signalling constant value:
- Flow temperature sensor incorrectly positioned at supply pipe.
- Flow temperature sensor defective.
F.72
Flow/return NTC fault
Flow/return NTC temperature difference too great -> flow and/or return
temperature sensor defective
F.73
Water pressure sensor signal in the wrong range
(too low)
Interruption/short circuit of water pressure sensor, interruption/short circuit to GND in supply line to water pressure sensor or water pressure sensor defective
F.74
Water pressure sensor signal outside correct
range
(too high)
Cable to water pressure sensor has short-circuited at 5 V/24 V
or internal fault in water pressure sensor
F.75
Fault, no pressure change detection when starting pump
Water pressure sensor and/or pump defective, air in heating installation,
too low water pressure in boiler; check adjustable bypass, connect external
expansion vessel to return
F.76
Overheating protection on primary heat
exchanger has responded
Cable or cable connections for safety fuse in primary heat exchanger or
primary heat exchanger defective
F.77
F.78
Flue non-return flap/condensate pump fault
Interruption to DHW outlet sensor at external
controller
No response from flue non-return flap or condensate pump defective
UK link box is connected, but hot water NTC not bridged
F.83
Flow and/or return temperature sensor temperature change fault
When the burner starts, the temperature change registered at flow and/or
return temperature sensor is non-existent or too small.
- Not enough water in the boiler
- Flow and/return temperature sensor not in correct position at pipe.
F.84
Fault: Flow/return temperature sensor temperature difference implausible
Flow and return temperature sensors returning implausible values.
- Flow and return temperature sensors have been inverted.
- Flow and return temperature sensors have not been correctly fitted.
F.85
Fault: Flow and return temperature sensors incor- Flow and/or return temperature sensors
rectly fitted
have been fitted to the same pipe/wrong pipe.
F.92
Coding resistor fault
The coding resistor on the PCB does not match the entered gas family
Check the resistor, repeat the gas family check and enter the correct gas
family.
13.2 Fault codes (continued)
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69
13 Troubleshooting
Code
Meaning
Cause
F.93
Gas group fault
Combustion quality outside the permitted range: Wrong gas restrictor,
recirculation, wrong gas group, internal pressure measuring point in venturi blocked (do not use lubricant on O-ring in venturi.). Gas family check
prematurely terminated.
Communication
fault
No communication with the PCB
Communication fault between display and PCB in the electronics box
13.2 Fault codes (continued)
13.3
Using the function menu
In order to remedy boiler problems, you can use the function menu, which allows you to actuate and test individual
components of the heating installation (¬ section 12.3).
13.4
Running test programs
By activating various test programs, you can trigger special
functions on the boiler
(¬ table. 10.1). The display shows which test program you
have chosen.
> Read how to start the test programs in ¬ section 10.4.
13.5
Resetting parameters to factory settings
As well as the option to manually reset individual parameters to the factory settings specified in ¬ table 11.1, you can
also reset all parameters at once.
> Set the value of the diagnosis code parameter D.096 to
"1" (¬ section 11.1).
You have now reset all parameters to factory settings.
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Replacing components 14
14
Replacing components
The work described in this section must only be carried out
by an approved competent person.
The original components of the product were also certified
as part of the CE declaration of conformity. If you do not
use certified Vaillant original spare parts for maintenance
or repair work, this voids the CE conformity of the product.
We therefore strongly recommend that you fit Vaillant genuine spare parts. You can find information about the available Vaillant original spare parts on the back page of these
instructions, below the contact address.
> If you require spare parts for maintenance or repair
work, use only Vaillant genuine spare parts.
14.1
Preparing for and completing replacement
work
14.1.1
Preparing for replacement work
14.1.2 Completing replacement work
> Perform a gas family check after working on the gas
route (¬ section 12.1.5).
b
Caution!
Malfunction or shortened life expectancy!
The leak detection spray can damage the
heating device.
> Do not spray the leak detection spray on
the cover cap on the filter of the Venturis
> Check the boiler for gas leaks.
> Reattach the front casing (¬ section 4.7).
> Perform a function check (¬ section 10.12).
14.2
Replacing the burner
> Remove the compact thermal module
(¬ section 12.4.1).
e
i
Danger!
Risk of death from electric shock!
Mains connection terminals L and N remain
live even if the continuous voltage on/off
switch is turned off.
> Before carrying out maintenance work
on the boiler, switch the boiler off using
the on/off button.
> Disconnect the boiler from the power
mains by disconnecting the mains plug
or by de-energising the boiler via a partition with a contact opening of at least
3 mm (e. g. fuses or power switches).
When carrying out any repair to the boiler, make
sure that you observe the following instructions
for your own safety and to avoid material damage to the boiler.
> Switch off the boiler.
> Disconnect the boiler from the power mains
(¬ section 11.3).
> Remove the front casing (¬ section 4.7).
> Close the gas isolator cock.
> Close the service valves in the heating flow and in the
heating return.
> Close the service valve in the cold water supply pipe.
> Drain the boiler if you want to replace components that
carry water (¬ section 11.3.2).
> Make sure that water does not drip on live components
(e.g. the electronics box).
> Use only new seals and O-rings.
1
14.1 Replacing the burner
> Undo the four screws (1) on the burner.
> Remove the burner.
> Fit the new burner with a new seal. Make sure that the
nose on the burner window grips the seal inside the
recess in the burner.
> Reinstall the compact thermal module.
(¬ section 12.4.6).
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14 Replacing components
14.3
Replacing the fan
1
1
2
7
3
3
2
4
5
6
14.3 Removing the gas valve and venturi from fan
14.2 Removing the fan
> Remove the air intake pipe (¬ section 12.4.1).
> Remove the three plugs from the gas valve
(5, ¬ fig. 14.2).
i
The plugs on the fan motor and the venturi have
latching lugs with which they engage in the slot.
You have to push in the latching lug to pull off
the plug.
> Remove the entire fan/venturi/gas valve unit from the
boiler.
> Unscrew the fixing screw (2, ¬ fig. 14.3) of the gas valve
out of the bracket.
> Remove the gas valve from the bracket.
> Remove the venturi (3, ¬ fig. 14.3) with the gas connecting pipe (1, ¬ fig. 14.3) out of the fan by turning the bayonet fitting of the venturi anti-clockwise as far as it will go
and pulling it out of the fan (straight).
> Remove the plug from the sensor of the venturi
(3, ¬ fig. 14.2).
> Remove the plug(s) (depending on the boiler version)
(4, ¬ fig. 14.2) from the fan motor.
> Unscrew the two cap nuts at the top (7, ¬ fig. 14.2) and
bottom (6, ¬ fig. 14.2) from the gas valve. Counterhold at
the opposite side of gas valve when unscrewing, or
unscrew both cap nuts at the same time.
> Unscrew the three screws (2, ¬ fig. 14.2) between the
mixture pipe (1, ¬ fig. 14.2) and the fan flange.
b
Caution.
Risk of damage to the gas pipe.
The corrugated gas pipe can be damaged
by incorrect handling.
> Do not suspend the gas valve on the flexible corrugated gas pipe.
> Do not suspend any loads on the corrugated gas pipe.
2
1
14.4 Removing the bracket of the gas valve
> Remove the bracket (1, ¬ fig. 14.4) of the gas valve from
the fan by unscrewing the three screws (2, ¬ fig. 14.4).
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Installation and maintenance instructions ecoTEC plus 0020116700_06
Replacing components 14
> Replace the defective fan.
14.4
2
1
5
Replacing the gas valve
b
3
Caution.
Risk of material damage caused by making not permissible setting.
Modifications to the gas pressure regulator
on the gas valve can destroy the gas valve
and cause operating faults on the boiler.
> Never modify the factory setting for the
gas pressure regulator of the gas valve.
4
1
14.5 Installing the gas valve
> Refit the components in the reverse order. It is imperative that you use new seals (4 and 5, ¬ fig. 14.5).
> Pay attention to the order in which the three screws
between the fan and the mixture pipe are screwed in, as
per the numbering 1, 2 and 3 (¬ fig. 14.5).
14.7 Gas pressure regulator
Gas valves with gas pressure regulators (1, ¬ fig. 14.7) are
not installed in all boilers There are also versions without
gas pressure regulators.
1
5
2
14.6 Tightening the cap nuts on the gas valve
> Screw the flexible gas pipe to the gas valve. Use new
seals.
When the cap nuts are being screwed to the gas valve,
counterhold the opposite side of the gas valve or screw
both cap nuts to the gas valve simultaneously.
> Perform a gas family check after fitting the new fan
(¬ section 12.1.5).
4
3
14.8 Replacing the gas valve
> Remove the air intake pipe (¬ section 12.4.1).
> Remove the three plugs from the gas valve
(2, ¬ fig. 14.8).
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73
14 Replacing components
i
The plug on the venturi has latching lugs with
which it engages in the slot. You have to release
the latching lug by pushing it in to pull off the
plug.
> Remove the plug from the sensor of the venturi
(1, ¬ fig. 14.8).
> Unscrew the two cap nuts at the top (5, ¬ fig. 14.8) and
bottom (4, ¬ fig. 14.8) of the gas valve. Counterhold at
opposite side of gas valve when unscrewing, or unscrew
both cap nuts at the same time.
> Unscrew the fixing screw of the gas valve (3, ¬ fig. 14.8)
out of the bracket.
i
6
5
1
4
Since the fixing screw is difficult to access
beneath the retaining plate, alternatively, you
can remove the entire fan assembly
(¬ section 14.3).
> Remove the gas valve from the bracket.
> Refit the new gas valve in the reverse order. Use new
seals.
> When the cap nuts are being screwed to the gas valve,
counterhold at the opposite side of the gas valve or
tighten both cap nuts simultaneously (¬ fig. 14.6).
> After installing the new gas valve, perform a gas family
check (¬ section 12.1.5) and a gas ratio setting
(¬ section 10.11).
14.5
> Remove the air intake pipe (¬ section 12.4.1).
> Remove the plug from the sensor of the venturi
(1, ¬ fig. 14.9).
> Unscrew the cap nut (3 ¬ fig. 14.9) of the gas connecting
pipe (2 ¬ fig. 14.9) from the gas valve.
> Remove the venturi including the gas supply pipe from
the fan by turning the bayonet fitting on the venturi anticlockwise as far as it goes and removing it from the fan.
3
2
14.10 Removing the gas connecting pipe
> Remove the gas connecting pipe (1, ¬ fig. 14.10) from the
venturi (2 ¬ fig. 14.10) by detaching the clamp
(3, ¬ fig. 14.10) and pulling out the gas connecting pipe
vertically. Dispose of the seal (6, ¬ fig. 14.10).
> Pull off the gas restrictor (5, ¬ fig. 14.10) in a straight
direction, and dispose of it.
> Check whether the venturi is free of residue at the gas
inlet side.
Replacing the venturi including the mass
flow sensor
1
2
Danger!
Risk of poisoning due to increased CO
levels!
Using the wrong gas restrictor size can
cause higher CO levels.
> When replacing the venturi, ensure that
you use the correct gas restrictor (colour
coding and position of pins on the underside of the gas restrictor).
3
> Insert the gas restrictor for the gas group in question
into the new venturi.
Ensure that the colour of the gas restrictor corresponds
with the colour of the coding resistor on the PCB in the
electronics box.
When inserting the gas restrictor, ensure that the gas
restrictor is correctly aligned using the specified position
marks on the top of the venturi and also the positioning
pins (4) on the bottom of the gas restrictor.
a
14.9 Replacing the venturi including the mass flow sensor
74
Installation and maintenance instructions ecoTEC plus 0020116700_06
Replacing components 14
b
Caution.
Risk of damage to boiler and possible
malfunctions.
The use of lubricant can block functionrelated channels in the venturi.
> Never use lubricant when installing the
gas restrictor.
> Refit the components in the reverse order. Use new
seals.
> After installing the new venturi, perform a gas family
check (¬ section 12.1.5) and a gas ratio setting
(¬ section 10.11).
14.6
14.7
Replacing the heat exchanger
b
Caution.
Risk of damage to the heat exchanger.
> You can neither loosen nor tighten the
four screws (¬ fig. 14.13, pos. 1).
> Drain the boiler (¬ section 12.2.2).
> Remove the compact thermal module (¬ section 12.4.1).
> Detach the condensate drain hose from the heat
exchanger.
1
Replacing the expansion vessel
> Drain the boiler (¬ section 12.2.2).
2
3
1
2
14.12 Replacing the heat exchanger
3
4
14.11 Replacing the expansion vessel
> Detach the clamps (2, ¬ fig. 14.12) and (3, ¬ fig. 14.12)
from the flow connection and the return connection.
> Detach the flow connection from the heat exchanger.
> Detach the return connection from the heat exchanger.
> Remove two screws (1, ¬ fig. 14.12) from each of the two
brackets of the heat exchanger.
> Slacken the screw connection (4) at the water connection on the underside of the expansion vessel.
> Remove both screws (1) on the support plate (2).
> Remove the support plate (2).
> Pull out the expansion vessel (3) from the front.
> Insert the new expansion vessel into the boiler.
> Screw the new expansion vessel to the water connection.
Use a new seal for this.
> Attach the support plate using both screws (1).
> If necessary, adjust the pressure to the static height of
the heating installation (¬ section 12.4.7).
> Fill and purge the boiler and the system, if necessary,
after installing the new expansion vessel (¬ section 10.7).
> On completion of the work, check for water leaks.
Installation and maintenance instructions ecoTEC plus 0020116700_06
75
14 Replacing components
> Fill and purge the boiler and, if necessary, the heating
installation (¬ section 10.7).
1
2
3
14.8
Replacing the PCB and/or the display
e
Danger!
Risk of death from electric shock!
Mains connection terminals L and N remain
live even if the continuous voltage on/off
switch is turned off!
> Before carrying out repair work on the
boiler, switch the boiler off using the on/
off button.
> Disconnect the boiler from the power
mains by disconnecting the mains plug
or by de-energising the boiler via a partition with a contact opening of at least
3 mm (e. g. fuses or power switches).
b
Caution.
Risk of material damage caused by incorrect repairs.
Using an incorrect spare part display can
cause damage to the electronics.
> Before replacing, check that the correct
spare part display is available.
> ONLY fit the correct spare part display.
i
Comply with the assembly and installation
instructions provided with the spare parts.
4
14.13 Heat exchanger brackets
> Disconnect the plug connection (2, ¬ fig. 14.13) of the
thermal fuse in the heat exchanger.
> Remove the bottom three screws (3, ¬ fig. 14.13) from
the rear part of the heat exchanger bracket.
> Swivel the bracket around the top screw (1, ¬ fig. 14.13)
to one side.
> Pull the heat exchanger downwards and to the right, and
remove it from the boiler.
b
Caution.
Risk of damage to the boiler.
Mineral oil-based lubricants may damage
the seals. The seals should therefore not be
lubricated.
> Only use water or commercially available
soft soap, if necessary, to assist with
installation.
i
With the new heat exchanger, ensure that you
use the cable with the coding resistor and the
correct plug.
> Install the new heat exchanger in the reverse order.
> Replace the seals.
> Insert the flow and return connections into the heat
exchanger as far as they will go.
i
Make sure that the brackets are seated correctly
on the flow and return connections.
> Re-install the expansion vessel (¬ section 14.6).
> Reinstall the compact thermal module.
(¬ section 12.4.6).
76
Installation and maintenance instructions ecoTEC plus 0020116700_06
Replacing components 14
Language
02 English
14.8.1 Replacing either the display or the PCB
> Replace the PCB or display according to the assembly
and installation instructions supplied.
Cancel
Ok
14.15 Setting the language
If you are replacing both components at the same time
(spare part case), the boiler switches directly to the menu
for selecting the language after switching on. The default
language setting is English. You can select the language
that you require using the minus and plus buttons and confirm with OK.
1
14.14 Coding resistor
i
You are then automatically taken to the appliance type setting D.093.
> Select the correct value for the relevant appliance type
in accordance with ¬ table 14.1.
After confirmation, the display restarts itself automatically
and then starts the installation assistant.
ecoTEC plus
If you replace the PCB, you must remove the
front left coding resistor (1) (plug X24) on the
old PCB and insert it into the new PCB.
612 (VU GB 126/5-5)
615 (VU GB 156/5-5)
618 (VU GB 186/5-5)
624 (VU GB 246/5-5)
630 (VU GB 306/5-5)
637 (VU GB 376/5-5)
824 (VUW GB 246/5-5)
831 (VUW GB 316/5-5)
837 (VUW GB 376/5-5)
If you are replacing only one of the two components (PCB
or display), the parameter matching functions automatically. By switching on the boiler, the new component takes
over the previously set parameters from the unreplaced
component.
Device specific
number
1
3
4
9
14
20
6
10
17
14.1 Device specific numbers for the appliance types
14.8.2 Replacing the PCB and the display at the
same time
Setting the language and appliance type
i
The electronics are now set to the appliance type and the
parameters of all adjustable diagnosis codes are set to factory settings.
> Make the system-specific settings (¬ section 11).
If you are replacing both components, you must
detach the coding resistor (¬ fig. 14.14, pos. 1)
(plug X24) at the front left from the old PCB and
plug it into the new PCB.
Installation and maintenance instructions ecoTEC plus 0020116700_06
77
15 Decommissioning
15
Decommissioning
15.1
15.3
Temporarily shutting down the boiler
b
Caution.
Risk of frost damage due to incorrect
shutdown.
If you switch off the boiler using the on/off
switch or disconnect it from the power
mains, this can cause frost damage to the
heating installation.
> Only shutdown the boiler fully if the
heating installation is otherwise protected from frost.
> Drain the heating installation fully.
Disposing of the boiler
The Vaillant ecoTEC plus boiler consists primarily of materials that can be recycled.
The boiler and its accessories must not be disposed of with
household waste.
> Make sure that the boiler and any existing accessories
are disposed of properly.
16
16.1
Guarantee and customer service
Factory guarantee
Two year guarantee for ecoTEC plus appliances
Vaillant undertakes to rectify any manufacturing defect that
occurs within twenty-four months of the installation date.
For the 2nd year of the guarantee to be valid an annual service must be carried out by a competent person approved
at the time by the Health and Safety Executive one year
after installation.
The cost of this annual service is not included in the guarantee.
2
50
Registering with us
1
Registration is simple. Just complete the Guarantee Registration Card and return to Vaillant within 30 days of installation. Your details will then be automatically registered
within the Vaillant scheme.
Note: No receipt will be issued.
15.1 Switching off the boiler
Immediate help
> Close the gas isolator cock.
> Close the cold water stop valve.
> Drain the heating installation fully
(¬ section 12.2.2).
> Press the on/off switch (1).
The display (2) goes off.
If your Vaillant boiler develops a fault your first action
should be to contact your installer, as his professional
assessment is needed under the terms of our Guarantee. If
you are unable to contact your installer, phone Vaillant Service Solutions: 0870 6060 777
16.2
15.2
Taking the boiler permanently out of
service
> Close the gas isolator cock.
> Close the cold water stop valve.
> Drain the heating installation fully
(¬ section 12.2.2).
> Press the on/off switch (1).
The display (2) goes off.
> Isolate the boiler from the power mains.
> Dispose of the boiler correctly (¬ section 15.3).
78
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.
Installation and maintenance instructions ecoTEC plus 0020116700_06
Technical data 17
17
Technical data
ecoTEC plus
Unit
612 (VU
GB
126/5-5)
615 (VU
GB
156/5-5)
618 (VU
GB
186/5-5)
624 (VU 630 (VU
GB
GB
246/5-5) 306/5-5)
637 (VU
GB
376/5-5)
Nominal heat output range P at 50/30 °C
kW
3.3 - 12.9
3.3 - 16.1
4.2 - 19.3
5.7 - 25.7
6.4 - 32.1
7.1 - 39.6
Nominal heat output range P at 80/60 °C
kW
3.0 - 12.2
3.0 - 15.4
3.8 - 18.5
5.2 - 24.4
5.8 - 30.4
6.4 - 37.6
Maximum heat output for hot water generation
kW
12.2
15.4
18.5
24.4
30.4
37.6
Maximum heat input
kW
12.4
15.5
18.6
24.7
30.9
38.1
Minimum heat input G20
kW
3.2
3.2
4.0
5.5
6.2
6.8
Minimum heat input G31
kW
–
–
5.3
6.4
9.0
9.0
Minimum heat output with G31
kW
–
–
5.0
6.0
8.5
8.5
Heating output setting range
kW
3 - 12
3 - 15
4 - 18
5 - 24
6 - 30
6 - 37
Heating
Max. flow temperature
Max. flow temperature setting range
(factory setting: 75 °C)
Min. pressure for full operation
Permissible total over-pressure
Expansion vessel capacity
Circulation water quantity
(with reference to DT = 20 K)
Condensate rate approx. (pH value 3.5 – 4.0)
in heating mode 50 °C supply/30 °C return
Remaining feed head of pump (at nominal circulation water volume)
General
Gas connection, boiler side
Flow/return heating connections, boiler side
Hot and cold water connection, boiler side
Connector expansion relief valve (minimum)
°C
85
°C
30 - 80
MPa/bar
MPa/bar
l
0.08/0.8
0.3/3
10
l/h
516
645
774
1032
1290
1591
l/h
1.2
1.6
1.9
2.5
3.1
3.8
MPa/bar
0.025/0.25
mm
mm
Inches
15
15
0.020/0.20
15
15
15
mm
15
Condensate discharge pipework (minimum)
mm
19
Flue gas spigot
Gas connection pressure (gas inlet working pressure) natural gas, G20
Gas connection pressure (gas inlet working pressure) propane, G31
Gas flow rate at 15 °C and 1013 mbar
(based on hot water generation if applicable) G20
G31
Flue gas mass flow min./max.
mm
60/100 (concentric), optional 80/125 (concentric)
kPa/mbar
0.20/20
kPa/mbar
0.37/37
Flue gas temperature min./max.
Certificated flue gas connections
NOx class
NOx
SEDBUK (2005)
SEDBUK (2009) (G20/G31)
Boiler dimensions (H x W x D)
Mounting weight approx.
Electrical connection
m3/h
kg/h
g/s
1.3
0.96
1.4/5.6
1.6
1.2
1.4/7.0
2.0
1.44
1.8/8.4
°C
mg/kWh
2.6
1.92
2.4/11.1
3.3
2.4
2.7/13.9
4.0
2.96
3.0/17.1
40/70
19.7
89.0/-
mm
kg
22
22
G 3/4
35
C13, C33, C43, C53, C83, C93, B53P
5
22.9
25.9
32.3
30.2
36.0
A
89.1/89.3/90.3
89.4/89.4/90.4
89.2/720 x 440 720 x 440
720 x 440 x 338
x 372
x 406
35
35
37
39
41
75/110
100/130
V/Hz
230/50
W
65/90
70/95
2 A, slow-blow
75/100
70/100
Electrical power consumption at 30% partial load
W
40
40
45
50
50
50
Standby electrical consumption
Level of protection
Certification number
W
<2
<2
<2
<2
<2
< 3,3
Built-in fuse
Electrical power consumption min./max.
IP X4 D
CE-0085CM0320
17.1 Technical data for ecoTEC plus VU boiler
Installation and maintenance instructions ecoTEC plus 0020116700_06
79
17 Technical data
ecoTEC plus
Unit
824 (VUW GB
246/5-5)
831 (VUW GB
316/5-5)
837 (VUW GB
376/5-5)
Nominal heat output range P at 50/30 °C
kW
4.2 - 20.4
5.7 - 25.7
7.1 - 30.1
Nominal heat output range P at 80/60 °C
kW
3.8 - 19.3
5.2 - 24.4
6.4 - 28.6
Maximum heat output for hot water generation
kW
24.4
30.8
38.7
Maximum heat input for hot water generation
kW
24.7
31.2
39.2
Maximum heat input at the heating side
kW
19.6
24.7
28.9
Minimum heat input G20
kW
4.0
5.5
6.8
Minimum heat input G31
kW
6.4
6.4
9.0
Minimum heat output with G31
Heating output setting range
Heating
Max. flow temperature
Max. flow temperature setting range
(factory setting: 75 °C)
Min. pressure for full operation
Permissible total over-pressure
Expansion vessel capacity
Circulation water quantity (with reference to DT = 20 K)
Condensate rate approx. (pH value 3.5 – 4.0)
in heating mode 50 °C supply/30 °C return
Remaining feed head of pump (at nominal circulation
water volume)
DHW mode (VUW boiler only)
Lowest water volume
Water volume (at DT = 42 K)
Water volume (at DT = 35 K)
Water volume (at DT = 30 K)
Permitted overpressure
Required connection pressure
Hot water output temperature range
General
Gas connection, boiler side
Flow/return heating connections, boiler side
Hot and cold water connection, boiler side
Connector expansion relief valve (minimum)
Condensate discharge pipework (minimum)
Flue gas spigot
Gas connection pressure (gas inlet working pressure)
natural gas, G20
Gas connection pressure (gas inlet working pressure)
propane, G31
Gas flow rate at 15 °C and 1013 mbar
(based on hot water generation if applicable)
G20
G31
Flue gas mass flow min./max.
Flue gas temperature min./max.
Certificated flue gas connections
NOx class
NOx
SEDBUK (2005)
SEDBUK (2009) (G20/G31)
Boiler dimensions (H x W x D)
Mounting weight approx.
Electrical connection
Built-in fuse
Electrical power consumption min./max.
Electrical power consumption at 30% partial load
Standby electrical consumption
Level of protection
Certification number
kW
kW
6.0
4 - 19
6.0
5 - 24
8.5
6 - 28
°C
85
°C
30 - 80
MPa/bar
MPa/bar
l
l/h
817
0.8
0.3/3
10
1032
1204
l/h
2.0
2.5
2.9
MPa/bar
l/min
l/min
l/min
l/min
MPa/bar
MPa/bar
°C
0.025/0.25
8.2
9,8
11.5
0.020/0.20
1.5
10.3
12,4
14.5
1.0/10
0.035/0.35
35 - 65
13.0
15,6
18.2
mm
mm
Inches
mm
mm
mm
15
22
22
G 3/4
15
19
60/100 (concentric), optional 80/125 (concentric)
kPa/mbar
0.20/20
kPa/mbar
0.37/37
m3/h
kg/h
g/s
°C
2.6
1.924
1.8/11.1
mg/kWh
mm
kg
V/Hz
W
W
W
15
3.3
4.1
2.42
3.05
2.4/14.0
3.0/17.6
40/70
C13, C33, C43, C53, C83, C93, B53P
5
27.7
32.3
27.4
A
89.1/89.3/90.3
89.3/720 x 440 x 338
720 x 440 x 372
36
38
41
230/50
2 A, slow-blow
80/105
70/105
100/130
45
50
50
<2
<2
< 3,3
IP X4 D
CE-0085CM0320
17.2 Technical data for ecoTEC plus VUW boiler
80
Installation and maintenance instructions ecoTEC plus 0020116700_06
Glossary 18
18
Glossary
required, which have not been configured using the installation assistant, then you can view and modify these using
the DIA.
Air/flue gas duct
An air/flue gas duct is a line system with two separate flow
channels. The flue gas is routed into separate chambers at
the same time as the required combustion air is pumped to
the boiler. The air/flue gas duct can be designed as a concentric or adjacent double flue gas line (the exhaust gas
channel is sealed from the air channel). Floor standing boilers and gas fired wall hung boilers can be operated independent of room air through the air/flue gas duct. As a
result, boilers can be installed in new buildings that do not
offer sufficient combustion air for open-flued heat generators due to their airtight construction.
Burner anti-cycling time
The burner is electronically locked for a specific time after
each time it is switched off ("restart interlock") to avoid frequent switching on and off of the burner (energy losses)
and to extend the working life of the boiler.
The burner anti-cycling time is only activated for the heating mode.
Hot water handling is not affected if burner anti-cycling
time is running.
eBUS
eBUS is an abbreviation for energyBUS. The eBUS is a special bus used in heating technology, which assists the communication between intelligent components in the heating
technology. In a Vaillant system, up to eight different heat
generators can be connected via the eBUS.
The eBUS communications protocol simplifies the controlrelated linking of different system components within a
heating installation. It provides particular flexibility for retrofitting and expanding the system. This simplifies the
installation of boiler cascades or the subsequent addition of
components such as solar hot water generation.
The eBUS provides extended facilities for connecting controllers.
Multi-functional module
The multi-functional module is an accessory that controls
additional functions or components in combination with
Vaillant boilers with eBUS electronics. It also allows you to
select and control 2 in 7, e. g. circulation pump, external
heating pump, external solenoid valve or response from the
flue non-return flap.
Calorific value
Unlike the heating value, the calorific value of a fuel
describes the total useable heat during combustion, based
on the quantity of fuel used, including the condensation
heat in the steam.
The energy contained in steam can also be used if the
steam liquefies on cooling.
Compact thermal module
The compact thermal module is an assembly of Vaillant
condensing units that consists of the following five main
components in the ecoTEC plus: speed-regulated fan, gas
valve including support plate, venturi including gas supply
pipe, burner door and premix burner.
Condensing technology
Technology which maximises the use of the calorific value
of the fuel. The flue gas is cooled until the water vapour
that it contains condenses. The condensation heat that this
releases can also be used.
In particular, the flue gas losses are greatly reduced. The
losses from conduction of heat and radiation are also
reduced by the lower system temperatures. The entire heating installation should therefore be designed for low system
temperatures (flow/return temperature) for the effective
use of the calorific value. The level of efficiency attainable
for boilers is always given based on the heating value of the
gas. Due to the additional condensation heat used, the calculated values can exceed 100%.
Digital information and Analysis system (DIA)
The Vaillant ecoTEC plus boiler is fitted with a digital information and analysis system (DIA). If additional settings are
Installation and maintenance instructions ecoTEC plus 0020116700_06
81
Benchmark Commissioning and
Servicing Section
It is a requirement that the boiler is installed and commissioned to the
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© Heating and Hotwater Industry Council (HHIC)
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
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ALL SYSTEMS
Yes
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SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
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PRIOR TO CO AND COMBUSTION RATIO CHECK
The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas
supply pressure/rate checked as required prior to commissioning.
As part of the installation process, especially where a flue has been fitted by persons other than the
boiler installer, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that manufacturer’s max. flue lengths have not been
exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
The flue gas analyser should be of the correct type, as specified by BS 7967
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the
manufacturer. The installer must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.
NOTE
THE AIR GAS RATIO VALVE IS FACTORY
SET AND MUST NOT BE ADJUSTED
DURING COMMISSIONING UNLESS THIS
ACTION IS RECOMMENDED FOLLOWING
CONTACT WITH THE MANUFACTURER.
If any such adjustment is recommended and
further checking of the boiler is required the
installer/service engineer must be competent
to carry out this work and to use the flue gas
analyser accordingly.
If the boiler requires conversion to operate with
a different gas family (e.g. conversion from
natural gas to LPG) separate guidance will be
provided by the boiler manufacturer
SET BOILER TO MAXIMUM RATE
In accordance with boiler instructions, set boiler to operate at max. rate
(full load condition). Allow sufficient time for combustion to stabilise.
NOTE - Do not insert analyser probe during this period to avoid
possible “flooding” of sensor.
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER
Insert analyser probe into air inlet test point and allow readings to stabilise.
NOTE - where no air inlet test point is provided then a flue integrity check
with the analyser is not possible. The installer should verify that flue
integrity has been visually checked in accordance with the yellow “Prior to
CO and combustion ratio check” box above before proceeding to the
“Check CO and combustion ratio at maximum rate” stage below.
VERIFY FLUE INTEGRITY
Analyser readings indicate that combustion products
and inlet air must be mixing. Further investigation of
the flue is therefore required.
Check that flue components are assembled, fixed
and supported as per boiler/flue manufacturer’s
instructions.
Check that flue and flue terminal are not obstructed.
NO
Is
O2 • 20.6%
and
CO2 < 0.2%
YES
Is
O2 • 20.6%
and
CO2 < 0.2%
YES
NO
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
FOR ADVICE.
THE APPLIANCE MUST NOT BE
COMMISSIONED UNTIL PROBLEMS ARE
IDENTIFIED AND RESOLVED.
CHECK CO AND COMBUSTION RATIO AT MAX. RATE
With boiler still set at maximum rate, insert analyser probe into flue gas
sampling point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is
not specified in the manual, consult boiler manufacturer for guidance.
NO
Check all seals around the appliance burner,
internal flue seals, door and case seals.
Rectify where necessary.
Is
CO less than
335ppm
and
CO/CO2 ratio less
than 0.004
Is
CO less than
350ppm and
CO/CO2 ratio
less than 0.004
YES
YES
SET BOILER TO MINIMUM RATE
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
NOTE - If manufacturer’s instructions do not specify how to set boiler to minimum
rate contact Technical Helpline for advice.
NO
CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE
With boiler still set at minimum rate, insert analyser probe into flue gas sampling
point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is not
specified in the manual, consult boiler manufacturer for guidance.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
FOR ADVICE.
THE APPLIANCE MUST NOT BE
COMMISSIONED UNTIL PROBLEMS ARE
IDENTIFIED AND RESOLVED. IF
COMMISSIONING CANNOT BE FULLY
COMPLETED, THE APPLIANCE MUST BE
DISCONNECTED FROM THE GAS SUPPLY IN
ACCORDANCE WITH THE GSIUR.
NOTE: Check and record CO and combustion ratio
at both max. and min. rate before contacting the
manufacturer.
NO
Is
CO less than
350ppm and
CO/CO2 ratio
less than 0.004
YES
BOILER IS OPERATING SATISFACTORILY
no further actions required.
Ensure test points are capped, boiler case is correctly replaced and
all other commissioning procedures are completed.
Complete Benchmark Checklist, recording CO and combustion ratio
readings as required.
Index
Index
A
D
Accessories.................................................................................... 12
Air/flue gas duct ................................................................... 25, 81
Air/flue system ............................................................................ 25
Article numbers ............................................................................ 4
Auxiliary relay............................................................... 30, 40, 50
Diagnosis codes....................................................... 48, 49, 50, 51
DIA system..................................................................................... 81
Disposal
Boiler ........................................................................................ 78
Packaging ................................................................................. 13
Domestic hot water cylinder ....................................... 22, 51, 60
Draining
Boiler ......................................................................................... 61
Heating installation ................................................................ 61
B
Burner...................................................................................... 61, 63
Burner anti-cycling time .............................................. 53, 66, 81
E
C
eBUS ............................................................................................... 81
Expansion vessel ......................................................................... 75
Calorific value ............................................................................... 81
Checking
Burner ...................................................................................... 63
Connection pressure............................................................. 45
Expansion vessel charge pressure .................................... 65
Function of boiler .................................................................. 47
Gas flow rate........................................................................... 45
Heating mode ......................................................................... 47
Leaks ........................................................................................ 47
Scope of delivery .................................................................... 12
Circulation pump............................................... 30, 31, 49, 50, 61
Comfort mode ............................................................................. 40
Commissioning ............................................................................ 39
Compact thermal module .................................................... 61, 81
Condensate discharge pipework ............................................. 23
Condensate siphon .............................................................. 43, 63
Condensing technology.............................................................. 81
Connecting
Additional components ........................................................ 30
Auxiliary relay ........................................................................ 30
Cold and hot water ................................................................ 22
Condensate discharge pipework ........................................ 23
Controller................................................................................. 29
Domestic hot water cylinder............................................... 22
Flow and return...................................................................... 22
Gas line .................................................................................... 20
Multi-functional module ........................................................ 31
Connection diagram ................................................................... 32
Connection measurements ....................................................... 17
Customer service ........................................................................ 78
86
F
Fan ................................................................................................... 61
Fault codes ............................................................................ 67, 68
Fault memory............................................................................... 67
Filling
Condensate siphon................................................................ 43
Heating installation ......................................................... 41, 42
Hot water system .................................................................. 43
with filling device................................................................... 43
Filling device ................................................................................ 43
Filling pressure ............................................................................. 41
Fitting
Controllers............................................................................... 29
Front casing ............................................................................. 18
Side panel ................................................................................. 19
Flue gas system........................................................................... 25
Frost protection............................................................................ 10
Function menu .............................................................................. 61
G
Gas Council Number .................................................................... 4
Gas family check ......................................................................... 59
Gas flow pressure ....................................................................... 45
Gas flow rate ................................................................................ 45
Gas setting.................................................................................... 44
Installation and maintenance instructions ecoTEC plus 0020116700_06
Index
H
R
Heating mode .............................................................................. 47
Heating partial load ................................................................... 40
Heating water
Preparation ............................................................................... 9
Removing
Burner ....................................................................................... 71
Compact thermal module ..................................................... 61
Display ....................................................................................... 76
Fan ....................................................................................... 72, 73
Front casing ............................................................................. 18
Gas valve ................................................................................. 73
Heat exchanger ...................................................................... 75
PCB ............................................................................................ 76
Side panel ................................................................................. 19
Venturi....................................................................................... 74
Repair ............................................................................................. 71
Replacement parts ...................................................................... 71
Reset .............................................................................................. 67
I
Installation assistant .................................................................. 39
Installation clearance.................................................................. 15
Installation site ........................................................................ 8, 15
Installation template ................................................................... 16
Installer level................................................................................ 36
L
S
Language ...................................................................................... 39
Low loss header .......................................................................... 23
M
Mains connection ........................................................................ 28
Manufacturer’s guarantee ........................................................ 78
Minimum clearance ..................................................................... 15
Multi-functional module ...................................................... 40, 81
O
Overview
Inspection and maintenance work .................................... 60
Menu structure........................................................................ 37
Parameters ................................................................. 49, 50, 51
Status codes ........................................................................... 66
Setting
Appliance variant ..................................................................
Burner anti-cycling time ......................................................
By-pass valve ..........................................................................
Heating partial load ..............................................................
Language .................................................................................
Maintenance interval ............................................................
Maximum flow temperature................................................
Pump operating mode..........................................................
Pump output ...........................................................................
Pump overrun.........................................................................
Return flow temperature control.......................................
Status codes.................................................................................
77
53
54
52
39
54
53
52
54
52
53
66
T
Test programs ....................................................................... 40, 70
Type overview ................................................................................. 5
P
V
Preparing
Electrical installation ............................................................ 28
Gas installation ...................................................................... 20
Hydraulic installation ............................................................. 21
Pump operating mode ........................................................ 49, 52
Pump overrun .............................................................................. 52
Purge
Heating installation ............................................................... 42
Vaillant customer service ......................................................... 78
W
Wall-mounting
Boiler ......................................................................................... 18
Water pressure ..................................................................... 43, 66
Water pressure sensor ................................................ 43, 67, 68
Wiring diagram ............................................................................ 32
Installation and maintenance instructions ecoTEC plus 0020116700_06
87
Manufacturer
0020116700_06 GBIE 012014 – Subject to change
Supplier