Vaillant ecoTEC plus Installation Manual

ecoTEC plus

VU, VUW ..6/5-5

0020244997_06 - 17.02.2021

en Installation and maintenance instructions

Installation and maintenance instructions

1

1.1

1.2

1.3

1.4

1.5

8.1

8.2

8.3

8.4

7.10

7.11

7.12

8

6

6.1

6.2

6.3

6.4

6.5

5.2

5.3

5.4

5.5

5.6

5.7

2

3

4

5

5.1

7.1

7.2

7.3

7.4

7.5

7.6

6.6

6.7

6.8

6.9

6.10

7

7.7

7.8

Contents

7.9

Safety .................................................................... 4

Intended use .......................................................... 4

Qualification ........................................................... 4

General safety information .................................... 4

Regulations (directives, laws, standards) .............. 6

List of relevant standards for Great Britain and

Ireland.................................................................... 6

Guarantee and Customer Service...................... 7

Technical data...................................................... 8

Notes on the documentation ............................ 15

Product description........................................... 15

CE marking .......................................................... 15

Energy Saving Trust Endorsed Products ............ 15

Hot Water Association ......................................... 15

Information on the identification plate.................. 15

Serial number ...................................................... 16

Product design..................................................... 16

Safety Devices..................................................... 17

Set-up.................................................................. 18

Checking the scope of delivery............................ 18

Dimensions .......................................................... 18

Installation site ..................................................... 19

Minimum clearances............................................ 19

Compartment Ventilation ..................................... 19

Air/flue pipe.......................................................... 19

Using the installation template............................. 22

Wall-mounting the product................................... 22

Removing/installing the front casing.................... 23

Removing/installing the side section ................... 23

Installation.......................................................... 24

Installation requirements ..................................... 24

Preparing for installation...................................... 24

Descaling the water ............................................. 24

Installing the gas connection ............................... 24

Checking the gas line for leak-tightness.............. 24

Installing the hot and cold water connection........ 25

Connecting the domestic hot water cylinder........ 25

Connecting the heating flow and heating return ................................................................... 25

Installing the drain pipe on the expansion relief valve .................................................................... 25

Connecting the condensate discharge pipe ........ 25

Flue installation.................................................... 28

Electrical installation ............................................ 28

Operation............................................................ 31

Operating concept ............................................... 31

Calling up the installer level................................. 31

Live Monitor (status codes) ................................. 31

Setting the hot water temperature ....................... 31

9

9.1

9.2

9.3

9.4

9.5

9.6

9.7

9.8

9.9

9.10

9.11

Start-up ............................................................... 32

Carrying out the initial start-up............................. 32

Switching the product on and off ......................... 32

Running the installation assistants ...................... 32

Restarting the installation assistants ................... 32

Test programmes................................................. 32

Performing a gas family check ............................ 33

Using check programmes.................................... 33

Checking and treating the heating water/filling and supplementary water .................................... 33

Filling the condensate trap .................................. 34

Preventing low water pressure ............................ 34

Flushing the heating installation for the first time ("cold") ......................................................... 34

9.12

9.13

9.14

9.15

9.16

9.17

10

12

12.1

12.2

12.3

12.4

12.5

12.6

12.7

12.8

10.1

10.2

10.3

10.4

11

Filling the heating installation .............................. 35

Purging the heating installation ........................... 35

Filling and purging the hot water system ............. 36

Gas inspection ..................................................... 36

Thoroughly flushing the heating installation

("hot")................................................................... 38

Checking leak-tightness ...................................... 38

Adapting the unit to the heating installation.......................................................... 39

Burner anti-cycling time ....................................... 39

Setting the maintenance interval ......................... 39

Setting the pump output....................................... 40

Setting the bypass valve...................................... 40

Handing over to the end user ........................... 41

Inspection and maintenance ............................ 42

Complete Service Interval Record section .......... 42

Using original seals.............................................. 42

Inspection and maintenance................................ 42

Preparing the maintenance work......................... 42

Function menu ..................................................... 42

Electronics self-test.............................................. 42

Checking the electrical plug connections ............ 42

Removing the compact thermal module .............. 42

12.9

Cleaning the heat exchanger............................... 43

12.10

Checking the burner ............................................ 43

12.11

Cleaning the condensate trap.............................. 44

12.12

Cleaning the strainer in the cold water inlet......... 44

12.13

Installing the compact thermal module ................ 44

12.14

Draining the product ............................................ 44

12.15

Checking the pre-charge pressure for the internal expansion vessel .................................... 44

12.16

Checking the filling pressure of the heating installation............................................................ 45

12.17

Checking the quality of the heating water............ 45

12.18

Completing inspection and maintenance work .... 45

12.19

Checking the product for leak-tightness .............. 45

13 Troubleshooting ................................................ 45

13.1

13.2

13.3

13.4

13.5

Checking service messages................................ 45

Eliminating faults.................................................. 45

Calling up and clearing the fault memory ............ 45

Resetting parameters to factory settings ............. 45

Preparing the repair work .................................... 45

2 Installation and maintenance instructions ecoTEC plus 0020244997_06

13.6

13.7

13.8

14

14.1

Replacing defective components......................... 46

Completing repair work........................................ 50

Checking the product for leak-tightness .............. 50

Decommissioning.............................................. 50

Temporarily decommissioning the product.......... 50

14.2

15

Permanently decommissioning the product......... 50

Recycling and disposal..................................... 50

A

B

Appendix ............................................................................ 51

Inspection and maintenance work................... 51

Installer level – Overview .................................. 52

C

D

E

F

G

H

H.1

H.2

H.3

Overview of diagnostics codes........................ 54

Status codes – Overview .................................. 59

Overview of fault codes .................................... 60

Check programmes – Overview ....................... 63

Function menu – Overview ............................... 63

Wiring diagrams................................................. 64

Wiring diagram, product for heating mode only, 12 - 35 kW................................................... 64

Connection diagram, product for heating mode only, ≥ 37 kW....................................................... 66

Connection diagram, product with integrated hot water generation, 12 - 35 kW ........................ 68

H.4

Wiring diagram, product with integrated domestic hot water generation, ≥ 37 kW ............. 70

Commissioning Checklist................................. 72 I

J Commissioning Flow Chart .............................. 76

Index ................................................................................... 77

0020244997_06 ecoTEC plus Installation and maintenance instructions 3

1 Safety

1.1

Intended use

The product is intended as a heat generator for sealed heating installations and for domestic hot water generation.

Improper use of any kind is prohibited.

Intended use also includes the following:

– use of the product only in mobile homes that are made, transported once and permanently situated in Great Britain and Ireland. After the transportation of the mobile home to its destination the complete product must be checked for leak-tightness again

– validity of the product only for Great Britain and Ireland and for the gas types in Great

Britain and Ireland as listed on the data plate

– Installing and operating the product only in conjunction with accessories for the air/flue pipe which are listed in the other applicable documents and comply with the type of unit

– Using the product while observing the accompanying operating, installation and maintenance instructions for the product along with all other components of the installation

– Installing and setting up the product while observing the product and system approval

– Observing all inspection and maintenance conditions listed in the instructions

– Installing while observing the IP code

The following is classed as improper use:

– Using the product in vehicles, such as mobile homes or caravans. Units that are not classed as vehicles are those that are installed in a fixed and permanent location

(known as "fixed installation").

– Any direct use in industrial or commercial processes

– Any use other than those described in these instructions and any use that goes beyond what is described here

1.2

Qualification

The person carrying out the work described here must have completed professional training. The competent person must demonstrably have all of the knowledge, skills and capabilities that are required in order to carry out the work mentioned below.

The following work must only be carried out by competent persons who are sufficiently qualified to do so:

– Set-up

– Dismantling

– Installation

– Start-up

– Inspection and maintenance

– Repair

– Decommissioning

▶ Proceed in accordance with current technology.

▶ Use the correct tool.

The above-mentioned work must always only be carried out by persons with sufficient qualifications.

This product can be used by children over eight years old and also by persons with limited physical, sensory or mental capabilities or insufficient experience and/or knowledge if they are supervised or have been provided with instructions on how to safely use the product, and they understand the risks resulting from using the product. Children must not play with the product. Cleaning and user maintenance work must not be carried out by children unless they are supervised.

1.3

General safety information

The following sections convey important safety information. It is essential to read and observe this information in order to prevent risk of death, risk of injury, material damage or environmental damage.

1.3.1 Gas

If you smell gas:

▶ Avoid rooms that smell of gas.

▶ If possible, open doors and windows fully and ensure adequate ventilation.

▶ Do not use naked flames (e.g. lighters, matches).

▶ Do not smoke.


▶

▶ Close the emergency control valve or the main isolator.

▶ If possible, close the gas stopcock on the product.

▶ Warn other occupants in the building by

▶

▶

Do not use any electrical switches, mains plugs, doorbells, telephones or other communication systems in the building.

yelling or banging on doors or walls.

Leave the building immediately and ensure that others do not enter the building.

Alert the police and fire brigade, and inform the emergency service department of the gas supply company as soon as you are outside the building.

1.3.2 Flue gas

Flue gases may cause poisoning, while hot flue gases may also cause burns. Flue gases must therefore never be allowed to escape uncontrollably.

What to do if you smell flue gas in the property:

▶ Open all accessible doors and windows fully to provide ventilation.

▶ Switch off the product.

▶ Check the flue gas routes in the product and the flue gas diversions.

To prevent flue gas exit:

▶ Only operate the product if the air/flue pipe has been completely installed.

▶ With the exception of short periods for testing purposes, only operate the product when the front casing is installed and closed.

▶ In order to operate the product, ensure that the condensate siphon is always full.

– Water seal level for units with condensate siphon (third-party accessory):

≥ 200 mm

To ensure that the seals are not damaged:

▶ Instead of grease, use only water or commercially available soft soap to aid installation.

1.3.3 Air supply

Unsuitable or insufficient combustion and room air may lead to material damage, but also to life-threatening situations.

To ensure that the combustion air supply is sufficient during open-flued operation:

▶ Ensure that the air supply to the product's installation room is permanently unobstructed and sufficient in accordance with the relevant ventilation requirements. This also applies, in particular, for cupboard installations.

To prevent corrosion on the product and in the flue system:

▶ Ensure that the combustion air supply is free from sprays, solvents, chlorinated cleaning agents, paint, adhesives, ammonia compounds, dust or similar substances.

▶ Ensure that no chemical substances are stored at the installation site.

▶ If you are installing the product in hairdressing salons, painter's or joiner's workshops, cleaning businesses or similar locations, choose a separate installation room in which the room air is technically free of chemical substances.

1.3.4 Electricity

The power supply terminals L and N remain live.

To prevent electric shocks, proceed as follows before working on the product:

▶ Disconnect the product from the power supply by switching off all power supplies at all poles (electrical partition with a contact gap of at least 3 mm, e.g. fuse or circuit breaker) or remove the mains plug (if present).

▶ Secure against being switched back on again.

▶ Wait at least three minutes until the condensers have discharged.

▶ Check that there is no voltage.

1.3.5 Weight

To prevent injuries when transporting the product:

▶ Make sure that the product is transported by at least two people.

To prevent material damage to the flexible gas pipe:

▶ Never suspend the compact thermal module on the flexible gas pipe.


1.3.6 Explosive and flammable substances

To prevent explosions and fire:

▶ Do not use the product in storage rooms that contain explosive or flammable substances (such as petrol, paper or paint).

are any leaks. In this case, there is a risk of explosion.

▶ Make sure that liquid gas cannot escape from the product or the gas pipe under any circumstances.

1.3.7 High temperatures

To prevent burns:

▶ Only carry out work on components once they have cooled down.

To prevent material damage that is caused by heat transfer:

▶ Only solder connectors if the connectors are not yet screwed to the service valves.

1.3.13 Risk of material damage caused by leak detection sprays and fluids

Leak detection sprays and fluids block the filter for the mass flow sensor on the Venturi, thereby destroying the mass flow sensor.

▶ During repair work, do not apply any leak detection sprays or fluids to the covering cap on the filter for the Venturi.

1.3.8 Heating water

Both unsuitable heating water and air in the heating water may cause material damage to the product and in the heat generator circuit.

▶ Check the quality of the heating water.

( → Page 33)

▶ If you use non-diffusion-tight plastic pipes in the heating installation, ensure that no air gets into the heat generator circuit.

1.3.14 Risk of damage to the flexible gas pipe

The corrugated gas pipe may become damaged if weight is placed on it.

▶ Do not suspend the compact thermal module on the flexible gas pipe, for example during maintenance work.

1.4

Regulations (directives, laws, standards)

▶ Observe the national regulations, standards, directives, ordinances and laws.

1.3.9 Neutralisation device

To prevent contamination of the waste water:

▶ Check whether a neutralising unit must be installed in accordance with national regulations.

▶ Observe local regulations on neutralising condensate.

1.5

▶

List of relevant standards for Great

Britain and Ireland

Observe the national regulations, standards, directives, ordinances and laws.

1.3.10 Frost

To prevent material damage:

▶ Do not install the product in rooms prone to frost.

1.3.11 Safety devices

▶ Install the necessary safety devices in the installation.

1.3.12 Risk of death from leaks if the product is installed below ground level

Liquid gas accumulates at floor level. If the product is installed below ground level, liquid gas may accumulate at floor level if there

You can find a list of relevant standards at: https://www.vaillant.co.uk/standards


2 Guarantee and Customer Service

Guarantee Registration

Thank you for installing a new Vaillant appliance in your home.

Vaillant appliances are manufactured to the very highest standard so we are pleased to offer our customers a comprehensive guarantee.

To maintain your guarantee, the boiler must be serviced annually by a competent person who holds the required qualifications in accordance with the rules in force of the country where the product is installed and in accordance with the manufactures recommendations.

We recommend you complete your guarantee registration as soon as possible.

Sales Support:

Telephone: 0345 602 0262

Technical Enquiries:

Telephone: 0344 693 3133

Email: [email protected]

General Enquiries:

Telephone: 0345 602 2922

Training Enquiries:

Telephone: 0345 601 8885

Email: [email protected]

Spares Enquiries:

Telephone: 01773 596 615

To register your Vaillant appliance visit: https://self-service.vaillant.co.uk/warranty-registration

Vaillant is a licensed member of the Benchmark Scheme. Benchmark places responsibilities on both manufacturers and installers.

The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved at the time by the Health and

Safety Executive and that it meets the requirements of the appropriate Building Regulations.

The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of

Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.

Benchmark is managed and promoted by the Heating and Hotwater Industry Council.


3 Technical data

Technical data – General

Designated country (designation in accordance with ISO 3166)

GB (Great

Britain), IE

(Ireland)

Approved unit categories I

2H

Gas connection, boiler side

15 mm

Flow/return heating connections, boiler side

22 mm

Domestic hot and cold water connection, boiler side

–

Expansion relief valve connection pipe (min.)

Air/flue gas connection

VU 126/5-

5 (H-GB) ecoTEC plus

612

15 mm

60/100 mm

Condensate drain pipework (min.)

G20 natural gas flow pressure

19 mm

2.0 kPa

(20.0 mbar)

– G31 propane gas flow pressure

Gas flow rate at 15 °C and 1013 mbar (based on domestic hot water generation, if applicable),

G20

1.3 m ³ /h


G31

Min. flue gas mass flow rate (G20)


–

1.44 g/s

–

Max. flue gas mass rate 5.6 g/s

Min. flue gas temperature 40 ℃

Max. flue gas temperature

70 ℃

Approved gas boiler types

30% efficiency

C13, C33,

C43, C53

109.3 %

NOx class

Test symbol/registration no.

SAP 2009/2012 annual efficiency (%)

Boiler dimension, width

6

CE ‑

0085CM0320

89.3 %

440 mm

Boiler dimension, height 720 mm

Boiler dimension, depth

Mounting weight

338 mm

36 kg

VU 156/5-


615

GB (Great

Britain), IE

(Ireland)

I

2H

15 mm

22 mm

–

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

1.7 m ³ /h

–

1.44 g/s

–

7.0 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109.3 %

6

CE ‑

0085CM0320

89.2 %

440 mm

720 mm

338 mm

36 kg

VU 186/5-


618

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

VU 186/5-

5 (P-GB) ecoTEC plus

618

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

VU 246/5-


624

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

VU 306/5-


630

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

22 mm

–

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

2.0 m ³ /h

–

1.80 g/s

–

8.4 g/s

40 ℃

70 ℃

440 mm

720 mm

338 mm

36 kg

22 mm

–

15 mm

60/100 mm

19 mm

–

3.7 kPa

(37.0 mbar)

–

1.5 kg/h

–

2.40 g/s

8.4 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109.6 %

6

CE ‑

0085CM0320

89.6 %

C13, C33,

C43, C53

108.5 %

6

CE ‑

0085CM0320

89.6 %

440 mm

720 mm

338 mm

36 kg

22 mm

–

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

2.6 m ³ /h

–

2.47 g/s

–

11.1 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109.5 %

6

CE ‑

0085CM0320

89.6 %

440 mm

720 mm

338 mm

37 kg

22 mm

–

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

3.7 m ³ /h

–

2.78 g/s

–

13.9 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109.4 %

6

CE ‑

0085CM0320

89.5 %

440 mm

720 mm

372 mm

38 kg


VU 306/5-


630


GB (Great

Britain), IE

(Ireland)

Approved unit categories II

2H3P

15 mm Gas connection, boiler side





22 mm

–

15 mm

60/100 mm



19 mm

–

G31 propane gas flow pressure

3.7 kPa

(37.0 mbar)

– Gas flow rate at 15 °C and 1013 mbar (based on domestic hot water generation, if applicable),

G20


G31



2.4 kg/h

–

4.08 g/s

Max. flue gas mass rate 13.9 g/s



70 ℃


30% efficiency

C13, C33,

C43, C53

108 %

NOx class



Boiler dimension, width

6

CE ‑

0085CM0320

89.7 %

440 mm



Mounting weight

372 mm

38 kg

VU 386/5-


637

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

22 mm

–

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

4.1 m ³ /h

–

3.05 g/s

–

17.4 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109.3 %

6

CE ‑

0085CM0320

89.5 %

440 mm

720 mm

406 mm

43 kg

VUW 196/5-


825

GB (Great

Britain), IE

(Ireland)

II

–

–

6

2H3P

15 mm

22 mm

G 3/4 ″

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

2.7 m ³ /h

1.80 g/s

8.4 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109.6 %

CE ‑

0085CM0320

89.5 %

440 mm

720 mm

338 mm

36 kg

VUW 246/5-


832

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

22 mm

G 3/4

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

–

3.4 m

–

2.47 g/s

–

11.1 g/s

40

70

℃

℃

C13, C33,

C43, C53

109.5 %

6

CE ‑

0085CM0320

89.5 %

440 mm

720 mm

338 mm

37 kg

″

³ /h

VUW 246/5-


832

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

VUW 306/5-


835

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

22 mm

G 3/4

–

–

–

40

70

℃

℃

37 kg

″

15 mm

60/100 mm

19 mm

3.7 kPa

(37.0 mbar)

2.5 kg/h

2.90 g/s

11.1 g/s

C13, C33,

C43, C53

108 %

6

CE ‑

0085CM0320

89.5 %

440 mm

720 mm

338 mm

22 mm

G 3/4

–

3.8 m

–

40

70

℃

℃

″

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

2.78 g/s

–

16.2 g/s

C13, C33,

C43, C53

109.4 %

6

CE ‑

0085CM0320

89.4 %

440 mm

720 mm

372 mm

41 kg

³ /h

VUW 286/5-


838


GB (Great

Britain), IE

(Ireland)

Approved unit categories II

2H3P


VUW 286/5-


838

15 mm Gas connection, boiler side





22 mm

G 3/4 ″

15 mm

60/100 mm



19 mm

2.0 kPa

(20.0 mbar)

– G31 propane gas flow pressure


G20


G31

4.2 m

–

³ /h



Max. flue gas mass rate

3.05 g/s

–

17.9 g/s



70 ℃


30% efficiency

C13, C33,

C43, C53

109.4 %

NOx class



6

CE ‑

0085CM0320

89.4 %

Boiler dimension, width 440 mm



Mounting weight

406 mm

44 kg

Technical data – G20 power/loading G20

VU 126/5-


612

VU 156/5-


615

VU 186/5-


618

VU 246/5-


624

VU 306/5-


630

VU 386/5-


637

3.3 to 13.2 kW 3.3 to 16.7 kW 4.1 to 20.0 kW 5.7 to 26.4 kW 6.4 to 32.8 kW 7.1 to 40.5 kW Nominal heat output range P at 50/30 °C

Nominal heat output range P at 80/60 °C

Maximum heat output for domestic hot water generation

3.0 to 12.2 kW 3.0 to 15.2 kW 3.8 to 18.2 kW 5.2 to 24.4 kW 5.8 to 30.4 kW 6.4 to 37.6 kW

12.2 kW 15.2 kW 18.2 kW 24.4 kW 30.4 kW 37.6 kW


VU 126/5-


612

12.4 kW Maximum heat input for domestic hot water generation

Maximum heat input, heating side

Minimum heat input

12.4 kW

3.2 kW

Heating adjustment range 3 to 12 kW

Nominal heat input efficiency (stationary) at

40/30 °C


50/30 °C


60/40 °C


80/60 °C

108.0 %

106.0 %

101.0 %

99 %

VU 156/5-


615

15.5 kW

15.5 kW

3.2 kW

3 to 15 kW

109.0 %

108.0 %

101.0 %

98.0 %

VU 186/5-


618

18.9 kW

18.6 kW

4.0 kW

4 to 19 kW

109.0 %

108.0 %

101.0 %

98.0 %

VU 246/5-


624

24.7 kW

24.7 kW

5.5 kW

5 to 24 kW

108.0 %

107.0 %

101.0 %

98.0 %

VU 306/5-


630

30.9 kW

VU 386/5-


637

38.1 kW

30.9 kW

6.2 kW

6 to 30 kW

107.0 %

106.0 %

101.0 %

98.0 %

38.1 kW

6.8 kW

6 to 38 kW

107.0 %

106.0 %

101.0 %

98.0 %



VUW 196/5-


825

VUW 246/5-


832

VUW 306/5-


835

VUW 286/5-


838

4.1 to 20.8 kW 5.7 to 26.4 kW 6.4 to 32.8 kW 7.1 to 30.9 kW

3.8 to 19.3 kW


Maximum heat input for domestic hot water generation

24.4 kW

24.7 kW



19.6 kW

4.0 kW

Heating adjustment range 4 to 19 kW

5.2 to 24.4 kW

31.8 kW

32.2 kW

24.7 kW

5.5 kW

5 to 24 kW

5.8 to 30.4 kW

34.0 kW

34.7 kW

30.9 kW

6.2 kW

6 to 30 kW

6.5 to 28.6 kW

38.7 kW

39.2 kW

28.9 kW

6.8 kW

6 to 29 kW


40/30 °C


50/30 °C


60/40 °C


80/60 °C

108.0 %

106.0 %

101.0 %

98.0 %

108.0 %

107.0 %

101.0 %

98.0 %

107.0 %

106.0 %

101.0 %

98.0 %

107.0 %

107.0 %

101.0 %

98.0 %

Technical data – Power/loading G31

VU 186/5-


618

VU 306/5-


630

VUW 246/5-


832

5.4 to 19.4 kW 9.4 to 31.9 kW 6.5 to 25.5 kW Nominal heat output range P at 50/30 °C



5.0 to 18.2 kW 8.5 to 30.4 kW 6.0 to 24.4 kW

18.3 kW 30.4 kW 31.8 kW


Maximum heat input for domestic hot water generation




40/30 °C


50/30 °C


60/40 °C


80/60 °C

VU 186/5-


618

18.6 kW

18.6 kW

5.3 kW

104.0 %

104.0 %

101.0 %

98.0 %

Technical data – Heating

VU 126/5-


612

85 ℃ Maximum flow temperature

Max. flow temperature adjustment range (default setting: 75 °C)

Permissible total excess pressure

Minimum pressure for full operation

30 to 80 ℃

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l Expansion vessel capacity

Circulation water volume

(with reference to

Δ T= 20 K)

Approx. condensate rate

(pH value 3.5 to 4.0) in

50/30 °C heating mode

Remaining feed head of pump (at nominal circulation water volume)

525 l/h

1.2 l/h

0.025 MPa

(0.250 bar)

VU 306/5-


630

30.9 kW

30.9 kW

9.0 kW

104.0 %

103.0 %

101.0 %

98.0 %

VU 156/5-


615

85 ℃

30 to 80 ℃

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

662 l/h

1.6 l/h

0.025 MPa

(0.250 bar)

Maximum flow temperature




Expansion vessel capacity

VU 306/5-


630

85 ℃

30 to 80 ℃

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

VU 386/5-


637

85 ℃

30 to 80

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

℃

VUW 246/5-


832

32.2 kW

24.7 kW

6.4 kW

104.0 %

103.0 %

101.0 %

98.0 %

VU 186/5-


618

85 ℃

30 to 80 ℃

VU 186/5-


618

85 ℃

30 to 80 ℃

VU 246/5-


624

85 ℃

30 to 80 ℃

VU 306/5-


630

85 ℃

30 to 80 ℃

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

796 l/h

1.9 l/h

0.025 MPa

(0.250 bar)

VUW 196/5-


825

85 ℃

30 to 80 ℃

VUW 246/5-


832

85 ℃

30 to 80 ℃

VUW 246/5-


832

85 ℃

30 to 80 ℃

VUW 306/5-


835

85 ℃

30 to 80 ℃

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

796 l/h

1.9 l/h

0.025 MPa

(0.250 bar)

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

1,049 l/h

2.5 l/h

0.025 MPa

(0.250 bar)

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

1,307 l/h

3.1 l/h

0.025 MPa

(0.250 bar)

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l


VU 306/5-


630

1,307 l/h Circulation water volume


Δ T= 20 K)


(pH value 3.5 to 4.0) in



3.1 l/h

0.025 MPa

(0.250 bar)

VU 386/5-


637

1,617 l/h

3.8 l/h

0.025 MPa

(0.250 bar)

Maximum flow temperature




Expansion vessel capacity

Circulation water volume


Δ T= 20 K)


(pH value 3.5 to 4.0) in



VUW 286/5-


838

85 ℃

30 to 80 ℃

0.25 MPa

(2.50 bar)

0.08 MPa

(0.80 bar)

10 l

1,230 l/h

2.9 l/h

0.025 MPa

(0.250 bar)

Technical data – Hot water handling mode

Lowest water volume

Water volume (at

Δ T = 30 K)


Δ T = 35 K)


Δ T = 42 K)

Permitted overpressure

VUW 196/5-


825

2.0 l/min

12.3 l/min

10.5 l/min

8.8 l/min

VUW 246/5-


832

2.0 l/min

15.2 l/min

13.0 l/min

10.9 l/min

Required connection pressure

Hot water output temperature range

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 to 65 ℃

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 to 65 ℃

Technical data – Electrics

Electric connection

Permissible connected voltage

VU 126/5-


612

230 V/50 Hz

190 to 253 V

VU 156/5-


615

230 V/50 Hz

190 to 253 V

VUW 196/5-


825

830 l/h

VUW 246/5-


832

1,049 l/h

VUW 246/5-


832

1,049 l/h

VUW 306/5-


835

1,307 l/h

2.0 l/h

0.025 MPa

(0.250 bar)

VUW 246/5-


832

2.0 l/min

15.2 l/min

VUW 306/5-


835

2.0 l/min

16.7 l/min

VUW 286/5-


838

2.0 l/min

18.5 l/min

13.0 l/min

10.9 l/min

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 to 65 ℃

2.5 l/h

0.025 MPa

(0.250 bar)

14.3 l/min

11.9 l/min

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 to 65 ℃

2.5 l/h

0.025 MPa

(0.250 bar)

15.9 l/min

13.2 l/min

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 to 65 ℃

3.1 l/h

0.025 MPa

(0.250 bar)

VU 186/5-


618

230 V/50 Hz

190 to 253 V

VU 186/5-


618

230 V/50 Hz

190 to 253 V

VU 246/5-


624

230 V/50 Hz

190 to 253 V

VU 306/5-


630

230 V/50 Hz

190 to 253 V


VU 126/5-


612

Built-in fuse (slow-blow) 2 A

Min. electrical power consumption

Max. electrical power consumption

Electrical power consumption, standby

Level of protection

35 W

55 W

< 2 W

IP X4 D

VU 156/5-


615

2 A

35 W

60 W

< 2 W

IP X4 D

VU 186/5-


618

2 A

35 W

65 W

< 2 W

IP X4 D

VU 186/5-


618

2 A

35 W

65 W

< 2 W

IP X4 D

VU 246/5-


624

2 A

35 W

70 W

< 2 W

IP X4 D

VU 306/5-


630

2 A

45 W

90 W

< 2 W

IP X4 D

VU 306/5-


630

230 V/50 Hz Electric connection


190 to 253 V


45 W Min. electrical power consumption




80 W

< 2 W

IP X4 D

VU 386/5-


637

230 V/50 Hz

190 to 253 V

2 A

55 W

95 W

< 3 W

IP X4 D

VUW 196/5-


825

230 V/50 Hz

190 to 253 V

2 A

35 W

80 W

< 2 W

IP X4 D

VUW 246/5-


832

230 V/50 Hz

190 to 253 V

2 A

35 W

85 W

< 2 W

IP X4 D

VUW 246/5-


832

230 V/50 Hz

190 to 253 V

VUW 306/5-


835

230 V/50 Hz

190 to 253 V

2 A

35 W

85 W

< 2 W

IP X4 D

2 A

45 W

90 W

< 2 W

IP X4 D

Electric connection

VUW 286/5-


838

230 V/50 Hz


190 to 253 V


Min. electrical power consumption




55 W

120 W

< 3 W

IP X4 D


4 Notes on the documentation

▶

Always observe all operating instructions enclosed with the installation components.

▶

Store these instructions and all other applicable documents for further use.

These instructions apply only to:

Product article number

Article number

Gas Council

Number

0010021828 41-694-20 VU 126/5-5 (H-GB) ecoTEC plus 612

VU 156/5-5 (H-GB) ecoTEC plus 615


VU 186/5-5 (P-GB) ecoTEC plus 618





VUW 196/5-5 (H-GB) ecoTEC plus 825


VUW 246/5-5 (P-GB) ecoTEC plus 832



0010021829 41-694-21

0010021830 41-694-22

0010021831 41-694-23

0010021832 41-694-24

0010021833 41-694-25

0010021834 41-694-26

0010021835 41-694-27

0010021823 47-044-83

0010021824 47-044-84

0010021825 47-044-85

0010021826 47-044-86

0010021822 47-044-82

5

5.1

Product description

CE marking

The CE marking shows that the products comply with the basic requirements of the applicable directives as stated on the data plate.

The declaration of conformity can be viewed at the manufacturer's site.

5.2

Energy Saving Trust Endorsed Products

Only the most energy efficient products can carry the

‘Energy Saving Trust Endorsed Product’ brandmark making it easy for consumers to choose products that have met strict energy performance criteria.

Available for: Boilers, Heating controls and chemical inhibitors, the Energy Saving Trust endorsed product brandmark gives consumers confidence that a product will cost less to run, help lower energy bills and reduce carbon emissions.

About the Energy Saving Trust

Energy Saving Trust is an independent and impartial organisation that provides trusted energy saving advice to empower millions of people to lead affordable, low energy lifestyles. For more information visit energysavingtrust.org.uk

5.3

Hot Water Association

Vaillant is a full member of the Hot Water Association and promotes the scheme in association with its cylinder range.

Details are available on the web site www.vaillant.co.uk

5.4

Information on the identification plate

The identification plate is mounted on the underside of the product in the factory.


Meaning

VU…

VUW…, VUI…

..6/5-5 ecoTEC plus

2H, G20 – 20 mbar

(2.0 kPa) ww/yyyy

Cat.

Types

PMS

PMW

T max.

ED 92/42

V Hz

W

IP

Read the instructions.

Vaillant gas-fired wall-hung boiler for heating

Vaillant gas-fired wall-hung boiler for heating and hot water generation

Calorific value power/product generation equipment

Product designation

Gas group and gas connection pressure as set at the factory

Date of manufacture: Week/year

Approved gas boiler category

Approved units of type

Permissible total overpressure in heating mode

Permissible total overpressure during hot water generation

Max. flow temperature

Current efficiency directive fulfilled with

4* rating

Mains voltage and mains frequency

Max. electrical power consumption

Level of protection


P

Q

D


Meaning

Heating mode

Hot water generation

Nominal heat output range

Heat input range

Nominal hot water draw-off rate

Bar code with serial number,

7th to 16th digit = product article number

9 Compact thermal module

10 Ignition electrode

11 Fan

12 Automatic air vent

13 Manometer

14 Internal pump

15 Bypass valve

16 Expansion relief valve

17 Prioritising diverter valve

18 Electronics box

Note

Make absolutely sure that the product is compatible with the gas group at the installation site.

5.5

Serial number

The serial number can be found on a plastic label behind the front flap and on the identification plate.

Note

The serial number can also be shown on the display of the product ( → Operating instructions).

5.6.2

Functional elements, product with domestic hot water generation

5

4

3

2

1

6

7

8

9

10

11

12

13

14

15

5.6

Product design

5.6.1

Functional elements, product for heating mode only

16

5

4

3

2

1

6

7

8

9

10

11

12

13

14

15

16

20

19

18

4

5

1

2

3

Gas valve assembly

Water pressure sensor

6

7

Venturi with mass flow sensor

Heat exchanger

Connection for the air/flue pipe

Flue gas test point

Expansion vessel

8 Air intake pipe

9 Compact thermal module

10 Ignition electrode

11 Fan

12 Automatic air vent

13 Manometer

14 Internal pump

15 Bypass valve

16 Expansion relief valve

17 Electronics box

18 Prioritising diverter valve

19 Impeller sensor (domestic hot water)

20 Secondary heat exchanger

17

1

2

3

4

Gas valve assembly


Venturi with mass flow sensor

Heat exchanger

5

6

7

8

Connection for the air/flue pipe

Flue gas test point

Expansion vessel

Air intake pipe

17

18


5.7

Safety Devices

5.7.1

Electrical Supply Failure

The boiler will not work without an electrical supply. Normal operation of the boiler should resume when the electrical supply is restored.

Reset any external controls, to resume normal operation of the central heating.

If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this call your Installation/Servicing company or Vaillant service.

5.7.2

Overheating Safety

The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens.

To restart the boiler, press the reset button on the boiler interface.

If the boiler fails to resume normal operation and all external controls are calling for heat, then call your Installation/ Servicing company or Vaillant service.

5.7.3

Frost protection

The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature of the boiler water falls below 12 °C.

A timer is used so that the temperature can be checked periodically. After 10 minutes the pump will be stopped if the temperature is higher than 10 °C or has already reached

35 °C. The burner will activate if the boiler temperature does not reach 10 °C after 30 minutes or at any time if the temperature drops to 5 °C.

The burner will switch off when the temperature reaches

35 °C.

5.7.4

Condensate Drain Blockage

As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions this may be due to the forming of ice in the condense drain external to the house. Release an ice blockage by the use of warm cloths on the pipe. After pressing reset the boiler should restart.


6 Set-up

6.1

Checking the scope of delivery

▶

Check that the scope of delivery is complete and intact.

6.1.1

Scope of delivery

Validity: Product with heating mode only

1

1

3

1

1

1

1

2

3

1

1

Number

1

Designation

Heat generator

Installation set containing the following:

- Unit mounting bracket

- Expansion relief valve connection pipe

- Gas connection pipe

- Heating flow/return connection pipe

- Service valve

- Bag with small parts

Lower cover

Mounting template

Condensate discharge hose

Enclosed documentation

6.1.2

Scope of delivery

Validity: Product with integrated hot water generation

1

1

1

3

1

2

2

4

1

1

1

1

1

Number

Designation

Heat generator

Installation set containing the following:

- Unit mounting bracket

- Expansion relief valve connection pipe

- Gas connection pipe

- Heating flow/return connection pipe

- Cold water, domestic hot water connection pipe

- Service valve

- Bag with small parts

Lower cover

Mounting template

Condensate discharge hose

Enclosed documentation

6.2

Dimensions

3 4* 5

9

440

35 35

100 100

188

6* 7

11 10

1

2

3

4*

5

6*

7

8

12

7

8

5

6

1

2

3

4

Air/flue pipe wall duct

Unit mounting bracket

Heating flow (22 × 1.5

diameter)

Domestic hot water connection (15 × 1.5

diameter)

Gas connection

(15 × 1.5 diameter)

Cold water connection

(15 × 1.5 diameter)

Heating return (22 × 1.5

diameter)

R1 tundish/condensate trap connection

9 Air/flue pipe connection

10 Condensate discharge connection, 19 mm diameter

11 Condensate trap

12 Drain pipework connection, expansion relief valve, heating, 15 mm diameter

*

**

Only products with integrated domestic hot water generation

Only products with heating mode only


Consult the installation template that is supplied to find the dimension A.

Installation depth, dimension B














338 mm

338 mm

338 mm

338 mm

338 mm

372 mm

372 mm

406 mm

338 mm

338 mm

338 mm

372 mm

406 mm

It is not necessary to maintain a clearance between the product and components made of combustible materials that go beyond the minimum clearances.

6.5

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 not required as the products are only certified, and can only be fitted with a concentric flue system.

6.6

Air/flue pipe

6.6.1

Regulation

Different flue outlet configurations can be carried out.

– Consult the installation manual for air/flue gas systems for more information about the other possibilities and associated accessories.

B

C

D

6.3

Installation site

This boiler is not suitable for outdoor installation. This boiler may be installed in any room. However if the boiler is being installed in a room containing a bath or shower it must only be installed in zones 2 or 3. In GB this is the current I.E.E.

WIRING REGULATIONS and BUILDING REGULATIONS. In

IE reference should be made to the current edition of I.S.813

“Domestic Gas Installations” and the current ETCI rules.

If the boiler is to be installed in a timber frame building it should be fitted in accordance with the current version of the

Institute of Gas Engineers document IGE/UP/7. If in doubt seek advice from local gas undertaking or the manufacturer.

6.4

C

Minimum clearances

C D

Minimum fall

44 mm/m

– Standard flue terminal kits have an in-built fall back to the boiler to drain the condensate. These can be fitted level between the appliance and the termination position.

All other extended flues must have a fall of at least 44 mm/m.

The maximum length of the flue outlet is defined according to its type (for example C13).

– Whatever the kind of flue system chosen, observe the minimum distances to position the flue terminals.

– To install the flue, refer to the separate flue instruction supplied with your appliance.

– Explain these requirements to the user of the appliance.

In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram overleaf.

In IE the minimum distances for flue terminal positioning must be those detailed in I.S. 813 “Domestic Gas Installations”.

The terminal must be exposed to the external air, allowing free passage of air across it at all times.

Being a condensing boiler some pluming may occur from the flue outlet. This should be taken into consideration when selecting the position for the terminal.

A

Minimum clearance

165 mm: Air/flue pipe, 60/100 mm diameter

275 mm: Air/flue pipe, 80/125 mm diameter

180 mm; optimum approx. 250 mm

5 mm; optimum approx. 50 mm

500 mm in front of the heat generator to enable easy access for maintenance work (may be provided by an opening door).


6.6.2

Position of the air/flue terminal

V M

S

Ba Z

G

C

W

Q

P

S

U

N

J

J

H

Z

G

J

J A

F

E

D

B

S

P

S

L

K

Aa

S

T

R

Boundar y

A

F

Y

Boundar y

X

6.6.2.1 Positioning the terminal of a fan-supported flue system

J

K

L

2)

A

B

1)

C

D

E

F

2)

G

H

M

N

P

Q


Adjacent to a boundary.

The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with a suitable silicon sealant.

Between a vertical flue terminal and a window or dormer window on a roof.

Between terminals facing each other.

Vertical flue clearance, adjacent to a boundary line.

Distance to a boundary line, unless it will cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

Minimum clearance from a skylight to a vertical flue or to another vertical flue.

Vertical flue clearance, to noncombustible building material.

Vertical flue clearance to combustible building material.

Above, below and either side of an opening door, air vent or opening window.

Diagonally to an opening door, air vent or opening window.

To an internal or external corner.

Below a Velux window.

Above or to either side of the Velux window.

From a pitched roof.

In regions with heavy snowfall.

From vertical drain pipes and soil pipes.

Below eaves.

Below gutters, pipe and drains.

1) There should be no ventilation/opening in the eaves within 300 mm distance of the terminal.

2) These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.

– Terminals must be positioned so to avoid combustion products entering the building.

– Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fixings.

– Installations in car ports are not recommended.

– The flue cannot be lower than 1 metre from the top of a lightwell due to the build up of combustion products.

– Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment.

Dimensions

300 mm

25 mm

1,500 mm

1,200 mm

300 mm

600 mm

Min. 300 mm

500 mm

1,500 mm

300 mm

600 mm

200 mm

2,000 mm

600 mm

400 mm

500 mm

25 mm

200 mm

75 mm


U

V

W

X

R

S

T

2)

Y

Z


The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant.

Above adjacent ground or balcony.

Distance to a surface facing a terminal, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal.

Clearance alongside another terminal.

Above roof level.

Minimum to vertical structure on roof, roof vent.

Minimum to opening in adjacent building.

Minimum at an angle to a boundary which is not less than 300 mm to the terminal

Minimum measured to the nearest corner of the OPEN window

Aa No more than this value above ridge.

300 mm

600 mm

300 mm

300 mm

Min. 300 mm

Min.

2000 mm

Min. 600 mm

Min. 600 mm

Max.

300 mm

Min. 300 mm Ba Not less than this value below the opening window

1) There should be no ventilation/opening in the eaves within 300 mm distance of the terminal.

2) These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.

– Terminals must be positioned so to avoid combustion products entering the building.

– Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fixings.

– Installations in car ports are not recommended.

– The flue cannot be lower than 1 metre from the top of a lightwell due to the build up of combustion products.

– Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment.

Dimensions

25 mm

6.6.2.2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals 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 directed to discharge directly across a boundary if the products are likely to cause a nuisance to a neighbour or discharge over a walkway or patio.

For IE see current issue of IS 813.

For boilers covered within this manual.

Dimensions B and R:

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 below.

Balcony/eaves

Gutter

Adequately secured air/flue gas pipe

The flue pipe must protrude beyond any overhang

You can use a plume management kit to enable the termination point to be positioned and directed away from the building fabric.


6.6.3

Flue Configuration Description

6.6.3.1 Horizontal Concentric Flue ⌀ 60/100 mm or

⌀ 80/125 mm (C13 type installation)

6.6.3.3 Vertical Concentric Flue ⌀ 60/100 mm or

⌀ 80/125 mm (C33 type installation)

1

1 Gasket (fitted)

Note

If the terminal is at less than 1.80 m from the ground, you must install a terminal protection kit.

Consult the separate installation manual for air/flue gas systems supplied with your appliance for all possibilities and associated accessories and how to install the flue system.

6.6.3.2 Terminal protection

Consult the separate installation manual for air/flue gas systems supplied with your appliance for all possibilities and associated accessories and how to install the flue system.

6.7

Using the installation template

▶

Use the installation template to ascertain the locations at which you need to drill holes and make breakthroughs.

6.8

Wall-mounting the product

1.

Check the load-bearing capacity of the wall.

2.

Note the total weight of the product.

3.

Only use fixing material that is permitted for the wall.

4.

If required, ensure that mounting apparatus on-site has sufficient load-bearing capacity.

5.

Wall-mount the product as described.

1

A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide minimum of 50 mm clearance from any part of the terminal and be central over the terminal.

The guard should be similar to that shown in the figure.

6.

Install the product bracket (1) on the wall.

7.

Hang the product on the product bracket from above using the hanging bracket.


6.9

Removing/installing the front casing

6.9.1

Removing the front casing

6.10

Removing/installing the side section

6.10.1 Removing the side section

2x

B

A

B

B

C

▶

Remove the front casing as shown in the illustration.

6.9.2

Installing the front casing

▶

Refit the components in the reverse order.

A

D

Caution.

Risk of material damage caused by mechanical deformation.

Removing both side sections may cause mechanical distortion in the product, which may cause damage to the piping, for example, and potentially result in leaks.

▶

Always only remove one side section – never both side sections at the same time.

▶

Remove the side section as shown in the illustration.

6.10.2 Installing the side section

▶

Refit the components in the reverse order.


7 Installation

7.1

Installation requirements

7.1.1

Information on the gas group

In the as-supplied condition, the product is preset for operation with the gas group indicated on the data plate.

7.1.2

Purging the liquid gas tank

If the liquid gas tank is not purged properly, this may result in ignition problems.

▶

Ensure that the liquid gas tank has been purged properly before installing the product.

▶

If required, contact the filler or the liquid gas supplier.

7.1.3

Using the correct gas type

Using the incorrect gas type may cause fault shutdowns in the product. Ignition and combustion noise may occur in the product.

▶

Only use the gas type listed on the data plate.

7.2

Preparing for installation

1.

Make sure that the existing gas meter is capable of passing the rate of gas supply required.

2.

Consider the maximum heat output given in DHW mode.

3.

Install a system separator (to be provided on-site) directly on the cold water connection for the combi boiler.

4.

Install the following components:

– Draining cocks at the lowest points in the heating installation ( → current version of "BS 2879")

– A stopcock on the cold water connection

– A stopcock in the gas pipe

5.

Check that the volumetric capacity of the expansion vessel is sufficient for the system volume.

Condition : The volume of the installed expansion vessel is insufficient

▶

Install an additional expansion vessel, connected as close to the product as possible, in the heating return.

Condition : External expansion vessel installed and warm start active

▶

Install a non-return valve in the product outlet (heating flow) or decommission the internal expansion vessel in order to prevent the warm start function from being increasingly activated due to backflow.

6.

Install the connection pipes such that they are free from mechanical stress.

7.

If you use non-diffusion-tight plastic pipes in the heating installation, ensure that no air gets into the heat generator circuit.

8.

Only solder connectors if the connectors are not yet screwed to the service valves.

9.

Only bend connection pipes if they have not yet been connected to the product.

10. Flush the heating installation thoroughly before installing the product.

11. If, during gas tightness tests, you also place the gas pipes and the gas valve assembly in the product under pressure, use a max. test pressure of ≤ 11 kPa

(110 mbar).

12. If you cannot limit the test pressure to 11 kPa

(110 mbar), close any gas stopcocks that are installed upstream of the product before you carry out the gas tightness test.

13. If, during gas tightness tests, you have closed the gas stopcock that is installed upstream of the product, relieve the gas line pressure before you open this gas stopcock.

7.3

Descaling the water

Scale deposition increases as the water temperature increases.

▶

Descale the water as required.

7.4

Installing the gas connection

1.

Install the gas pipe in accordance with the recognised rules of technology.

2.

Connect the product to the gas line as shown in accordance with the recognised rules of good engineering practice.

3.

Remove the residues from the gas line by blowing through the gas line beforehand.

4.

Purge the gas line before start-up.

7.5

Checking the gas line for leak-tightness

▶

Check the entire gas line properly for leak-tightness.


7.6

Installing the hot and cold water connection


7.9

Installing the drain pipe on the expansion relief valve

1.

Install the drain pipe for the expansion relief valve so that it does not interfere with the removal and fitting of the lower section of the condensate trap.

1.

Make the water connections as shown in accordance with the relevant standards.

2.

Ensure correct water pressure and flow requirements and that any expansion can be accommodated with the cold supply pipe work.

7.7

Connecting the domestic hot water cylinder

Validity: Product with heating mode only

▶

When connecting the domestic hot water cylinder, follow the Installation instructions for the domestic hot water cylinder.

7.8

Connecting the heating flow and heating return

2.

Install the drain pipe as shown (do not shorten).

3.

Make sure that the end of the pipe is visible.

4.

Ensure that discharged water or steam cannot cause injury to persons or damage to electronic components.

5.

Ensure the discharge pipe work is installed, routed and terminated correctly to minimise the risk of freezing up.

7.10

Connecting the condensate discharge pipe

Danger!

Risk of death from escaping flue gases!

The condensate drain pipework for the siphon must not be connected tightly to wastewater piping because, otherwise, the internal condensate trap may be drained fully and flue gas may escape.

▶

Do not connect the condensate drain pipework tightly to the waste-water piping.

min.

180

11

2

3

▶

Make the heating connections as shown in accordance with the relevant standards.

The product is equipped with a condensate trap (2) . The condensate trap collects the condensate that has formed in a vessel with a volumetric capacity of approximately 200 ml, and intermittently releases the contents into the drain pipe.

This minimises the risk of the drain pipe freezing.

▶

Follow the instructions listed here and observe directives and local regulations on condensate discharge.


▶

If you cannot guarantee that the materials from which the condensate discharge pipe is made are suitable, install a system to neutralise the condensate.

▶

Connect the condensate discharge (1) to a condensate discharge pipe (3) that has a minimum internal diameter of 19 mm (30 mm internal diameter for all external pipes that are fed out of the building) and is made from an acidresistant material (e.g. plastic overflow pipe).

– 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.

7.10.1.2 Direct connection to external soil and vent stack

≤ 3 m Ø22mm

Ø 32mm

Note

Ensure that the connection between the condensate discharge pipe and the drain hose is not air-tight.

7.10.1.3 External termination to gulley or hopper

▶

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.

▶

Ensure that the condensate discharge pipe terminates 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.

▶

Leave an installation space of at least 180 mm beneath the condensate trap.

7.10.1 Condensate discharge systems

The condensate is discharged periodically in ‘slugs’ by siphonic action. It is not necessary to provide extra traps in the discharge pipe as there is already a trap inside the boiler.

Fitting an extra trap may cause the boiler siphon to work incorrectly. Refer to BS5546 or BS6798 for further advice on disposal of boiler condensate.

7.10.1.1 Direct Connection to internal soil and vent stack

Ø22mm

Ø 32mm

Best practice

7.10.1.4 Internal termination into combined sink waste

≥ 3 m

≤ 3 m

Ø32mm

100mm

Ø22mm

Preferred option for external termination

Ø22mm

Preferred option


7.10.1.5 External termination into soakaway 7.10.1.7 External termination into rain water down pipe

Ø32mm

≤ 3 m

< 500 mm

1

100 mm ≤ 3 m

Ø22mm

4

5

6

2

3

Ø12

25

1

2

3

Ground (either/or)

Seal

Plastic tube,

100 mm diameter

4

5

6

Bottom of sealed tube

Limestone chippings

Hole depth 400 mm minimum

Least preferred option, must not terminate in rain water drain

7.10.1.6 Internal termination downstream of sink waste

Ø 32mm

NB only combined foul/rainwater drain

7.10.1.8 Additional methods of introducing air breaks

1

Ø22mm

100mm

1

2

Air break

Using a tundish

2 3

3 Using a pipe

≤ 3 m

Ø32mm

7.10.1.9 Connection of condensate pump

Open end of pipe direct into gulley below ground level but above water level

Susceptible to siphonage, must terminate in a gulley

Ø32mm

≥ 3 m

Ø22mm

Preferred option for external connection


7.11

Flue installation

7.11.1 Installing and connecting the air/flue pipe

1.

You can find out which air/flue pipes may be used by consulting the enclosed set-up instructions for the air/flue system.

2.

Observe the information on positioning the air/flue terminal.

Condition : Installation in damp rooms

▶

You must connect the product to a room-sealed air/flue system. The combustion air must not be taken from the installation site.

7.11.2.2 Installing the connector for the air/flue pipe,

80/125 mm diameter

1.

Remove the connector for the air/flue pipe.

2.

Insert the alternative connector. In doing so, pay attention to the latching lugs.

3.

Turn the connector clockwise until it clicks into position.

7.12

Electrical installation

Only qualified electricians may carry out the electrical installation.

Caution.

Risk of poisoning due to escaping flue gas.

Mineral-oil-based greases can damage the seals.

▶

Instead of grease, use only water or commercially available soft soap to aid installation.

3.

Install the air/flue pipe using the set-up instructions.

Danger!

Risk of death from electric shock!

Power supply terminals L and N remain live even if the on/off button is switched off:

▶

Disconnect the product from the power supply by switching off all power supplies at all poles (electrical partition with a contact gap of at least 3 mm, e.g. fuse or circuit breaker).

▶

Secure against being switched back on again.

▶

Wait for at least 3 minutes until the capacitors have discharged.

▶

Check that there is no voltage.

7.11.2 Replacing the connector for the air/flue pipe as required

1.

Replace the connector for the air/flue pipe as required.

The product-specific standard equipment is listed under

Technical data.

2.

Remove the connector for the air/flue pipe. ( → Page 28)

3.

If required, install the connector for the air/flue pipe,

80/125 mm diameter. ( → Page 28)

7.12.1 Opening the electronics box

7.11.2.1 Removing the connector for the air/flue pipe

3.

1.

2.

1.

Insert a screwdriver into the slot between the test points.

2.

Press the screwdriver carefully down (1.) .

3.

Turn the connector anti-clockwise (2.) as far as it will go and then remove it by pulling it upwards (3.) .

▶

Open the electronics box as shown in the illustration.

7.12.2 Carrying out the wiring

Caution.

Risk of material damage caused by incorrect installation.

Mains voltage at incorrect terminals and plug terminals may destroy the electronics.

▶

Do not connect any mains voltage to the eBUS terminals (+/-).

▶

Only connect the mains connection cable to the terminals marked for the purpose.


1.

Route the connection cables of the components to be connected through the grommet provided on the underside of the product on the left.

2.

Use strain reliefs.

3.

If required, shorten the connection cables.

≤ 30 mm

4.

Strip the flexible line as shown in the figure. In doing so, ensure that the insulation on the individual conductors is not damaged.

5.

Only strip inner conductors just enough to establish good, sound connections.

6.

To avoid short circuits resulting from loose individual wires, fit conductor end sleeves on the stripped ends of the conductors.

7.

Screw the respective plug to the connection cable.

8.

Check whether all conductors are sitting mechanically securely in the terminals of the plug. Remedy this if necessary.

9.

Plug the plug into the associated PCB slot; see the wiring diagram in the appendix.

7.12.3 Establishing the power supply

Caution.

Risk of material damage due to high connected voltage.

At mains voltages greater than 253 V, electronic components may be damaged.

▶

Make sure that the rated voltage of the mains is 230 V.

1.

Observe all valid regulations.

2.

Make sure that the nominal mains voltage is 230 V.

3.

Provide one common power supply for the boiler and for the corresponding control:

– Power supply: Single-phase, 230 V, 50 Hz

– Fuse protection: ≤ 3 A

4.

Do not interrupt the mains supply with a time switch or programmer.

5.

Open the electronics box. ( → Page 28)

6.

Connect the product using a fixed connection and an electrical partition with a contact gap of at least 3 mm

(e.g. fuses or power switches).

7.

Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3 mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It should be identified as to its use.

8.

Route a three-core power supply cable that complies with the relevant standards through the grommet and into the product.

– Power supply cable: Flexible duct

9.

Carry out the wiring. ( → Page 28)

10. Remove the supplied plug from the bracket in the electronics box and screw the plug onto the power supply cable.

11. Close the electronics box.

12. Make sure that access to the power supply is always available and is not covered or blocked.

7.12.4 Installing the product in a wet room

Danger!

Risk of death from electric shock!

If you install the product in a room with high levels of moisture, e.g. a bathroom, observe the nationally recognised technical standards for electrical installations.

▶

Connect the product using a fixed connection and an electrical partition with a contact gap of at least 3 mm (e.g. fuses or power switches).

▶

Use a flexible line for the power supply cable, which is routed through the grommet into the product.

1.


2.

Detach the plug from the PCB slot for the power supply

(X1).

3.

Use a suitable, three-core power supply cable that complies with the relevant standards.

4.


5.

Close the electronics box.

6.

Observe the flue-gas connection that is required on a

room-sealed air/flue system. ( → Page 28)

7.12.5 Connecting controls to the electronics

1.

Install the control if necessary.

2.


3.


4.

Observe the wiring diagram in the appendix.

Condition : Connecting a weather-compensated control or a room temperature control via eBUS

▶

Connect the control to the eBUS connection.

▶

Bridge the 24 V = RT connection (X100 or X106), if there is not already a bridge.

Condition : Connecting a low-voltage control (24 V)

▶

Remove the bridge and connect the control to the

24 V = RT connection (X100 or X106).

Condition : Connecting 230 volt controller

▶

Connect the switched live supply of your 230 V RT to the

RT marked X1 position (besides LNPE). Do NOT connect the 230 V to any other terminal e.g. not to X100.

Condition : Connecting a limit thermostat for underfloor heating

▶

Remove the bridge and connect the limit thermostat to the Burner off connection.

5.


6.

For multi-circuit controls, change D.018

from Eco (intermittently operating pump) to Comfort (continuously op-

erating pump). ( → Page 39)

7.12.6 Connecting additional components

You can actuate an additional component with the aid of the auxiliary relay that is installed, and you can actuate two other components with the multi-functional module.


7.12.6.1 Using the auxiliary relay

1.

Connect an additional component directly to the integrated auxiliary relay using the grey plug on the PCB.

2.

Carry out the wiring.

3.

To start up the connected component, select the component in diagnostics code D.026

. ( → Page 39)

7.12.6.2 Using the VR 40 ("2 in 7" multi-functional module)

1.

Install the components in accordance with the respective instructions.

Condition : Components connected to relay 1

▶

Activate D.027

. ( → Page 39)

Condition : Components connected to relay 2

▶

Activate D.028

. ( → Page 39)

7.12.7 Actuating the circulation pump according to requirements

1.

Carry out the wiring.

2.

Connect the supply line for the external button using terminals 1 (0) and 6 (functional drawing) on the X41 edge connector, which is supplied with the controller.

3.

Plug the edge connector into the PCB slot X41.


8 Operation

8.1

Operating concept

The operating concept and the read-off and setting facilities of the operator level are described in the operating instructions.

An overview of the reading and setting options for the installer level is included in the table in the appendix.

Installer level –

Overview ( → Page 52)

8.2

Calling up the installer level

1.

Only call up the installer level if you are a competent person.

2.

Navigate to Menu → Installer level and confirm by pressing .

3.

Set the value 17 (code) and confirm by pressing .

8.3

Live Monitor (status codes)

Menu → Live monitor

Status codes in the display provide information on the product's current operating mode.

Status codes –


8.4

Setting the hot water temperature


OR Product with hot water generation through external domestic hot water cylinder

Danger!

Risk of death from legionella.

Legionella multiply at temperatures below

60 °C.

▶

Ensure that the end user is familiar with all of the Anti-legionella measures in order to comply with the applicable regulations regarding legionella prevention.

▶

Set the hot water temperature.

Condition : Water hardness: > 3.57 mol/m ³

– Water temperature: ≤ 50 ℃


9 Start-up

9.1

Carrying out the initial start-up

Initial start-up must be carried out by a customer service technician or an authorised competent person using the

Benchmark Checklist. The Benchmark Checklist in the ap-

pendix ( → Page 72) of the installation instructions must be

filled in and stored carefully along with the unit's documentation.

▶

Carry out the start-up procedure using the Benchmark

Checklist in the appendix.

▶

Fill out and sign the Benchmark Checklist.

9.2

Switching the product on and off

▶

Press the on/off button on the product.

◁

The basic display appears on the display.

9.3.3

Purging

1.

Unlike in the Check programs menu, to purge the system, start check programme P.00

by pressing or .

2.

If you need to change the circuit that is being purged, press .

9.3.4

Target feed temperature, hot water temperature, Comfort mode

1.

To set the target flow temperature, hot water temperature and Comfort mode, use and .

2.

Press to confirm this setting.

9.3

Running the installation assistants

The installation assistant is displayed whenever the product is switched on until it has been successfully completed.

It provides direct access to the most important check programmes and configuration settings for starting up the product.

To recheck and reset the most important system parameters, call up the Appliance config.

.

Menu → Installer level → Appliance config.

The settings options for more complex systems can be found in the Diagnostics menu .

Menu → Installer level → Diagnostics menu

▶

Press to confirm installation assistant start-up.

◁

All heating and hot water requests are blocked whilst the installation assistant is active.

▶

Note

If you do not confirm the launch of the installation assistant within 10 seconds of switching the system on, the basic display reappears.

To access the next point, confirm by pressing case.

in each

9.3.5

Heating partial load

The heating partial load of the product is set to Auto at the factory. The product independently determines the optimum heating output depending on the current heat demand of the system. You can retroactively change the setting in the

Diagnostics menu under D.000

.

9.3.6

Auxiliary relay and multi-functional module

1.

If you have connected additional components to the product, assign these components to the individual relays.

2.

In each case, confirm by pressing .

Note

This setting can be retroactively changed in the Diagnostics menu using D.026

, D.027

and D.028

.

9.3.7

Contact data

▶

If required, store your telephone number in the Appliance config.

(max. 16 digits/no blank spaces). The operator can view the telephone number.

9.3.8

Ending the installation assistant

▶

Once you have run through the installation assistant successfully, confirm by pressing .

◁

The installation assistant will close and will not launch again when the product is next switched on.

9.4

Restarting the installation assistants

Menu → Installer level → Start inst. assistant

You can restart the installation assistant at any time by calling it up in the menu.

9.3.1

Language

▶

Set the required language.

▶

To confirm the set language and to avoid unintentionally changing it, press to confirm this twice.

If you have unintentionally set a language that you do not understand, proceed as follows to change it:

▶

Press and hold and at the same time.

▶

Also briefly press .

▶

Press and hold and until the display shows the language setting option.

▶

Select the required language.

▶

Press twice to confirm this change.

9.5

Test programmes

Menu → Installer level → Test programs

As well as the installation assistants, you can also call up the following test programmes for start-up, service and troubleshooting.

– Check programs

– Function menu

– Electronics self-test

9.3.2

Filling mode

Filling mode (check programme P.06

) is activated automatically in the installation assistant for as long as the filling mode appears on the display.


9.6

Performing a gas family check

Danger!

Risk of poisoning!

Inadequate combustion quality (CO), indicated by F.92/93 , leads to an increased risk of poisoning.

▶

Make sure that the fault is completely eliminated before starting up the product for continuous operation.

Menu → Installer level → Test programs → Gas family check

The gas family check checks the product setting with regard to combustion quality.

Note

If additional condensing boilers are connected to the same flue pipework in the heating installation, ensure that none of these condensing boilers are in operation or start operating throughout the entire test programme, so that the test result is not distorted.

▶

Perform the gas family check as part of routine product maintenance work, after replacing components, carrying out work on the gas route and following gas conversion.

Result Meaning Measure

F.92

See the table of fault codes in the appendix

"Successful" Combustion quality is good.

Unit configuration matches the specified gas group.

"Warning" Combustion quality inadequate.

CO ₂ content is incorrect.


None

F.93


Start check programme

P.01 and adjust the

CO ₂ content with the adjusting screw in the

Venturi.

If the correct CO ₂ content cannot be set:

Check that the gas restrictor is correct (yellow:

G20 natural gas, blue:

G25 natural gas, grey:

Liquid gas) and undamaged.

Repeat the gas family check.


Note

It is not possible to perform CO ₂ measurements during the gas family check.

9.7

Using check programmes

Menu → Installer level → Test programs → Check programs

By activating various check programmes, you can trigger special functions on the product.

Check programmes –


9.8

Checking and treating the heating water/filling and supplementary water

Caution.

Risk of material damage due to poor-quality heating water

▶

Ensure that the heating water is of sufficient quality.

▶

Before filling or topping up the installation, check the quality of the heating water.

Checking the quality of the heating water

▶

Remove a little water from the heating circuit.

▶

Check the appearance of the heating water.

▶

If you ascertain that it contains sedimentary materials, you must desludge the installation.

▶

Use a magnetic rod to check whether it contains magnetite (iron oxide).

▶

If you ascertain that it contains magnetite, clean the installation and apply suitable corrosion-inhibition measures, or fit a magnetic filter.

▶

Check the pH value of the removed water at 25 °C.

▶

If the value is below 8.2 or above 10.0, clean the installation and treat the heating water.

▶

Ensure that oxygen cannot get into the heating water.

Checking the filling and supplementary water

▶

Before filling the installation, measure the hardness of the filling and supplementary water.

Treating the filling and supplementary water

▶

Observe all applicable national regulations and technical rules when treating the filling and supplementary water.

Provided the national regulations and technical rules do not stipulate more stringent requirements, the following applies:

You must treat 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 guideline values listed in the following table are not met, or

– If the pH value of the heating water is less than 8.2 or more than 10.0.

Total heating output kW

< 50

> 50 to ≤ 200

> 200 to ≤ 600

Water hardness at specific system volume

1)

≤ ppm

20 l/kW

CaCO ₃ mol/ m ³

> 20 l/kW

≤ 50 l/kW ppm

CaCO ₃ mol/ m ³

> 50 l/kW ppm

CaCO ₃ mol/ m ³

< 300 < 3

200 2

200

150

2

1.5

2

2

0.02

0.02

150 1.5

2 0.02

2 0.02


Total heating output kW

Water hardness at specific system volume

1)

≤ 20 l/kW

> 20 l/kW

≤ 50 l/kW

> 50 l/kW ppm

CaCO ₃

2 mol/ m ³

0.02

ppm

CaCO ₃

2 mol/ m ³

0.02

ppm

CaCO ₃

2 mol/ m ³

0.02

> 600

1) Nominal capacity in litres/heating output; in the case of multiboiler systems, the smallest single heating output is to be used.

Caution.

Risk of material damage if the heating water is treated with unsuitable additives.

Unsuitable additives may cause changes in the components, noises in heating mode and possibly subsequent damage.

▶

Do not use any unsuitable antifreeze and corrosion inhibitors, biocides or sealants.

9.9

Filling the condensate trap

1

No incompatibility with our products has been detected to date with proper use of the following additives.

▶

When using additives, follow the manufacturer's instructions without exception.

We accept no liability for the compatibility of any additive or its effectiveness in the rest of the heating system.

Additives for cleaning measures (subsequent flushing required)

– Adey MC3+

– Adey MC5

– Fernox F3

– Sentinel X 300

– Sentinel X 400

Additives intended to remain permanently in the installation

– Adey MC1+

– Fernox F1

– Fernox F2

– Sentinel X 100

– Sentinel X 200

Additives for frost protection intended to remain permanently in the installation

– Adey MC ZERO

– Fernox Antifreeze Alphi 11

– Sentinel X 500

▶

If you have used the above-mentioned additives, inform the end user about the measures that are required.

▶

Inform the end user about the measures required for frost protection.

1.

Remove the lower section from the condensate trap (1) .

2.

Fill the lower section with water up to 10 mm below the upper edge.

3.

Attach the lower section to the condensate trap.

9.10

Preventing low water pressure

To ensure that the heating installation operates smoothly, the indicator on the pressure gauge must point to the upper half of the grey area or to the middle of the bar graph display in the display (marked by the dashed limit values) 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).

If the heating installation extends over several storeys, higher filling pressures may be required to avoid air entering the heating installation.

If the filling pressure falls below 0.08 MPa (0.8 bar), the product indicates low pressure by displaying a flashing pressure value. If the filling pressure falls below 0.05 MPa

(0.5 bar), the product switches off. The display shows F.22

.

▶

Top up the heating water to start the product up again.

The pressure value flashes in the display until a pressure of

0.11 MPa (1.1 bar) or higher has been reached.

9.11

Flushing the heating installation for the first time ("cold")

Note

The complete heating system must be flushed at least twice: Once with cold water and once with hot water in accordance with the following instructions.

1.

Check whether all thermostatic radiator valves and both service valves on the product are open.

2.

Connect a hose to the drain valve that is located at the lowest position in the heating system.

3.

Open the radiator valves and the drain valves so that the water can drain quickly. Start at the next point in the installation and open the purging valves on the radiators so that the contaminated water can completely drain.

4.

Close the draining cocks.

5.

Refill the heating system with water.


6.

Check that the expansion relief valve of the heating system is functioning correctly by turning the handle on the valve.

7.

Check the pressure in the heating system and top up with water if necessary.

8.

Close the filling valve and the cold water tap.

9.12

Filling the heating installation

1

▶

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.

▶

Monitor the rising filling pressure in the heating installation.

▶

Fill with water until the required filling pressure is reached.

▶

After filling, close both isolation valves and disconnect the filling device by removing the double non-return valve from the cold-water isolation valve.

Note

Both isolation valves must be closed while the heating system is operating and the filling line must be removed from the double non-return valve again.

1.

Flush the heating installation through.

2.

Undo the cap of the automatic air vent (1) by one to two rotations and leave it open, as the product purges itself via the automatic air vent even in continuous operation.

3.

Select the check programme P.06

.

◁

The prioritising diverter valve moves to the midposition, the pumps do not run and the product does not switch to heating mode.

4.

Observe the information on treating heating water.

( → Page 33)

5.

Check all connections and the entire system for leaks.

Condition : Applies to: Products with integrated domestic hot water generation

3

1

2

4

▶

Open all radiator valves (thermostatic valves) of the heating installation.

▶

Fit the double non-return valve (1) of the filling line to the cold-water isolation valve and secure the valve with the spring clip (2) .

▶

To fill, first open the isolation valve (3) .

▶

Open the isolation valve (4) so that the water flows into the heating system. Fill the heating system.

▶


Condition : Applies to: Products with heating mode only

▶

Connect the filling/draining cock in the heating installation to a heating water supply, if possible with the cold water tap, in accordance with the relevant standards.

▶

Open the heating water supply.

▶

Open all radiator valves (thermostatic valves) of the heating installation.

▶

If necessary, check that both service valves on the product are open.

▶

Slowly open the filling/draining cock so that the water flows into the heating system.

▶

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.

▶

Monitor the rising filling pressure in the heating installation.

▶

Fill with water until the required filling pressure is reached.

▶

Close the filling/draining cock and the cold water tap.

▶


9.13

Purging the heating installation

1.

Select the check programme P.00

.

◁

The product does not start up, the internal pump operates intermittently and purges either the heating circuit or the hot water circuit.

◁

The display shows the filling pressure of the heating installation.

2.

Make sure that the filling pressure of the heating installation does not fall below the minimum filling pressure.

– ≥ 0.08 MPa ( ≥ 0.80 bar)

◁

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 counter-pressure of the expansion vessel ("Exp") (P

0.02 MPa (0.2 bar)).

Installation

≥ P

Exp

+

3.

If there is still too much air in the heating installation at the end of the check programme P.00

, repeat the check programme.


9.14

Filling and purging the hot water system


1.

Open the cold water stop valve on the product.

2.

Fill the hot water system by opening all the hot water draw-off valves until water escapes.

9.15

Gas inspection

9.15.1 Checking the factory-set gas setting

Caution.

Risk of material damage caused by making unauthorised settings.

▶

Never modify the factory setting of the gas pressure regulator of the gas valve.

▶

Ensure that all other gas appliances in the property are turned off.

▶

Measure the gas flow rate at the gas meter.

▶

Compare the measured values with the corresponding values in the table.

Qnw from the data plate

Nom.

H gas in m ³ /h

+5% − 10%

15.3

18.4

24.7

25.7

28.6

30.6

35.7

1.62

1.95

2.61

2.72

3.03

3.24

3.78

1.70

2.05

2.74

2.86

3.18

3.40

3.97

1.46

1.76

2.35

2.45

2.73

2.92

3.40

▶

Before you start up the product, compare the gas group information on the data plate with the gas group available at the installation site.

Condition : The product design is not compatible with the local gas group

Only Vaillant Service may perform a gas conversion.

If a gas conversion to liquefied petroleum gas has been carried out, the smallest possible partial load is higher than is shown on the display. The correct values can be found in the

Technical data in the appendix.

▶

Call Vaillant Service (0330 1003 143).

▶

Do not start up the product.

Condition : The product design is compatible with the local gas group

▶

Proceed as described below.

9.15.2 Checking the air/flue pipe/flue gas recirculation

1.

Check the flue gas installation is intact in accordance with the latest gas safe technical bulletin and information supplied in the installation instructions.

2.

For extended flue gas installations check for flue gas recirculation using the air analysis point.

3.

Use a flue gas analyser.

4.

If you discover unusual levels of CO or CO

2 in the supply air, search for the leak in the flue system or for signs of flue gas recirculation.

5.

Eliminate the damage properly.

6.

Check again whether the supply air contains any unusual levels of CO or CO

2

.

7.

If you cannot eliminate the damage, do not start up the product.

9.15.3 Checking the gas flow rate

The gas flow rate has been set during production and does not require adjustment. With the front casing fitted check the gas flow rate of the boiler as follows:

▶

Start up the product with the check programme P.01

.

▶

In addition, ensure that maximum heat can be dissipated into the heating system by turning up the room thermostat.

▶

Wait at least 5 minutes until the boiler has reached its operating temperature.

Condition : Gas flow rate not in the permissible range

▶

Check all of the piping and ensure that the gas flow rates are correct.

▶

Only put the product into operation once the gas flow rates have been corrected.

Condition : Gas flow rate in the permissible range

▶

End the check programme P.01

.

▶

Allow the boiler to cool down by allowing pump overrun to operate for a minimum of 2 minutes.

▶

Record the boiler maximum gas flow rate onto the

Benchmark Checklist.

9.15.4 Checking the gas flow pressure

1.

Ensure that the gas inlet working pressure can be obtained with all other gas appliances in the property working.

2.

Close the gas stopcock.


1

2

Caution.

Risk of material damage and operating faults caused by incorrect gas connection pressure.

If the gas connection pressure lies outside the permissible range, this can cause operating faults in and damage to the product.

▶

Do not make any adjustments to the product.

▶

Do not start up the product.

▶


.

▶

Allow the boiler to cool down by allowing pump overrun to operate for a minimum of two minutes.

▶


▶

Remove the pressure gauge and retighten the sealing screw (1) for the measuring nipple.

▶

Open the gas stopcock.

▶

Check the test nipple for gas tightness.

▶


▶

Install the front casing.

▶

Disconnect the product from the power grid.

▶

You must not start up the boiler.

Condition : Gas flow pressure in the permissible range

▶


.

▶

Allow the boiler to cool down allowing pump overrun to operate for a minimum of two minutes.

▶


▶

Remove the pressure gauge and retighten the sealing screw (1) for the measuring nipple.

▶


▶

Check the test nipple for gas tightness.

▶


▶

Reset boiler controls for normal operation.

▶

Record the appliance gas inlet working pressure (kPa resp. mbar) in the Benchmark gas boiler commissioning checklist.

3.

Use a screwdriver to undo the test nipple screw (1)

(lower screw) at the gas valve assembly.

4.

Connect a manometer (2) to the test nipple (1) .

5.


6.


.

7.

In addition, ensure that maximum heat can be dissipated into the heating system by turning up the room thermostat.

8.

With the boiler operating at full load check that the gas inlet working pressure at the reference test point complies with the requirements.

– Permissible gas flow pressure for operation with natural gas H: 1.3 to 2.3 kPa (13.0 to 23.0 mbar)

– Permissible gas flow pressure for operation with liquefied petroleum gas P: 2.3 to 4.3 kPa (23.0 to

43.0 mbar)

9.

Should the pressure recorded at the reference test point in the boiler be lower than indicated check if there is any blockage in the pipework or if the pipework is undersized.

Condition : Gas flow pressure not in the permissible range

9.15.5 Checking and, if required, adjusting the

CO ₂ content and the CO/CO ₂ ratio (air ratio setting)

1.


.

2.

Wait at least five minutes until the product reaches its operating temperature.

3.

Measure the CO ₂ and CO/CO ₂ content at the flue gas analysis point.

4.

Compare the measured value with the corresponding value in the table.

Set values Unit Natural gas H

Liquefied petroleum gas P

CO ₂ after 5 minutes in full load mode with front casing closed

CO ₂ after 5 minutes in full load mode with front casing removed

Set for Wobbe index

W ₀

O ₂ after 5 minutes in full load mode with front casing closed

Vol%

Vol% kWh/m

Vol%

CO value with full load ppm

CO/CO ₂

³

9.2

± 1.0

10.4

± 0.5

9.0

± 1.0

10.2

± 0.5

14.09

4.5

± 1.8

≤ 250

≤ 0.0031

21.34

5.1

± 0.8

≤ 250

≤ 0.0026

▶

If you cannot correct the failure, notify the gas supply company and proceed as follows:


Condition : The CO ₂ content must be adjusted

1

2

9.16

Thoroughly flushing the heating installation

("hot")

1.

Operate the appliance until the boiler and the heating system are up to temperature.

2.

Check the heating system for leaks.

3.

Connect a hose to the drain valve located at the lowest position of the heating system.

4.

Shut off the boiler, open the drain valve and all purge valves on the radiators and allow the water to flow out of the heating system and the boiler quickly and fully.

5.

Close the drain valve.

6.

Fill the heating system again with water as described in

Filling the heating installation ( → Page 35) and Purging the heating installation ( → Page 35).

7.

Re-fill the system until the system design pressure of

0,1 MPa (1,0 bar) is attained.

▶

Pierce the covering cap (1) at the mark using a small flatblade screwdriver and unscrew it.

▶

After performing the adjustments, tilt the air intake pipe back up.

▶

Check the CO ₂ content again.

▶

If necessary, repeat the setting process.

▶

Set the CO ₂ content (value with front casing removed) by turning the screw (2) .

– Higher CO ₂ content: Turn anti-clockwise

– Lower CO ₂ content: Turn clockwise

▶

For natural gas only: Only perform the adjustment in increments of 1 turn and wait approx. 1 minute after each adjustment until the value stabilises.

▶

For liquefied petroleum gas only: Only perform the adjustment in small increments (approx. 1/2 turn), and wait approx. 1 minute after each adjustment until the value stabilises.

▶

Check the CO ₂ content again.

▶

If necessary, repeat the setting process.

▶

Press ( Cancel ) once the adjustments have been made.

▶

If an adjustment is not possible in the specified adjustment range, you must not start up the product.

▶

If this is the case, inform Customer Service.

▶

Screw the covering cap back in.

▶


Note

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.

8.


9.17

Checking leak-tightness

▶

Check the gas pipe, the heating circuit and the hot water circuit for leak-tightness.

▶

Check that the air/flue pipe has been installed correctly.

Condition : Room-sealed operation

▶

Check whether the vacuum chamber has been closed tightly.

9.17.1 Checking the heating mode

1.

Make sure that there is a heat requirement.

2.

Call up Live monitor .

◁

If the product is working correctly, the display shows

S.04

.

9.17.2 Checking the hot water generation


1.

Open a hot water valve all the way.

2.


◁

If the hot water generation is working correctly, S.14

appears in the display.


9.17.3 Checking the domestic hot water generation

Validity: Product with hot water generation through external domestic hot water cylinder

1.

Ensure that the cylinder charging mode is requesting heat.

2.


◁

If the cylinder is charged correctly, the display shows S.24

.

3.

If you have connected a Vaillant eBUS control which can be used to set the domestic hot water temperature, set the domestic hot water temperature on the boiler to the maximum possible temperature.

4.

Adjust the target temperature for the connected domestic hot water cylinder to the eBUS control.

◁

The product adopts the target temperature that is set on the eBUS control.

T

Flow

(target)

[°C]

70

75

Set maximum burner anti-cycling time [min]

1 5 10 15 20 25 30

T

Flow

(target)

[°C]

50

55

60

65

30

35

40

45

70

75

2.0

1.5

2.0

2.5

2.5

3.0

3.5

2.0

1.0

1.0

1.0

1.0

1.0

1.0

Set maximum burner anti-cycling time

[min]

35 40 45 50 55 60

29.0

33.0

37.0

41.0

45.0

49.5

25.5

29.5

33.0

36.5

40.5

44.0

22.5

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

13.5

15.0

17.0

19.0

20.5

22.5

10.5

11.5

13.0

14.5

15.5

17.0

7.0

4.0

1.0

8.0

4.5

1.0

9.0

10.0

11.0

11.5

5.0

5.5

6.0

6.5

1.0

1.0

1.0

1.0

10 Adapting the unit to the heating installation

To reset the most important system parameters, use the

Unit configuration menu item.

Menu → Installer level → Appliance config.

Or manually relaunch the installation assistant.

Menu → Installer level → Start inst. assistant

You can find setting options in the Diagnostics menu .

Menu → Installer level → Diagnostics menu

Overview of diagnostics codes ( → Page 54)

10.1

Burner anti-cycling time

To prevent frequent switching on and off of the burner and thus prevent energy losses, an electronic restart lockout is activated for a specific period each time the burner is switched off. The burner anti-cycling time is only active for the heating mode. Hot water handling during a burner anti-cycling time does not affect the time function element

(default setting: 20 mins).

10.1.1 Setting the burner anti-cycling time

1.

Navigate to Menu → Installer level → Diagnostics menu → D.002 Max. anti-cycl. time: Heating and confirm by pressing .

2.

Set the burner anti-cycling time and confirm by pressing

.

Set maximum burner anti-cycling time [min]

45

50

55

60

65

T

Flow

(target)

[°C]

30

35

40

1 5 10 15 20 25 30

2.0

4.0

8.5

12.5

16.5

20.5

25.0

2.0

4.0

7.5

11.0

15.0

18.5

22.0

2.0

3.5

6.5

10.0

13.0

16.5

19.5

2.0

3.0

6.0

8.5

11.5

14.0

17.0

2.0

3.0

5.0

7.5

9.5

12.0

14.0

2.0

2.5

4.5

6.0

8.0

10.0

11.5

2.0

2.0

3.5

5.0

6.0

7.5

9.0

2.0

1.5

2.5

3.5

4.5

5.5

6.5

10.1.2 Resetting the remaining burner anti-cycling time

1.

1.

Alternatives 1:

▶

Navigate to Menu → Reset anti-cycl. time .

◁

The current burner anti-cycling time appears in the display.

▶

Press to reset the burner anti-cycling time.

Alternatives 2:

▶

Press .

10.2

Setting the maintenance interval

1.

Navigate to Menu → Installer level → Diagnostics menu → D.084 Maintenance in and confirm by pressing .

2.

Set the maintenance interval (operating hours) until the next maintenance work is due and confirm by pressing

.

Heat demand

5.0 kW

10.0 kW

15.0 kW

20.0 kW

25.0 kW

> 27.0 kW

Number of persons

1 ‑ 2

2 ‑ 3

1 ‑ 2

2 ‑ 3

2 ‑ 3

3 ‑ 4

3 ‑ 4

4 ‑ 5

3 ‑ 4

4 ‑ 6

3 ‑ 4

4 ‑ 6

Guideline value for burner operating hours until the next inspection/maintenance work is due for an average operating time of one year

(dependent upon the system type)

1050 h

1150 h

1500 h

1600 h

1800 h

1900 h

2600 h

2700 h

2800 h

2900 h

3000 h

3000 h


10.3

Setting the pump output

1.

Navigate to Menu → Installer level → Diagnostics menu → D.014 Pump speed target value and confirm by pressing .

2.

Set the required pump output.

Condition : Low loss header installed

▶

Switch off the speed regulation and set the pump output to a fixed value.

10.3.1 Remaining feed head of the pump

10.3.1.1 Pump characteristic line for VU 126, VU 156,

VU 186

10.3.1.4 Pump characteristic line for VUW 246, VUW

326

400

300

200

100

0

0

100% PWM

85%

70%

60%

53%

200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

400

10.3.1.5 Pump characteristic line for VU 376, VU 386,

VUW 286, VUW 386

300

200

100

0

0

100% PWM

85%

70%

60%

53%

200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

400

300

200

100

100% PWM

85%

70%

60%

53%

Minimum

with Auto

10.3.1.2 Pump characteristic line for VU 246, VUW

196, VUW 256

0

0 200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

400

350

300

250

200

150

100

50

0

0 200 400 600 800 1000 1200 1400

Flow rate [l/hr]

100% PWM

80%

70%

60%

53%

10.3.1.3 Pump characteristic line for VU 306, VUW

306, VUW 356

10.4

Setting the bypass valve

Caution.

Risk of material damage caused by incorrect setting of the high-efficiency pump

If the pressure at the bypass valve is increased (by turning it clockwise) and the pump output is set to less than 100%, the product may not operate correctly.

▶

In this case, set the pump output to

5 = 100% using diagnostics code D.014.

▶

Remove the front casing. ( → Page 23)

400

300

200

100% PWM

85%

70%

60%

53%

1

100

0

0 200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

40

▶

Regulate the pressure using the adjusting screw (1) .

Installation and maintenance instructions ecoTEC plus 0020244997_06

Position of the adjusting screw

Pressure in MPa

(mbar)

Right-hand stop

(turned all the way down)

0.035

(350)

Mid-position

(5 turns to the left)

0.025

(250)

5 further turns to the left from the mid-position

0.017

(170)

▶


Notes/application

If the radiators do not heat up sufficiently at the default setting. In this case, you must set the pump to the maximum speed.

Default setting

If noises are produced in the radiators or radiator valves

11 Handing over to the end user

▶

At the time of commissioning complete all relevant sections of the Benchmark commissioning checklist, located at the rear of this document.

▶

For IE: Complete a “Declaration of Conformity” to indicate compliance to I.S. 813. An example of this is given in the current edition of I.S. 813.

▶

When you have finished the installation, affix the enclosed sticker (which requests that the user reads the instructions) to the front of the product in the end user's language.

▶

Draw attention, to the current issue of the Gas Safety

(Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK.

▶

Explain to the end user how the safety devices work and where they are located.

▶

Inform the end user how to handle the product.

▶

In particular, draw attention to the safety warnings that the end user must follow.

▶

Inform the end user that they must have the product maintained in accordance with the specified intervals.

▶

Pass all of the instructions and documentation for the product to the end user for safe-keeping.

▶

Inform the end user about measures taken to ensure the supply of combustion air and flue gas guiding, and instruct the operator that he must not make any changes.

▶

Inform the end user that they must not store or use explosive or highly flammable substances (such as petrol, paper or paint) in the installation room of the product.

▶

Complete and sign off the Benchmark commissioning check list.

▶

Complete and sign off the guarantee documentation.


12 Inspection and maintenance

12.1

Complete Service Interval Record section

▶

After servicing, complete the relevant Service Interval

Record section of the Benchmark Checklist located on the inside back pages of this document.

12.2

Using original seals

If you replace components, use only the enclosed original seals; additional sealing materials are not required.

12.3

Inspection and maintenance

▶

You must carry out an annual inspection of the product.

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 the table in the appendix 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 the table in the appendix.

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.

– The gas flow rates.

– 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.

12.4

Preparing the maintenance work

1.

Switch off the product.

2.


3.


4.


5.

Close the service valves in the heating flow and in the heating return.

6.

Close the service valve in the cold water pipe.

7.

Drain the product to clean hydraulic components

( → Page 44).

8.

Ensure that water does not drip on live components

(e.g. the electronics box).

9.

Use only new seals and o'ring. Do not use additional compounds.

12.5

Function menu

Menu → Installer level → Test programs → Function menu

The function menu allows you to actuate and test individual components in the heating installation.

Function menu –


12.6

Electronics self-test

Menu → Installer level → Test programs → Electronics self-test

You can use the electronics self-test to check the PCB.

12.7

Checking the electrical plug connections

1.

Use the main switch to switch off the product.

2.

Disconnect the product from the power supply by switching off the circuit breaker in the case of a fixed connection.

Condition : Product disconnected from the power supply

▶

Check that the electrical plug connections and connections are working correctly and are connected correctly.

12.8

Removing the compact thermal module

Note

The compact thermal module consists of five main components:

– Speed-regulated fan,

– Gas valve assembly including support plate,

– Venturi including mass flow sensor and gas connection pipe,

– Burner flange,

– Premix burner.

Danger!

Risk of death and risk of material damage caused by hot flue gas.

The seal, insulating mat and self-locking nuts on the burner flange must not be damaged.

Otherwise, hot flue gases may escape and cause personal injury and material damage.

▶

Replace the seal each time you open the burner flange.

▶

Replace the self-locking nuts on the burner flange each time you open the burner flange.

▶

If the insulating mat on the burner flange or on the back wall of the heat exchanger shows signs of damage, replace the insulating mat.

1.

Switch off the product using the on/off button.

2.


3.


4.

Hinge the electronics box forward.


2

12.9

Cleaning the heat exchanger

1.

Protect the hinged down electronics box against spraying water.

2

3

8

7

1

2

3

4

5.

Unscrew the retaining screw (2) and remove the air intake pipe (1) from the intake stub.

6.

Unscrew either the union nut on the gas valve assembly

(3) or the union nut (4) between the flexible gas pipe and the fixed gas pipe.

1

4

2.

Never undo the four nuts on the stud bolt (1) or tighten them.

3.

Clean the spiral immersion heater (3) of the heat exchanger (4) using water or, if required, vinegar (to a maximum of 5% acid). Allow the vinegar to act on the heat exchanger for 20 minutes.

4.

Rinse away any loose dirt with a sharp jet of water or use a plastic brush. Do not point the jet of water directly at the insulating mat (2) on the rear of the heat exchanger.

◁

The water flows out of the heat exchanger through the condensate trap.

12.10 Checking the burner

3

6

1

4

5

7.

Remove the plugs of the ignition line (7) and of the earth connection (6) from the ignition electrode.

8.

Remove the plug (4) from the fan motor by pushing in the latching lug.

9.

Remove the three plugs from the gas valve assembly

(5) .

10. Remove the plug from the Venturi (3) by pushing in the latching lug.

11. Release the cable harness from the clip on the gas valve assembly retainer.

12. Unscrew the four nuts (8) .

13. Remove the entire compact thermal module (2) from the heat exchanger (1) .

14. Check the burner and the heat exchanger for damage and dirt.

15. If necessary, clean or replace the components according to the following sections.

16. Fit a new burner flange seal.

17. Check the insulating mat on the burner flange and on the back panel of the heat exchanger. If you notice any signs of damage, replace the relevant insulating mat.

2 2

1.

Check the surface of the burner (1) for damage. If you see any damage, replace the burner.

2.

Fit a new burner flange seal (3) .

3.

Check the insulating mat (2) on the burner flange. If you notice any signs of damage, replace the insulating mat.


12.11 Cleaning the condensate trap

1.

Remove the lower section from the condensate trap (1) .

2.

Flush out the lower section with water.

3.

Fill the lower section with water up to about 10 mm below the upper edge.

4.

Attach the lower section to the condensate trap.

12.12 Cleaning the strainer in the cold water inlet


12.13 Installing the compact thermal module

8

7

6

1

2

3

4

5

1

2

1.

Close the cold-water isolation valve.

2.

Drain the product on the domestic hot water side.

3.

Unscrew the union nut (2) and the lock nut (1) from the product's housing.

2 1

4.

Hinge the electronics box forward.

5.

Remove the clamp (2) .

6.

Remove the pipe (1) from the product.

7.

Rinse the strainer under a jet of water, holding it against the direction of flow.

8.

If the strainer is damaged or it can no longer be cleaned sufficiently, you must replace the strainer.

9.

Refit the pipe.

10. Reinsert the clamp.

11. Always use new seals and retighten the union nuts and the lock nut.

12. Open the cold-water isolation valve.

1.

Connect the compact thermal module (2) to the heat exchanger (1) .

2.

Tighten the four new nuts (8) across the diagonal until the burner flange fits closely and uniformly onto the mating surfaces.

– Tightening torque:6 Nm, if a torque spanner is available

3.

Reconnect the plugs (3) to (7) .

4.

Connect the gas pipe using a new seal. In the process, secure the gas pipe against twisting.

5.


6.

Make sure that there are no leaks.

7.

Check that the sealing ring in the air intake pipe is positioned correctly in the seal seat.

8.

Reconnect the air intake pipe to the intake stub.

9.

Secure the air intake pipe with the retaining screw.

10. Check the gas flow pressure.

12.14 Draining the product

1.

Close the service valves of the product.

2.

Start the check programme P.06

(prioritising diverter valve mid-position).

3.

Open the drain valves.

4.

Make sure that the cap of the automatic air vent on the internal pump is open so that the product can be drained fully.

12.15 Checking the pre-charge pressure for the internal expansion vessel

1.

Close the service valves and drain the product.

2.

Measure the pre-charge pressure of the expansion vessel at the vessel valve.

Condition : Pre-charge pressure < 0.075 MPa (0.75 bar)

▶

Ideally, you should top up the expansion vessel with nitrogen. Otherwise, top it up with air. Ensure that the drain valve is open when topping up.

3.

If water escapes from the valve of the expansion vessel, you must replace the expansion vessel.

( → Page 49)

4.

Fill the heating installation. ( → Page 35)


5.

Purge the heating installation. ( → Page 35)

12.16 Checking the filling pressure of the heating installation

1.

Check the filling pressure of the heating installation, top it up with heating water, if necessary, and purge it.

2.

Fill the heating installation. ( → Page 35)

3.

Purge the heating installation. ( → Page 35)

12.17 Checking the quality of the heating water

▶

Check the quality of the heating water: Clarity (clouding),

correct inhibitor and pH value. ( → Page 33)

12.18 Completing inspection and maintenance work

▶

Start a test operation after the maintenance.

▶

Check the heating mode and, if required, the domestic hot water generation (if available).

▶

Carry out a gas family check. ( → Page 33)

▶

Check the gas flow pressure. ( → Page 36)

▶

Check and, if required, adjust the CO ₂ content and the

CO/CO ₂

ratio (air ratio setting). ( → Page 37)

▶

If required, reset the maintenance interval. ( → Page 39)

▶


▶

Fill out the relevant Service Record section in the Benchmark Checklist.

12.19 Checking the product for leak-tightness

▶

Check that the product is leak-tight. ( → Page 38)

13 Troubleshooting

13.1

Checking service messages appears if you have set a maintenance interval, for example, and this has passed or a service message is issued.

The product is not in fault mode.

▶

Navigate to Menu → Live monitor and confirm by pressing .

Condition : S.40

is displayed

The product is in Comfort protection mode. The product continues to run with restricted comfort after it has detected a fault.

▶

To establish whether or not a component is defective,

read the fault memory. ( → Page 45)

Note

If no fault message is present, the product will automatically switch back to normal operating mode after a certain time.

13.2

Eliminating faults

▶

If fault messages ( F.XX

) occur, eliminate the faults by checking the table in the appendix or using the function menu or the check programmes.

Overview of fault codes ( → Page 60)

Function menu –


Check programmes –


If several faults occur at the same time, the display shows the corresponding fault messages for two seconds each in alternation.

▶

Press (max. three times) to restart the product.

▶

If you are unable to eliminate the fault and the fault recurs despite reset attempts, contact customer service.

13.3

Calling up and clearing the fault memory

The last 10 fault messages are stored in the fault memory.

▶

Navigate to the Fault list menu.

◁

The display shows the number of faults that have occurred, the fault numbers and the corresponding plain text display.

▶

Press or to call up individual fault messages.

▶

Press twice to delete the fault list.

13.4

Resetting parameters to factory settings

1.

Navigate to Menu → Installer level → Diagnostics menu → D.096 Reset to factory settings?

and confirm by pressing .

2.

Set the diagnostics code to 1, and confirm by pressing

.

13.5

Preparing the repair work

1.

Decommission the product.

2.

Disconnect the product from the power mains.

3.


4.

Close the gas isolator cock.

5.

Close the service valves in the heating flow and in the heating return.

6.

Close the service valve in the cold water pipe.

7.

Drain the product if you want to replace water-bearing components of the product.

8.

Make sure that water does not drip on live components

(e.g. the electronics box).

9.

Use only new seals.

13.5.1 Procuring spare parts

The original components of the product were also certified by the manufacturer as part of the declaration of conformity.

If you use other, non-certified or unauthorised parts during maintenance or repair work, this may void the conformity of the product and it will therefore no longer comply with the applicable standards.

We strongly recommend that you use original spare parts from the manufacturer as this guarantees fault-free and safe operation of the product. To receive information about the available original spare parts, contact the contact address provided on the back page of these instructions.

▶

If you require spare parts for maintenance or repair work, use only the spare parts that are permitted for the product.


13.6

Replacing defective components

13.6.1 Replacing the burner

1.

Remove the compact thermal module. ( → Page 42)

1

1

3

2

2

2.

Undo the four screws (1) on the burner.

3.

Remove the burner.

4.

Install a new seal (2) on the new burner.

5.

Install the compact thermal module. ( → Page 44)

13.6.2 Replacing the fan

1

2

7.

Remove the entire unit comprising the fan, Venturi and gas valve assembly from the product.

8.

Unscrew the gas valve assembly fixing screw (2) from the retainer.

9.

Remove the gas valve assembly from the retainer.

10. Remove the Venturi (3) , including the gas connection pipe (1) , from the fan by turning the bayonet fitting on the Venturi anti-clockwise as far as it goes and removing it straight from the fan.

7

3

4

6

5

2

1

1.

Remove the air intake pipe.

2.

Remove the three plugs from the gas valve assembly (5

) .

3.

Remove the plug from the sensor on the Venturi (3) by pushing in the latching lug.

4.

Remove the plug/plugs (4) (depending on the unit design) from the fan motor by pushing in the latching lug in each case.

5.

Unscrew the two union nuts (7) and (6) on the gas valve assembly. Use an open-ended spanner to counterhold the opposite side of the gas valve assembly when unscrewing.

6.

Unscrew the three screws (2) between the mixture pipe

(1) and the fan flange.

11. Remove the gas valve assembly retainer (1) from the fan by unscrewing the three screws (2) .

12. Replace the defective fan.


2

1

4.

Unscrew the two union nuts (5) and (4) on the gas valve assembly. Use an open-ended spanner to counterhold the opposite side of the gas valve assembly (4) and (5) when unscrewing.

5.

Either remove the unit comprising the fan with gas valve

assembly (Replacing the fan ( → Page 46)), or use an

offset screwdriver or Torx T20 socket to unscrew the fixing screw of gas valve assembly (3) from the retainer.

5

3

4

Note

The screw in the gas valve assembly retainer secures the gas valve assembly against turning and must be screwed back in once the gas valve assembly has been replaced.

13. Refit the components in the reverse order. New seals

(4) and (5) must be used for this. 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) .

14. Screw the flexible gas supply to the gas valve assembly. Use new seals for this.

15. When tightening the union nut on the gas valve assembly, use an open-ended spanner to counterhold the opposite side of the gas valve assembly.

16. Perform a gas family check after installing the new fan.

( → Page 33)

13.6.3 Replacing the gas valve assembly

Note

To replace the gas valve assembly, you will need a Torx T20. To replace the gas valve assembly directly from the front, you will need an offset screwdriver or a Torx T20 socket. If you do not have access to an offset screwdriver or the like, you must first remove the entire unit comprising the fan with gas valve assembly before you can remove the gas valve assembly from the retainer.

6.

Remove the gas valve assembly from the retainer.

7.

Reinstall the new gas valve assembly in the reverse order. Use new seals for this.

8.

When tightening the union nuts on the gas valve assembly, use an open-ended spanner to counterhold the opposite side of the gas valve assembly (4) and (5) .

9.

After installing the new gas valve assembly, perform

a leak-tightness test ( → Page 38), gas family check

( →

Page 33) and gas setting ( → Page 36).

13.6.4 Replacing the Venturi

1

2

5 1

2

3

1.


2.


3.

Unscrew the union nuts (3) of the gas connection pipe

(2) on the gas valve assembly.

4.

Remove the Venturi, including the gas connection pipe, from the fan by turning the bayonet fitting on the Venturi anti-clockwise as far as it goes and removing it straight from the fan.

4

3

1.


2.

Remove the three plugs from the gas valve assembly

(2) .

3.



7

6

5

1

2

1

2

3

4

3

5.

Remove the gas connection pipe (1) from the Venturi

(3) by removing the clamp (4) and pulling the gas connection pipe out vertically. Dispose of the seal (7) .

6.

Pull the gas injector (6) straight off, and keep it for reuse.

7.

Check whether the Venturi is free of residue at the gas inlet side.

Caution.

Risk of material damage to the product.

Lubricant can block function-related channels in the Venturi.

▶

Do not use lubricant when installing the gas restrictor.

4.

Remove the clamps (2) and (3) from the flow connection and the return connection.

5.

Detach the flow connection.

6.

Detach the return connection.

7.

Remove two screws (1) on each of the two retainers.

1

2

8.

Ensure that you use the correct gas injector (colour coding and position of pins on the underside of the gas injector). The colour of the gas injector must match the colour of the coding resistor on the PCB.

9.

Insert the gas injector for the gas group in question into the new Venturi (yellow: G20 natural gas, grey: Liquefied petroleum gas).

10. When inserting the gas injector, ensure that the gas injector is correctly aligned using the indicated position marks on the upper side of the Venturi and also the positioning pins (5) on the underside of the gas injector.

11. Refit the components in the reverse order. Use new seals for this.

12. After installing the new Venturi, carry out a gas setting.

( → Page 36)

13. If you cannot adjust the CO2 content, the gas injector has been damaged during installation. In this case, replace the gas injector with an appropriate spare part.

14. Perform a gas family check. ( → Page 33)

8.

Remove the lower three screws (2) on the rear section of the retainer.

9.

Swing the retainer to the side around the top screw (1) .

10. Pull the heat exchanger downwards and to the right, and remove it from the product.

11. Install the new heat exchanger in reverse order.

12. Replace the seals.

Note

Instead of grease, use only water or commercially available soft soap to aid installation.

13.6.5 Replacing the heat exchanger

1.

Drain the product. ( → Page 44)

2.

Remove the compact thermal module. ( → Page 42)

3.

Detach the condensate discharge hose from the heat exchanger.

13. Insert the flow and return connections into the heat exchanger as far as they will go.

14. Make sure that the clamps are seated correctly on the flow and return connections.

15. Install the compact thermal module. ( → Page 44)

16. Fill and purge the product and, if necessary, the heating

installation. ( → Page 35)


13.6.6 Replacing the expansion vessel

1.


1

1

2

3

4

2.

Undo the screwed connection (4) .

3.

Remove both screws (1) on the support plate (2) .

4.

Remove the support plate (2) .

5.

Pull out the expansion vessel (3) towards the front.

6.

Insert the new expansion vessel into the product.

7.

Screw the new expansion vessel to the water connection. Use a new seal for this.

8.

Attach the support plate using both screws (1) .

9.

Fill and purge the product and, if necessary, the heating

installation. ( → Page 35)

13.6.7 Replacing the PCB or the display

Note

If you only replace one component, when the product is switched on, the new component adopts the parameters that were previously set from the component that was not replaced.

1.


2.

Replace the PCB or display according to the assembly and installation instructions supplied.

1

3.

If you are replacing the PCB, remove the coding resistor (1) (plug X24) from the old PCB and plug the plug onto the new PCB.

4.


13.6.8 Replacing the PCB and the display

1.


2.

Replace the PCB and display according to the assembly and installation instructions supplied.

3.

Remove the coding resistor (1) (plug X24) from the old

PCB and plug the plug into the new PCB.

4.


5.

Press the on/off button on the product. ( → Page 32)

◁

After switching on, the product switches directly to the menu to select the language. The factory-set language setting is English.

6.

Select the required language and confirm by pressing

.

◁

You are automatically taken to D.093

to set the device specific number.

7.

Set the correct value for the relevant product type in accordance with the table below and confirm by pressing

.

Product type number











1

3

4

4

9

14

14

20

6

10



10

13


17

◁

The electronics are now set to the product type and the parameters of all diagnostics codes are set to factory settings.

◁

The installation assistant starts.

8.

Make the system-specific settings.


13.7

Completing repair work

1.

Establish the power supply.

2.

Switch the product back on if this has not yet been

done. ( → Page 32)

3.


4.

Open all service valves and the gas stopcock.

13.8

Checking the product for leak-tightness

▶

Check that the product is leak-tight. ( → Page 38)

14 Decommissioning

14.1

Temporarily decommissioning the product

▶

Press the on/off button.

◁

The display goes out.

▶


▶

For products with domestic hot water generation and products with a connected domestic hot water cylinder, you must also close the cold-water isolation valve.

14.2

Permanently decommissioning the product

▶

Press the on/off button.

◁

The display goes out.

▶


▶


▶

Close the cold-water isolation valve.

▶


15 Recycling and disposal

Disposing of the packaging

▶

Dispose of the packaging correctly.

▶

Observe all relevant regulations.

▶

For detailed information refer to www.vaillant.co.uk.


Appendix

A Inspection and maintenance work

22

23

24

25

26

27

28

29

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If national regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed. Each time inspection and maintenance work is carried out, carry out the required preparatory and completion work.

#

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

30

31

Maintenance work Interval

Record all of the analysis results in the Benchmark Checklist in these instructions

Ask the end user whether any significant problems occur when operating the product

Use the diagnostics system to check the product's fault history

Visually inspect whether the air/flue pipe and its opening have been installed correctly in accordance with the set-up instructions

Check that the unit has been installed correctly and the connections have been secured

Check that the condensate pipe is in good condition, that it is leak-tight and that the drain is correct

Check whether all of the externally routed condensate pipes are dimensioned correctly and have been insulated sufficiently (frost protection)

Check whether the gas flow rate corresponds with the specifications on the data plate and lies within the tolerances specified in these instructions

If the gas flow rate lies outside of the tolerances specified in these instructions, eliminate the fault in accordance with the regulations and the current technology

Check the general condition of the product and, if required, eliminate any faults that are found

Carry out the combustion analysis: Measure the CO content, CO ₂ content and the CO/CO ₂ ratio. For products with a rear air/flue connection: The combustion analysis can only be carried out when the unit casing has been removed; it is not necessary to test these products for flue gas recirculation

Check the product's recirculation at the supply air test point on the air/flue pipe. If required, inspect the entire air/flue system and, if necessary, correct the fault

Disconnect the product from the electrical installation

Check and, if required, correct the electrical installation

Removing dirt from the product and the vacuum chamber

Visually check the heat cell to ascertain its condition and detect any corrosion, rust or damage, and carry out maintenance work, if required

Check that the gas stopcock and service valves function correctly

Check the quality of the heating water: Clarity (clouding), correct inhibitor and pH value

Removing the compact thermal module

Check the burner for damage

Checking the insulating mats in the combustion area and replacing damaged insulating mats

Cleaning the heat exchanger

Cleaning the condensate trap

Filling the condensate trap

Installing the compact thermal module

Checking the pre-charge pressure of the expansion vessel

Cleaning the strainer in the cold water inlet

Check the impeller sensor for dirt/damage

If the water volume is insufficient (domestic hot water) or the outlet temperature is insufficient, check the secondary heat exchanger

Reassemble the product

Opening the service valves

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually

Annually at regular intervals at regular intervals at regular intervals at regular intervals

Annually

Annually at regular intervals at regular intervals at regular intervals at regular intervals at regular intervals

After each time maintenance work is carried out

Annually

42

44

43

44

34

44


#

32

33

34

35

36

37

Maintenance work

Filling the heating installation

Completing inspection and maintenance work

Perform the gas family check

Visually check the ignition and burner behaviour

Checking the CO/CO ₂ content following maintenance work

Check the product for gas, flue gas, water and condensate leaks

B Installer level

–

Overview

Setting level Values

Min.

Max.

Installer level →

Enter code 00 99

Unit

–

Interval at regular intervals

Annually at regular intervals

Annually

Annually

Annually

Increment, select, explanation

1 (competent person code 17)

Installer level → Fault list →

F.XX

– F.XX

¹

Installer level → Test programs →

Gas family check

Current value

Current value

Installer level → Test programs → Check programs →

P.00 Purging – –

P.01 Maximum load

P.02 Minimum load

P.06 Filling mode

–

–

– –

–

–

–

–

–

–

–

–

LPG, natural gas

Yes, No

Yes, No

Yes, No

Yes, No

–

Installer level → Test programs → Function menu →

T.01 Internal pump – –

T.02 3-way valve

T.03 Fan

–

–

–

–

T.04 Cylinder charging pump

T.05 Circulation pump

T.06 External pump

T.08 Burner

–

–

–

–

–

–

–

– –

–

–

–

–

–

–

On, Off

On, Off

On, Off

On, Off

On, Off

On, Off

On, Off

Installer level → Test programs → Electronics self-test →

Self-test – – – Yes, No

Installer level → Appliance config.

→

Language – – – Languages available for selection

Target flow temp.

30 75 ℃ 1

DHW temperature 30 60 ℃ 1

Product with domestic hot water generation or connected domestic hot water cylinder

Comfort mode – – – On, Off

¹ Fault lists are only displayed, and can only be deleted, if faults have occurred.

Factory setting

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

Countryspecific

–

–

Off

35

45


Setting level

Auxiliary relay

Accessory relay 1


Min.

1

1

1

Values

Max.

10

10

10

Unit

–

–

– kW

–

Increment, select, explanation

1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extraction hood

5 = External solenoid valve

6 = External fault message

7 = Solar pump (not active)

8 = eBUS remote control (not active)

9 = Anti-legionella pump (not active)

10 = Solar valve (not active)


2 = External pump


4 = Extraction hood








2 = External pump


4 = Extraction hood







Partial load only, full load only, auto

0 – 9

Factory setting

2

2

2


Contact details

Factory setting

–

Phone number

–

–

–

–

Installer level → Diagnostics menu →

D.XXX

– D.XXX

Current value

– On, Off

Auto

–

–

– – –

Installer level → Start inst. assistant →

Language – – – Languages available for selection

Filling mode: 3-way valve is in midposition

0 2 – 0 = Normal operating mode

1 = Mid-position (parallel operation)

2 = Permanent heating position

Purge program: Select circ. using

+/-

– – – Automatic adaptive purging of the heating circuit and domestic hot water circuit

Not active

Active

Target flow temp.

DHW temperature

30

35

75

60

℃

℃

1

1

Product with domestic hot water generation

Comfort mode


–

–

–

–

– kW

On, Off

Partial load only, full load only, auto


Countryspecific

–

–

–

–

–

Auto


Setting level Values

Unit Increment, select, explanation

Min.

Max.

Auxiliary relay


1

1

10

10

–

–


2 = External pump


4 = Extraction hood








2 = External pump


4 = Extraction hood







Accessory relay 2 1 10 – 1 = Circulation pump

2 = External pump


4 = Extraction hood







Contact details

End the installation assistant?

Phone number –

– – –

0-9

Yes, No


Factory setting

2

C Overview of diagnostics codes

Note

Since the code table is used for various products, some codes may not be visible for the product in question.

2

2

–

–

Code Parameter

D.000 Heating partial load

D.001 Pump overrun: Heating

D.002 Max. anti-cycl. time: Heating

D.003 Outlet temperature actual value

Values or explanations

Adjustable partial heat load in kW

Auto: Product automatically adjusts max. partial load to current system demand

1 to 60 min

2 to 60 min

In °C

D.004 Cylinder temperature actual value In °C

D.005 Heating target flow temperature

D.006 Outlet temperature target value

In °C; the maximum value that is set in D.071

and is restricted by means of an eBUS control if such a control is connected

35 to 65 ℃

Factory setting

Auto

5 min

20 min

Own setting

Not adjustable

Not adjustable

Not adjustable

Not adjustable


Code Parameter

D.007 Comfort mode target value

APC target value

Cylinder temperature target value

D.008 Controller 3-4

D.009 eBUS controller target value


Product with integrated domestic hot water generation, and product with integrated domestic hot water generation and shift-load cylinder

35 to 65 ℃

Product with heating mode only

Frost protection is at 15 °C, then 40 to 70 °C (max.

temperature can be adjusted under D.020

)

Room thermostat open (no heat requirement)

Room thermostat closed (heat requirement)

In °C

D.010 Internal pump

D.011 External pump

On, Off

On, Off

Factory setting

D.012 Cyl. charging pump

D.013 Circulation pump

D.017 Control type

D.018 Pump operating mode

D.019 Pump operating mode: 2-stage pump

On, Off

On, Off

D.014 Pump speed target value Target value of internal high-efficiency pump in %. Possible settings:

0 = Auto

1 = 53

2 = 60

3 = 70

4 = 85

5 = 100

Actual value for internal high-efficiency pump in % D.015 Pump speed actual value

D.016 Controller 24 V DC: Heating mode Heating mode off/on

0 = Auto

Control type:

0 = Flow, 1 = Return

Return: Automatic detection function for heat output inactive. Max. possible partial heat load when D.000

is on Auto .

1 = Comfort (continuously operating pump)

Internal pump is switched on when the heating flow temperature is not at Heating off and the heat requirement is enabled via an external control

3 = Eco (intermittently operating pump)

Internal pump is switched on every 25 minutes for 5 minutes once the overrun time has elapsed

Setting for two-stage pump operating mode

0: Burner mode stage 2, pump prerun/overrun stage 1

1: Heating mode and pump prerun/overrun stage 1, domestic hot water mode stage 2

2: Automatic heating mode, pump prerun/overrun stage 1, domestic hot water mode stage 2

3: Always stage 2

4: Automatic heating mode, pump prerun/overrun stage 1, domestic hot water mode stage 1

Adjustment range: 50 – 70 °C ( actoSTOR 65 °C)

0 = Flow

3 = Eco

2

65 °C D.020 Max. DHW temperature target value

D.022 DHW demand On, Off

Heating on, heating off (summer mode) D.023 Heating mode status

D.025 Ext. eBUS signal: Cylinder charging

On, Off

Own setting

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable



Code Parameter

D.050 Offset min. speed

D.051 Offset max. speed

D.058 Solar post-heating

D.060 Number of safety therm. shutdowns

D.061 No. of shut-downs in ign. flame controller

D.064 Avg. ignition time

D.065 Max. ignition time

D.067 Remaining anti-cycl. time for heating

D.068 Number of first start attempts

D.069 Number of second start attempts


In rpm, adjustment range: 0 to 3000

In rpm, adjustment range: -990 to 0

0 = Solar post-heating deactivated

3 = DHW activation target value minimum 60 °C, thermostatic mixing valve required between product and drawoff point

Number of shutdowns

Factory setting

Nominal value set in factory

Nominal value set in factory

0 = Solar post-heating deactivated

Number of unsuccessful ignitions in the last attempt

In seconds

In seconds

In minutes

Number of unsuccessful ignitions

Number of unsuccessful ignitions

Own setting

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

D.070 3-way valve operation

D.071 Max. heating target flow temp.

D.072 Pump overrun after cylinder charging

D.073 Offset setting for comfort mode

D.074 Anti-legionella funct. with integrated cyl.

D.075 Max. cylinder charging time

D.076 Device Specific Number

D.077 DHW partial load

D.078 DHW max. flow temperature

D.080 Heating operating hours

0 = Normal operating mode

1 = Parallel operation (mid-position)

2 = Permanent heating position

40 to 80 ℃

0 = Normal operating mode

75 ℃

Adjustable from 0 – 10 minutes in increments of 1 minute 2 mins

Adjustable from -15 K to 5 K

0 = Off

1 = On

20 – 90 min

Device specific number = DSN

1 = VU 126/5-5 (H-GB) ecoTEC plus 612


4 = VU 186/5-5 (H-GB) ecoTEC plus 618, VU 186/5-5

(P-GB) ecoTEC plus 618


14 = VU 306/5-5 (H-GB) ecoTEC plus 630, VU 306/5-5

(P-GB) ecoTEC plus 630


6 = VUW 196/5-5 (H-GB) ecoTEC plus 825

10 = VUW 246/5-5 (H-GB) ecoTEC plus 832, VUW

246/5-5 (P-GB) ecoTEC plus 832

62 = VUW 306/5-5 (H-GB) ecoTEC plus 835

17 = VUW 286/5-5 (H-GB) ecoTEC plus 838, VUI 286/5-

5 (H-GB) ecoTEC plus 938

Adjustable cylinder charging output in kW

Limit on cylinder charging temperature in °C

50 °C – 80 °C

Note

The chosen value must be at least 15 K or 15 °C above the target cylinder value.

In hours (h)

0

1 = On

45 mins

Not adjustable

75 °C

D.081 DHW operating hours

D.082 Heating burner starts

In hours (h)

Number of burner start-ups

Not adjustable

Not adjustable

Not adjustable


Code Parameter

D.083 DHW burner starts

D.084 Maintenance in

D.088 Min. DHW flow rate

D.090 eBUS controller

D.091 Status DCF77

D.092 actoSTOR communication status

D.093 Adjust Device Specific Number

D.094 Clear fault history

D.095 Software version: PeBUS participant

D.096 Reset to factory settings?

D.098 Coding resistor


Number of burner start-ups

Factory setting

Own setting

Not adjustable

Adjustment range: 0 to 3000 hrs and "---" for deactivated „---”

Switch-on delay for domestic hot water draw-off detection via impeller (only products with integrated domestic hot water generation)

0 = 1.5 l/min and no delay,

1 = 3.7 l/min and 2 sec. delay

Status of digital control

Recognised, not recognised

Status of DCF with outdoor temperature sensor connected

No reception

Reception

Synchronised

Valid actoSTOR module detection

0 = Not connected

1 = Connection fault: No communication via PeBus, actoSTOR module was previously detected

2 = Connection active

Device Specific Number (DSN)

Adjustment range: 0 to 99

Delete fault list

0 = No

1 = Yes

PCB (BMU)

Display (AI) actoSTOR (APC)

HBI/VR34

Reset all adjustable parameters to factory setting

0 = No

1 = Yes

Display xx.yy

xx = Coding resistor 1 in cable harness for output range:

8 = VU 126/5-5 (H-GB) ecoTEC plus 612; VU 156/5-5

(H-GB) ecoTEC plus 615; VU 186/5-5 (H-GB) ecoTEC plus 618, VU 186/5-5 (P-GB) ecoTEC plus 618; VUW

196/5-5 (H-GB) ecoTEC plus 825

9 = VU 246/5-5 (H-GB) ecoTEC plus 624; VUW 246/5-5

(H-GB) ecoTEC plus 832; VUW 246/5-5 (P-GB) ecoTEC plus 832

10 = VU 306/5-5 (H-GB) ecoTEC plus 630; VU 306/5-5

(P-GB) ecoTEC plus 630; VUW 306/5-5 (H-GB) ecoTEC plus 835

11 = VU 386/5-5 (H-GB) ecoTEC plus 637; VUW 286/5-

5 (H-GB) ecoTEC plus 838; VUI 286/5-5 (H-GB) ecoTEC plus 938 yy = Coding resistor 2 on PCB for gas group:

02 = P gas

03 = H gas

07 = L gas

1.5 l/min and no delay

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable


D Status codes

–

Overview

Note


Code Meaning

S.00 Heating: No heat demand

S.01 Heating mode: Fan startup

S.02 Heating mode: Pump pre-run

S.03 Heating mode: Ignition

Heating has no heat demand. The burner is off.

The fan start-up for heating mode is activated.

The pump prerun for heating mode is activated.

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: Anti-cycling time

S.10 DHW demand

The ignition for heating mode is activated.

The burner for heating mode is activated.

The pump/fan overrun for heating mode is activated.

The fan overrun for heating mode is activated.

The pump overrun for heating mode is activated.

The anti-cycling time for heating mode is activated.

The domestic hot water demand is activated.

S.11 DHW mode: Fan start-up The fan start-up for domestic hot water mode is activated.

S.13 DHW mode: Ignition

S.14 DHW mode: Burner on

The ignition for domestic hot water mode is activated.

The burner for domestic hot water mode is activated.

S.15 DHW mode: Pump/fan overrun

The pump/fan overrun for domestic hot water mode is activated.

S.16 DHW mode: Fan overrun The fan overrun for domestic hot water mode is activated.

S.17 DHW mode: Pump overrun

S.20 DHW demand

The pump overrun for domestic hot water mode is activated.

The domestic hot water demand is activated.

S.21 DHW mode: Fan start-up The fan start-up for domestic hot water mode is activated.

S.22 DHW mode: Pump prerun

S.23 DHW mode: Ignition

S.24 DHW mode: Burner on

The pump prerun for domestic hot water mode is activated.

The ignition for domestic hot water mode is activated.

The burner for domestic hot water mode is activated.

S.25 DHW mode: Pump/fan overrun

The pump/fan overrun for domestic hot water mode is activated.

S.26 DHW mode: Fan overrun The fan overrun for domestic hot water mode is activated.

The pump overrun for domestic hot water mode is activated.

S.27 DHW mode: Pump overrun

S.28 DHW anti-cycling time The anti-cycling time for domestic hot water mode is activated.

S.30 No heat demand: Controller

S.31 No heat demand: Summer mode

S.32 Waiting time deviation:

Fan speed

S.34 Heating mode: Frost protection

Room thermostat blocks heating mode.

Summer mode is activated; there is no heat demand.

The waiting period for the fan start-up is activated.

The frost protection function for heating mode is activated.

S.39 Contact thermostat triggered

S.40 Comfort protection active

The surface-mounted thermostat or the condensate pump has triggered.

The comfort protection mode is activated.

S.41 Water pressure too high The system pressure is too high.

S.42 Flue non-return flap closed

Flue non-return flap return signal blocks burner operation (only in conjunction with the multi-functional module) or condensate pump defective, heat demand is blocked.


Code Meaning

S.46 Comfort protection: Minimum load, loss of flame

S.53 Waiting time: Water shortage

S.54 Waiting time: Water shortage

S.57 Waiting time: Measuring program

Comfort protection mode for flame loss at minimum load is activated.

The product is within the waiting period of the modulation block/operating block function as a result of a water deficiency (flow/return spread too large).

Product is in the waiting period of the operation blocking function as a result of low water pressure

(temperature gradient).

The product is within the waiting period as a result of the measuring programme.

S.58 Burner modulation limitation

The burner modulation limitation is activated.

S.61 Fault: Incorrect gas type The coding resistor on the PCB does not match the entered gas group (see also F.92).

S.62 Adjust CO2

S.63 Fault: Check gas route

S.76 Service message: Check water pressure

S.88 Purging programme is running

S.92 Water circulation volume self-test

S.93 Flue gas measurement not possible

S.96 Return temperature sensor self-test

S.97 Water pressure sensor self-test

S.98 Flow/return temperature sensor self-test

S.99 Vaillant self-test

Set the CO

2 content.

A fault message is activated. Check the gas route.

A service message is activated. Check the water pressure.

The purge programme is activated.

The self-test for the water circulation volume is activated.

Flue gas analysis is not currently possible.

The self-test for the return temperature sensor is activated.

The self-test for the water pressure sensor is activated.

The self-test for the flow/return temperature sensor is activated.

The Vaillant self-test is activated.

E Overview of fault codes

Note


Code/meaning Possible cause

F.00

Interruption: Flow sensor Flow temperature sensor defective or not connected

F.01

Interruption: Return sensor Return temperature sensor defective or not connected

F.02

Interruption: DHW outlet sensor

F.03

Interruption: Cylinder sensor

Cylinder temperature sensor for the shift-load cylinder defective or not connected

Temperature sensor for the shift-load cylinder defective or not connected

F.10

Short circuit: Flow sensor

F.11

F.12

F.13

Short circuit: Return sensor

Short circuit: DHW outlet sensor

Short circuit: Cylinder sensor

Flow temperature sensor defective or has short-circuited

Return temperature sensor defective or has short-circuited

Cylinder temperature sensor defective or has short-circuited

Warm start sensor/cylinder temperature sensor defective or not connected

F.20

Safety switch-off: Temperature limiter

Maximum temperature at the flow/return temperature sensor is too high when the safety cutout function is operating using the NTC

Measure

▶

Check: Flow temperature sensor, plug, cable harness, PCB.

▶

Check: Return temperature sensor, plug, cable harness, PCB.

▶

On the shift-load cylinder, check (only in conjunction with

F.91): Plug, cable harness, temperature sensor.

▶

On the shift-load cylinder, check (only in conjunction with

F.91): Temperature sensor plug, temperature sensor, PCB plug, cable harness.

▶

Check: NTC plug, cable harness, cable/housing, PCB, NTC sensor.

▶

Check: NTC plug, cable harness, housing, PCB, NTC sensor.

▶

Check (only in conjunction with F.91): NTC plug, cable harness, NTC sensor, PCB.

1.

Check: NTC plug, earth connection, cable harness, NTC sensor, PCB.

2.

Check the following on the shift-load cylinder (in conjunction with F.91): NTC plug, earth connection, cable harness, NTC sensor, connection to the PCB.

▶

Check: Flow temperature sensor (correct thermal connection), cable harness, sufficient purging.


Code/meaning

F.22

Safety switch-off: Low water pressure

F.23

Safety switch-off:

Temp.spread too large

F.24

Safety switch-off: Temp.

incr. too fast

F.25

Safety switch-off: Flue temp. too high

Possible cause

No/insufficient water in the product or the water pressure is too low

Temperature spread too great.

Water circulation too low

Temperature increase too fast flue gas temperature too high

Measure

1.

Check: Plug, cable to heating pump or water pressure sensor, water pressure sensor, heating pump.

2.

Activate and purge check programme P.0.

▶

Check: Plug, cable to heating pump/water pressure sensor, air/insufficient water in the heating circuit, flow and return temperature sensor inverted, strainer in the hydraulic block, water pressure sensor, heating pump (sufficient circulation, level 2:

D.19, D.14, non-return valve). Activate check programme P.0.

▶

Check: Plug, cable to the heating pump, air/insufficient water in the heating circuit, internal air vent (function), heating pump

(system pressure too low, temperature gradient too great on heating flow, non-return valve). Activate check programme P.0.

▶

Check: Plug, safety cut-out plug, cable harness, cable to the heating pump, internal air vent (function), flue gas route (blockage, adverse wind conditions, flue pipework too long), insufficient water in heating circuit, heating pump, activate check programme P.0.

▶

Check: Gas valve assembly stepper motor (plug, cable, passage for rinsing, voltage), multiple plug, cable harness.

F.26

Fault: Fuel valve not working

F.27

Safety switch-off: Flame simulation

F.28

Start-up failure: Ignit. unsuccessful

F.29

Operating failure: Ignit.

unsuccessful

F.32

Fault: Fan

F.42

Fault: Coding resistor

F.49

Fault: eBUS

F.52

Mass flow sensor not connected

F.53

Fault: Mass flow sensor

Gas valve assembly stepper motor defective or not connected

Monitoring electrode reports an incorrect flame

Failure during start-up or ignition unsuccessful. Gas pressure monitor or thermal cut-out has been triggered.

Gas supply interrupted intermittently. Re-ignition failed.

Fan defective or not connected

Coding resistor or gas group resistor causes a short circuit

Undervoltage on the eBUS

Mass flow sensor defective or not connected

Mass flow sensor defective

▶

Check: Gas pressure at upper test opening, monitoring electrode, PCB, gas solenoid valve.

▶

Check: Gas stopcock, gas flow pressure, gas valve assembly, air intake pipe (blockage, loosened screw), condensate route

(blockage), multiple plug, cable harness, ignition transformer, ignition cable, ignition plug, ignition electrode, monitoring electrode, electronics, earthing, CO ₂ setting.

▶

Check: Flue gas recirculation, condensate route (blockage), earthing, cable to the gas valve assembly and electrode (loose connection).

▶

Check: Plug, cable harness, fan (blockage, function, correct speed), Hall sensor, PCB, flue gas route (blockage).

▶

Check: Plug, earth connection, cable, output coding resistor (in the cable harness).

▶

Check: eBUS (overload, two power supplies with different polarities, short circuit).

▶

Check: Plug, cable harness, mass flow sensor.

▶

Check: Filter below Venturi filter cap wet or blocked, gas flow pressure too low, internal pressure measuring point in the Venturi is blocked (do not use any lubricants on the O-ring in the

Venturi).

▶

Check (in conjunction with F.28/F.29): Gas stopcock, gas valve assembly, plug, cable harness.

F.54

Fault: Boiler start

F.55

Fault: CO sensor

F.56

Safety switch-off: CO limit exceeded

No gas inlet pressure or insufficient gas inlet pressure causes faults when the product is started

All-gas sensor defective or has short-circuited

Safety shutdown after the CO limit value is exceeded

▶

Check: Plug, cable harness, all-gas sensor, PCB.

▶

Check: Gas valve assembly, plug, cable harness. If the fault occurs again after being cleared, the gas valve assembly is defective.

▶

Check: Ignition electrode, PCB (microcontrol).

F.57

Fault: Measuring program Regulation fault caused by corroded ignition electrode

F.61

Fault: Fuel valve actuation The gas valve assembly cannot be actuated

F.62

Fault: Fuel valve switch-off delay

F.63

Fault: EEPROM

Delayed switch-off sequence for the gas valve after the flame is extinguished

EEPROM faulty

F.64

Fault: Electronics/sensor Electronics, safety-relevant sensor or cable defective

F.65

Fault: Electronics temp.

F.67

Fault: Electronics/flame

Electronics defective or too hot due to external influences

Implausible flame signal

▶

Check: Cable harness, plug, gas valve assembly (rinse), PCB.

▶

Check: Gas valve, surface of the burner (dirt), plug, cable harness, PCB.

▶

Replace: PCB.

▶

Check: Flow sensor, cable to the sensor, flame recording sensor (e.g. ionisation electrode) for an unstable signal, electronics.

1.

Check: PCB.

2.

If required, reduce the environmental temperature.

▶

Check: Cable harness, flame monitor, PCB.


Code/meaning

F.68

Fault: Flame signal unstable

F.70

Fault: Invalid Device Specific Number

F.71

Fault: Flow sensor

F.72

Fault: Flow/return sensor

F.73

Fault: Water press. sensor

(signal too weak)

F.74

Fault: Water press. sensor

(signal too strong)

F.75

Fault: Pump/ water shortage

F.77

Fault: Flue non-ret.

valve/condens. pump

F.78

Interrupt.: DHW outlet sensor on ext. contr.

F.80

Fault: actoSTOR inlet sensor

F.81

Fault: cylinder charging pump

F.82

Fault: Ext. current anode

F.83

Fault: NTC temp. gradient Temperature difference between flow and return temperature sensor is too small

F.84

Fault: NTC temp. diff. implausible

F.85

Fault: NTCs fitted incorrectly

Temperature difference is implausible

Flow/return temperature sensors returning incorrect/implausible values

F.90

Fault: Communication Communication with actoSTOR interrupted

F.91

Fault: actoSTOR sensor

F.92

Fault: Incorrect gas type

F.93

Fault: Check gas route

F.94

Fault: Vortex and differential pressure

Possible cause

Flame monitor reports an unstable flame signal

Incorrect/missing Device

Specific Number or incorrect/missing coding resistor

Flow temperature sensor returns implausible values

Temperature difference between flow and return temperature sensor is too great

Water pressure sensor reports that the water pressure is too low

Water pressure too high

Insufficient pressure jump detected when starting the pump

No flue non-return flap feedback; condensate pump overflow

UK link box is connected without the domestic hot water temperature sensor being bridged

Inlet temperature sensor defective or not connected

Cylinder is not fully charged after specified time

External current anode defective or not connected

Measure

▶

Check: Air ratio, gas flow pressure, condensate route (blockage), gas injector, ionisation flow (cable, electrode), flue gas recirculation.

▶

If the display and PCB have been replaced, change the Device

Specific Number under D.93

.

▶

Check: Flow temperature sensor (correct thermal connection).

▶

Check: Flow temperature sensor/return temperature sensor

(function, correct thermal connection).

▶

Check: Water pressure, earth connection, cable, plug, water pressure sensor (short circuit to GDN).

1.

Drain water.

2.

Check the water pressure sensor.

1.

Check: Water pressure sensor, heating pump (blockage), heating circuit (air, sufficient water volume), adjustable bypass, external expansion vessel (must be connected at the return). Activate check programme P.0.

2.

If a low loss header or heating pipes with a diameter greater than 1 1/2 inch are installed, replace the 3/4-inch seal in the heating flow with a screen. If required, install the F.75 service set.

▶

Check: Cable to VR40 accessory, flue non-return flap (wiring, feedback switch), condensate pump, bridge from the surfacemounted thermostat, 2 in 7 multi-functional module (bridge).

1.

Check: Accessory (configuration/electrical connection).

2.

The unit displays a fault, but the unit has not malfunctioned.

▶

Check (only in conjunction with F.91): NTC sensor, plug, cable harness, PCB.

▶

Check (only in conjunction with F.91): Cylinder charging sensor, cylinder sensor, impeller sensor/limiter, prioritising diverter valve, pump, actoSTOR pump (air), cable harness, secondary heat exchanger (blockage).

▶

Check: Cable harness, external current anode. If the external current anode is not installed: Plug edge connector X43 with a bridge into the PCB.

▶

Check: Flow/return temperature sensor (function, correct thermal connection), sufficient water volume.

Sensor on the actoSTOR is defective

The coding resistor on the PCB does not match the gas group that is entered

Combustion quality outside the permitted range

Sensors return implausible values.

▶

Check: Flow/return temperature sensor (correct thermal connection, sensors are inverted).

▶

Check: Flow/return temperature sensor (correct thermal connection).

1.

Check: Plug, check cable harness to the actoSTOR module

(PEBus).

2.

If the product is to be operated without an actoSTOR : Set

D.092=0, if required, plug edge connector X31 into the BMU, if required plug edge connector X1 into the actoSTOR.

▶

Check: Plug, cable harness, sensor.

1.

Check: Coding resistor.

2.

Carry out the gas family check again and enter the correct gas group.

▶

Check: Gas injector (suitable for the gas group), flue gas recirculation, gas group, internal pressure measuring point in the

Venturi (blockage). Do not use any lubricants on the O-ring in the Venturi.

▶

Check: Cable harness, plug, sensors.


Code/meaning

LED actoSTOR Modul actoSTOR communication status

Communication fault

Possible cause actoSTOR communication status: Not connected, Connection error, Connection active

Communication fault between the display and the PCB in the electronics box

F Check programmes

–

Overview

Measure

1.

LED on: Communication OK.

2.

LED flashing: Communication not OK.

3.

LED off: No power supply.

▶

Check: Cable/plug between the display and the PCB.

Check programme

P.00 Purging

P.01 Maximum load

P.02 Minimum load

P.06 Filling mode

Meaning

The internal pump is cyclically actuated. The heating circuit and the domestic hot water circuit are adaptively purged by automatically switching the circuits using the automatic air vent (the automatic air vent's cap must be loose). The active circuit is shown in the display. Press once to start purging the heating circuit. Press once to end the purge programme. Note: The purge programme runs for

7.5 min per circuit and then terminates. Purging the heating circuit: Prioritising diverter valve in heating position, actuation of internal pump for 9 cycles: 30 sec. on, 20 sec. off. Display: Active heating circuit. Purging the domestic hot water circuit: After the above-mentioned cycles have run or the righthand selection button has been pressed again: Prioritising diverter valve in the domestic hot water position, actuation of the internal pump as above. Display: Active domestic hot water circuit.

After successful ignition, the product is operated at maximum heat input.

After successful ignition, the product is operated at minimum heat input.

The prioritising diverter valve is moved to the mid-position. The burner and pump are switched off (to fill or drain the product).

G Function menu

–

Overview

Function menu

T.01 Internal pump

T.02 3-way valve

T.03 Fan

Meaning

The internal pump is switched on and off.

The prioritising diverter valve is moved to the heating or domestic hot water position.

The fan is switched on and off. The fan runs at maximum rotational speed.

T.04 Cylinder charging pump The cylinder charging pump is switched on and off.

T.05 Circulation pump The circulation pump is switched on and off.

T.06 External pump

T.08 Burner

The external pump is switched on and off.

The product starts up and switches to minimum load. The flow temperature is shown in the display.


1

2

H Wiring diagrams

H.1

Wiring diagram, product for heating mode only, 12 - 35 kW

2

X51

X22

4

2

X25

8

7

2

1

11

10

5

3

4

9

6

12

X41 3

4

5

6

1

2

8

X20

17

3

4

16

7

5

2

15

12

13

X51

X100

1

X90

X40 X51

X30

X35

X31

X20

X22

X25

X24

X100

X2

X16

X11

2 1

X18

T2

X12

X1

18

7

17

8

X2

14

13

11

4

12

1

16

X24

3

17

X16

L

N

X18

L

N

X1

RT

L

N

*

3

1

2

3

4

5

6

4

5

6

3

2

1

1

2

+24V

Hallsignal

4

5

PWM

Masse

11

12

13

10

7

8

9

1

3

4

6

1

3

4

M

14

15

16

17

18

C1

C2

24V

230V~

19

20

21

Main PCB

Control panel PCB

3

4

Gas valve assembly

Mass flow sensor


5

9

10

11

12

6

7

8

13

Outdoor temperature sensor, flow temperature sensor (optional, external), DCF receiver

Circulation pump remote control

Power coding resistor

Return temperature sensor

Flow temperature sensor

Fan

Surface-mounted thermostat/burner off

24 V DC room thermostat

Bus connection (digital room thermostat/control)

18

19

20

21

14

15

16

17

*

Prioritising diverter valve


Cylinder temperature sensor

Cylinder contact "C1/C2"

Gas group coding resistor

Additional relay (select via D.026)

Internal pump

Ignition electrode

Depending on product type


1

2

3

4

H.2

Connection diagram, product for heating mode only, ≥ 37 kW

2

X51

X22

4

2

X25

8

7

2

1

11

10

5

3

4

9

6

12

X41 3

4

5

6

1

2

8

X20

17

3

4

16

7

5

2

15

12

13

X51

X100

1

X90

X40 X51

X30

X35

X31

X20

X22

X25

X24

X100

X2

X16

2

X11

1

X18

T2

X12

X1

X16

L

N

X11

L

N

X18

L

N

18

7

17

8

X2

14

13

11

4

12

1

16

X24

3

17

X1

RT

L

N

*

3

3

4

5

6

1

2

4

5

6

3

2

1

3

2

1

19

10

20

1

2

+24V

Hallsignal

4

5

PWM

Masse

11

12

13

10

7

8

9

1

3

4

6

1

3

4

M

14

15

16

17

18

C1

C2

24V

230V~

Main PCB

Operator control panel PCB

Gas valve

Mass flow sensor

5

6

7

8

21

Outside temperature sensor, flow temperature sensor (optional, external), DCF receiver





13

14

15

9

10

11

12


Fan

Contact thermostat/burner off


Bus connection (digital room thermostat/controller)

Diverter valve


20

21

*

16

17

18

19

Cylinder temperature sensor

Cylinder contact "C1/C2"


Auxiliary relay (select via D.026)

Internal pump

Ignition electrode



1

2

3

4

H.3

Connection diagram, product with integrated hot water generation, 12 - 35 kW

2

X51

X51

1

X90

X40 X51

X30

X35

X31

X20

X22

X25

X24

X100

X2

X16

2

X11

1

X18

T2

X12

X1

X100

18

7

17

8

X2

14

13

11

4

12

1

5

3

2

6

X24

3

17

X16

L

N

X18

L

N

X1

RT

L

N

*

X22

4

2

X25

8

7

2

1

11

10

5

3

4

9

6

12

X41 3

4

5

6

1

2

8

X20

17

3

4

16

7

5

2

15

12

13

3

2

1

3

3

4

5

6

1

2

1

2

3

1

3

4

1

3

4

6

M

1

2

+24V

Hallsignal

4

5

PWM

Masse

10

7

8

9

11

12

13

14

15

16

17

18

19

4

5

6

20

21

Main PCB

Operator control panel PCB

Gas valve

Mass flow sensor

5

6

7

8

24V

230V~

22

Outside temperature sensor, flow temperature sensor (optional, external), DCF receiver





13

14

15

16

9

10

11

12


Fan

Contact thermostat/burner off


Bus connection (digital room thermostat/controller)

Diverter valve


Impeller sensor

21

22

*

17

18

19

20

Warm start sensor

Hot water sensor


Auxiliary relay (select via D.026)

Internal pump

Ignition electrode



1

2

3

4

H.4

Wiring diagram, product with integrated domestic hot water generation, ≥ 37 kW

2

X51

X51

1

X90

X40 X51

X30

X35

X31

X20

X22

X25

X24

X100

X2

X16

2

X11

1

X18

T2

X12

X1

X100

18

7

17

8

X2

14

13

11

4

12

1

5

3

2

6

X24

3

17

X16

L

N

X11

L

N

X18

L

N

X1

RT

L

N

*

X22

4

2

X25

8

7

2

1

11

10

5

3

4

9

6

12

X41 3

4

5

6

1

2

8

X20

17

3

4

16

7

5

2

15

12

13

3

3

4

5

6

1

2

1

2

3

1

3

4

1

3

4

6

M

1

2

+24V

Hallsignal

4

5

PWM

Masse

10

7

8

9

11

12

13

14

15

16

17

18

19

3

2

1

3

2

1

20

10

21

4

5

6

Main PCB

Control panel PCB

Gas valve assembly

Mass flow sensor

5

6

7

8

24V

230V~

22

Outdoor temperature sensor, flow temperature sensor (optional, external), DCF receiver





13

14

15

16

9

10

11

12


Fan

Surface-mounted thermostat/burner off


Bus connection (digital room thermostat/control)

Prioritising diverter valve


Impeller sensor

21

22

*

17

18

19

20

Warm start sensor

Domestic hot water sensor


Additional relay (select via D.026)

Internal pump

Ignition electrode



I Commissioning Checklist

Benchmark Commissioning &

Warranty Validation Service Record

It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full.

To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. The warranty rests with the end-user (consumer), and they should be made aware it is ultimately their responsibility to register with the manufacturer, within the allotted time period.

It is essential that the boiler is serviced in line with the manufacturers’ recommendations, at least annually. This must be carried out by a competent Gas

Safe registered engineer. The service details should be recorded on the Benchmark

Service and Interim Boiler Work Record and left with the householder. Failure to comply with the manufacturers’ servicing instructions and requirements will invalidate the warranty.

72

www.hhic.co.uk

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.

Failure to install and commission according to the manufacturers’ instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.

© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk


GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME):

Company name:

Company email:

Gas Safe registration number:

Telephone number:

Company address:

Commissioning date:

Heating and hot water system complies with the appropriate Building Regulations? Yes

Time, temperature control and boiler interlock provided for central heating and hot water

Boiler Plus requirements (tick the appropriate box(s))

Boiler Plus option chosen for combination boiler in ENGLAND

Time and temperature control to hot water

Weather compensation

Load compensation

Cylinder thermostat and programmer/timer

Yes

Smart thermostat with automisation and optimisation

Flue Gas Heat Recovery

Combination boiler

Zone valves

Thermostatic radiator valves

Automatic bypass to system pre-existing pre-existing pre-existing pre-existing

Fitted

Fitted

Fitted

Fitted

Not required

Not required

Not required

Not required

Water quality

What system cleaner was used?

What inhibitor was used?

Brand:

Brand: pre-existing Fitted

CENTRAL HEATING MODE measure and record (as appropriate) m 3/ hr Gas rate (for combination boilers complete DHW mode gas rate)

Central heating output left at factory settings?

If no, what is the maximum central heating output selected?

Dynamic gas inlet pressure

Yes or

instructions

Product:

Product:

Yes

No ft 3 /hr kW mbar

°C

°C Central heating return temperature

System correctly balanced/rebalanced?

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)?

Water scale reducer/softener pre-existing

Yes

Fitted

Yes

No

Not required

Brand: Product:

If yes- DHW expansion vessel

Pressure reducing valve

DOMESTIC HOT WATER MODE Measure and record

Gas rate

Dynamic gas inlet pressure at maximum rate

Cold water inlet temperature

Hot water has been checked at all outlets

CONDENSATE DISPOSAL pre-existing pre-existing m 3/ hr

Yes

The condensate drain has been installed in accordance with the manufacturers’ instructions and/or BS5546/BS6798

Point of termination

Method of disposal

ALL INSTALLATIONS

Internal

Gravity

Yes

Fitted

Fitted or

No

Not required

Not required ft 3 /hr mbar

°C

Temperature °C

External (only where internal termination impractical)

Pumped

Yes

Record the following

At max rate:

At min rate (where possible)

CO ppm CO

2

% CO/CO

2

Ratio

CO ppm CO

2

% CO/CO

2

Ratio

instructions, and readings are correct?

Yes

The operation of the boiler and system controls have been demonstrated to and understood by the customer

The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Yes

Yes

Commissioning Engineer’s signature

Customer’s signature



74

SERVICE & INTERIM BOILER WORK RECORD

It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed.

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:

Gas Safe registration N o :

CO² % CO/CO²

CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m 3 /h delete as appropriate

OR

Yes ft 3 /h

No yes


Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

Comments: yes n/a


Comments: yes n/a

Signature: instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.


Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments: yes n/a



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments: yes n/a



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments:

Signature: yes n/a instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.


Comments: yes n/a




SERVICE & INTERIM BOILER WORK RECORD

It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed.

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the


Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments: yes n/a


Comments: yes n/a



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments: yes n/a



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments: yes n/a



Date:

Engineer name:

Telephone N o :

Max rate CO ppm

Min rate CO ppm

Company name:


CO² % CO/CO²



OR

Yes ft 3 /h

No yes


Comments:

Signature: yes n/a instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.


Comments: yes n/a




J Commissioning Flow Chart

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

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.

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 “Prior to

CO and combustion ratio check” box above before proceeding to the

“Check CO and combustion ratio at maximum rate” stage below.

NO

Is

O

2

20.6% and

CO

2

< 0.2%

YES

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.

Is

O

2

20.6% and

CO

2

< 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 all seals around the appliance burner, internal flue seals, door and case seals.

Rectify where necessary.

Is

CO less than

335ppm and

CO/CO

2

ratio less than 0.004

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. 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

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

Is

CO less than

350ppm and

CO/CO

2


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.

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.

Is

CO less than

350ppm and

CO/CO

2


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

A

Air ratio setting .................................................................... 37

Air/flue pipe ......................................................................... 28

Air/flue pipe, horizontal wall duct......................................... 22

Air/flue pipe, type C13 ......................................................... 22

Air/flue pipe, type C33 ......................................................... 22

Air/flue pipe, vertical roof duct ............................................. 22

Article number ............................................................... 15

–

16

Automatic air vent................................................................ 35

Auxiliary relay ...................................................................... 32

B

Burner anti-cycling time....................................................... 39

Burner anti-cycling time, resetting ....................................... 39

Burner anti-cycling time, setting .......................................... 39

Burner, checking ................................................................. 43

Burner, replacing ................................................................. 46

Bypass valve, setting........................................................... 40

C

CE marking.......................................................................... 15

Check programmes ....................................................... 32

–

33

Checking, pre-charge pressure for the internal expansion

vessel .................................................................................. 44

Circulation pump ................................................................. 30

CO ₂

content, checking......................................................... 37

CO ₂

content, setting ............................................................ 37

Cold water connection......................................................... 25

Cold water inlet strainer, cleaning ....................................... 44

Comfort mode...................................................................... 32

Comfort protection mode..................................................... 45

Compact thermal module ...................................................... 6

Compact thermal module, installing .................................... 44

Compact thermal module, removing ................................... 42

Component test ................................................................... 42

Condensate discharge pipe................................................. 25

Condensate siphon ....................................................... 34, 44

Condensate trap............................................................ 34, 44

Connection dimensions ....................................................... 18

Contact details..................................................................... 32

Control, connecting ............................................................. 29

Corrugated gas pipe.............................................................. 6

D

Decommissioning ................................................................ 50

Decommissioning, temporarily ............................................ 50

Diagnostics codes, calling up .............................................. 39

Disposal, packaging ............................................................ 50

Disposing of the packaging ................................................. 50

Documents .......................................................................... 15

Drain pipe, expansion relief valve ....................................... 25

E

Electronics box, closing....................................................... 28

Electronics box, opening ..................................................... 28

Electronics self-test ............................................................. 42

F

Fan, replacing...................................................................... 46

Fault codes.......................................................................... 45

Fault memory, calling up ..................................................... 45

Fault memory, deleting........................................................ 45

Fault messages ................................................................... 45

Filling ................................................................................... 35

Filling mode ......................................................................... 32

Frost protection ................................................................... 17

Function menu............................................................... 42, 63

G

Gas conversion ................................................................... 36

Gas Council Number ........................................................... 15

Gas family check, performing.............................................. 33

Gas flow rate ....................................................................... 36

Gas group............................................................................ 24

Gas injector ......................................................................... 47

Gas setting .......................................................................... 36

Gas type .............................................................................. 24

Gas valve assembly ............................................................ 46

Gas valve assembly, replacing............................................ 47

Guarantee and Customer Service......................................... 7

H

Handing over to the end user .............................................. 41

Heat exchanger, cleaning.................................................... 43

Heat exchanger, replacing .................................................. 48

Heating flow......................................................................... 25

Heating partial load ............................................................. 32

Heating return...................................................................... 25

Hot water connection........................................................... 25

Hot water temperature......................................................... 32

I

Identification plate ............................................................... 15

Inspection work, carrying out............................................... 42

Inspection work, completing ................................................ 45

Installation assistant, ending ............................................... 32

Installation assistants, restarting ......................................... 32

Installer level, calling up ...................................................... 31

Intended use.......................................................................... 4

Internal expansion vessel, replacing ................................... 49

Isolators............................................................................... 50

K

Kammerbelüftung ................................................................ 19

L

Language ............................................................................ 32

Leak detection spray ............................................................. 6

Leak-tightness ......................................................... 38, 45, 50

Liquid gas ........................................................................ 6, 24

M

Maintenance interval, setting............................................... 39

Maintenance work, carrying out .......................................... 42

Maintenance work, completing............................................ 45

Manometer .......................................................................... 16

Mass flow sensor, replacing ................................................ 47

Minimum clearance ............................................................. 19

Multi-functional module ....................................................... 32

O

Operating concept ............................................................... 31

Overheating protection ........................................................ 17

P

PCB and display, replacing ................................................. 49

PCB or display, replacing .................................................... 49

Power supply....................................................................... 29

Pre-charge pressure for the internal expansion vessel,

checking .............................................................................. 44

Preparing, maintenance work.............................................. 42

Preparing, repair work ......................................................... 45

Product dimensions............................................................. 18

Product, draining ................................................................. 44

Product, switching off .......................................................... 50

Pump output, setting ........................................................... 40

Pump, remaining feed head ................................................ 40

Purging ................................................................................ 35


R

Regulations ........................................................................... 6

Remaining feed head, pump ............................................... 40

Repair work, completing...................................................... 50

Repair work, preparing .................................................. 42, 45

S

Safety devices ..................................................................... 17

Scale ................................................................................... 24

Scale deposition .................................................................. 24

Scope of delivery................................................................. 18

Self-test ......................................................................... 42, 63

Serial number ...................................................................... 16

Service message................................................................. 45

Side section, installing......................................................... 23

Side section, removing ........................................................ 23

Spare parts.......................................................................... 45

Status codes........................................................................ 31

Switching off ........................................................................ 32

Switching on ........................................................................ 32

T

Target feed temperature...................................................... 32

Technical data ....................................................................... 8

Telephone number, competent person ............................... 32

Test programmes .......................................................... 32, 63

Treating the heating water................................................... 33

U

Unit configuration ................................................................ 39

Unit connection piece for the air/flue pipe, removing .......... 28

Unit connection piece for the air/flue pipe, replacing .......... 28

Unit connection piece, 80/125 mm diameter, installing....... 28

V

Validity of the instructions.................................................... 15

Venturi ................................................................................. 46

Venturi, replacing ................................................................ 47

W

Weight ................................................................................. 22


Supplier

Vaillant Ltd.

Nottingham Road Belper

Telephone 0330 100 3461 [email protected]

Derbyshire www.vaillant.co.uk

DE56 1JT

0020244997_06

Publisher/manufacturer

Vaillant GmbH

Berghauser Str. 40

Tel. +492191 18 0 [email protected]

D-42859 Remscheid

Fax +492191 www.vaillant.de

18 2810

© These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.

Subject to technical modifications.

Vaillant ecoTEC plus Installation Manual

ecoTEC plus

Installation and maintenance instructions

Contents

1 Safety

1.1

Intended use

1.2

Qualification

1.3

General safety information

1.3.1 Gas

1.3.2 Flue gas

1.3.3 Air supply

1.3.4 Electricity

1.3.5 Weight

1.3.6 Explosive and flammable substances

1.3.7 High temperatures

1.3.13 Risk of material damage caused by leak detection sprays and fluids

1.3.8 Heating water

1.3.14 Risk of damage to the flexible gas pipe

1.4

Regulations (directives, laws, standards)

1.3.9 Neutralisation device

1.5

List of relevant standards for Great

Britain and Ireland

1.3.10 Frost

1.3.11 Safety devices

1.3.12 Risk of death from leaks if the product is installed below ground level

2 Guarantee and Customer Service

Guarantee Registration

Sales Support:

Telephone: 0345 602 0262

Technical Enquiries:

Telephone: 0344 693 3133

Email: [email protected]

General Enquiries:

Telephone: 0345 602 2922

Training Enquiries:

Telephone: 0345 601 8885

Email: [email protected]

Spares Enquiries:

Telephone: 01773 596 615

To register your Vaillant appliance visit: https://self-service.vaillant.co.uk/warranty-registration

3 Technical data

4 Notes on the documentation

5

Product description

6 Set-up

7 Installation

8 Operation

9 Start-up

10 Adapting the unit to the heating installation

11 Handing over to the end user

12 Inspection and maintenance

13 Troubleshooting

14 Decommissioning

15 Recycling and disposal

Appendix

A Inspection and maintenance work

B Installer level

Overview

C Overview of diagnostics codes

D Status codes

Overview

E Overview of fault codes

F Check programmes

Overview

G Function menu

Overview

H Wiring diagrams

I Commissioning Checklist

Benchmark Commissioning &

Warranty Validation Service Record

www.hhic.co.uk

J Commissioning Flow Chart

Index

Related manuals

Vaillant