Vaillant ecoTEC plus SERIES Installation And Maintenance Instructions Manual

Installation and maintenance instructions

For the competent person

Installation and maintenance instructions

Publisher/manufacturer

Vaillant GmbH

Berghauser Str. 40 D-42859 Remscheid

Tel. +49 21 91 18‑0 Fax +49 21 91 18‑28 10 [email protected] www.vaillant.de

ecoTEC plus

VU, VUW

GB, IE

Contents

6.2

6.3

6.4

7

7.1

7.2

5.8

5.9

6

6.1

7.3

7.4

7.5

4.1

4.2

4.3

4.4

4.5

3.1

3.2

3.3

3.4

3.5

4

2.1

2.2

2.3

2.4

2.5

3

1

1.1

1.2

1.3

1.4

2

5.1

5.2

5.3

5.4

5.5

4.6

4.7

4.8

4.9

4.10

5

Contents

5.6

5.7

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

Action-related warnings ......................................... 4

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

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

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

Notes on the documentation .............................. 8

Observing other applicable documents ................. 8

Storing documents................................................. 8

Applicability of the instructions .............................. 8

Benchmark............................................................. 8

Local regulations.................................................... 8

Product description............................................. 9

Product design....................................................... 9

Information on the identification plate.................... 9

Serial number ...................................................... 10

CE label ............................................................... 10

Energy Saving Trust Endorsed Products ............ 10

Installation.......................................................... 10

Unpacking the product......................................... 10

Checking the scope of delivery............................ 10

Transporting the product ..................................... 11

Dimensions .......................................................... 11

Minimum clearances............................................ 12

Clearance from combustible components ........... 12

Using the installation template............................. 12

Wall-mounting the product................................... 12

Removing the front casing................................... 13

Removing the side section .................................. 13

Installation.......................................................... 13

Installation requirements ..................................... 14

Installing the gas connection ............................... 14

Installing the hot and cold water connection........ 14

Connecting the domestic hot water cylinder........ 15

Connecting the heating flow and heating return ................................................................... 15

Connecting the condensate drain pipework ........ 15

Installing the discharge pipe on the expansion relief valve............................................................ 16

Flue gas installation ............................................. 16

Electrical installation ............................................ 17

Operation............................................................ 18

Operating concept ............................................... 18

Calling up the installer level................................. 18

Live Monitor (status codes) ................................. 19

Setting the hot water temperature ....................... 19

Start-up ............................................................... 19

Carrying out the initial start-up............................. 19

Switching the product on and off ......................... 19

Running the installation assistants ...................... 19

Restarting the installation assistants ................... 20

Test programmes................................................. 20

7.6

7.7

7.8

7.9

7.10

Performing a gas family check ............................ 20

Using check programmes.................................... 20

Checking and treating the heating water/filling and supplementary water .................................... 21

Preventing low water pressure ............................ 22

Flushing the heating installation for the first time ("cold") ......................................................... 22

Filling the heating installation .............................. 22

Purging the heating installation ........................... 23

7.11

7.12

7.13

7.14

7.15

7.16

7.17

8

10.2

10.3

10.4

10.5

10.6

10.7

9.4

9.5

9.6

9.7

10

10.1

8.1

8.2

8.3

8.4

8.5

9

9.1

9.2

9.3

Filling and purging the hot water system ............. 23

Filling the condensate trap .................................. 23

Gas ratio setting................................................... 23

Checking function and leak-tightness.................. 26

Thoroughly flushing the heating installation

("hot")................................................................... 26

Adapting the unit to the heating installation.......................................................... 26

Burner anti-cycling time ....................................... 26

Setting the maintenance interval ......................... 27

Setting the pump output....................................... 27

Setting the bypass valve...................................... 28

Handing the product over to the operator............ 28

Troubleshooting ................................................ 29

Checking service messages................................ 29

Rectifying faults ................................................... 29

Calling up and clearing the fault memory ............ 29

Resetting parameters to factory settings ............. 29

Preparing the repair work .................................... 29

Replacing defective components......................... 29

Completing repair work........................................ 33

Inspection and maintenance ............................ 33

Function menu ..................................................... 34

Electronics self-test.............................................. 34

Removing the compact thermal module .............. 34

Cleaning the heat exchanger............................... 35

Checking the burner ............................................ 35

Cleaning the condensate trap.............................. 35

Cleaning the filter in the cold water inlet.............. 35

10.8

10.9

Installing the compact thermal module ................ 36

Draining the product ............................................ 36

10.10

Checking the pre-charge pressure for the internal expansion vessel .................................... 36

10.11

Completing inspection and maintenance work .... 36

11 Decommissioning.............................................. 36

11.1

11.2

12

Temporarily decommissioning the product.......... 36

Decommissioning the product ............................. 37

Recycling and disposal..................................... 37

C

D

A

B

13 Customer service............................................... 37

Appendix ............................................................................ 38

Installer level – Overview .................................. 38

Overview of diagnostics codes........................ 40

Status codes – Overview .................................. 44

Overview of fault codes .................................... 46

2

Installation and maintenance instructions ecoTEC plus 0020209591_00

E

E.1

E.2

E.3

E.4

Connection diagrams ........................................ 49

Connection diagram, product for heating mode only, 12 - 35 kW................................................... 49

Connection diagram, product for heating mode only, ≥ 37 kW....................................................... 51

Connection diagram, product with integrated hot water generation, 12 - 35 kW ........................ 53

Connection diagram, product with integrated hot water generation, ≥ 37 kW............................. 55

I

F

G

H

H.1

Inspection and maintenance work –

Overview............................................................. 56

Commissioning Checklist................................. 58

Opening of the flue pipe.................................... 62

Positioning of the opening of a fan-supported flue gas pipe ........................................................ 62

Text from BS 5440-1 on fan-supported flue gas pipes ............................................................ 63

J

K

Opening of the flue pipe below eaves and balconies ............................................................ 63

Technical data.................................................... 63

Index ................................................................................... 69

Contents

0020209591_00 ecoTEC plus Installation and maintenance instructions

3

1 Safety

1 Safety

1.1

Action-related warnings

Classification of action-related warnings

The action-related warnings are classified in accordance with the severity of the possible danger using the following warning signs and signal words:

Warning symbols and signal words

Danger!

Imminent danger to life or risk of severe personal injury

Danger!

Risk of death from electric shock

Warning.

Risk of minor personal injury

Caution.

Risk of material or environmental damage

1.2

Intended use

There is a risk of injury or death to the user or others, or of damage to the product and other property in the event of improper use or use for which it is not intended.

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

The products referred to in these instructions must only be installed and operated in conjunction with the flue pipe accessories listed in other applicable documents.

Exceptions: For C63 and B23P installation types, follow the specifications in these instructions.

Intended use includes the following:

– observance of accompanying operating, installation and servicing instructions for the product and any other system components

– installing and fitting the product in accordance with the product and system approval

– compliance with all inspection and maintenance conditions listed in the instructions.

Any other use that is not specified in these instructions, or use beyond that specified in this document shall be considered improper use. Any direct commercial or industrial use is also deemed to be improper.

Caution.

Improper use of any kind is prohibited.

1.3

General safety information

1.3.1 Risk caused by inadequate qualifications

Assembly and disassembly, installation, startup, maintenance, repairs and decommissioning must only be carried out by a competent person who is sufficiently qualified to observe all of the instructions that come with the product, to proceed in accordance with the current state of the art, and to comply with all applicable directives, standards, laws and other regulations.

1.3.2 Risk of death from escaping gas

What to do if you smell gas in the building:

▶ 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.

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

▶ If it is safe to do so, close the emergency control valve or the main isolator.

▶ If possible, close the gas isolator cock on the product.

▶ Warn other occupants in the building by yelling or banging on doors or walls.

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

▶ Notify the gas supply company or National

Grid Transco +44 (0) 800 111999 by telephone from outside of the building.

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

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

4


Safety 1

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 line under any circumstance.

1.3.4 Risk of death due to blocked or leaking flue gas routes

Installation errors, damage, tampering, unauthorised installation sites or similar can cause flue gas to escape and result in a risk of poisoning.

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.

1.3.5 Risk of poisoning and burns caused by escaping hot flue gases

▶ 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.

1.3.6 Risk of death due to explosive and flammable materials

▶ Do not use or store explosive or flammable materials (e.g. petrol, paper, paint) in the installation room of the product.

1.3.7 Risk of death due to cabinet-type casing

Cabinet-type casing can give rise to dangerous situations when used on a product which is operated with an open flue.

▶ Ensure that the product is supplied with sufficient combustion air.

1.3.8 Risk of poisoning caused by insufficient supply of combustion air

Conditions: 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.

1.3.9 Risk of death due to lack of safety devices

The schematic drawings included in this document do not show all safety devices required for correct installation.

▶ Install the necessary safety devices in the system.

▶ Observe the applicable national and international laws, standards and guidelines.

1.3.10 Risk of death from electric shock

There is a risk of death from electric shock if you touch live components.

Before commencing work on the product:

▶ Disconnect the product from the power supply by switching off all power supplies

(electrical partition with a contact opening of at least 3 mm, e.g. fuse or line protection switch).

▶ Secure against being switched back on again.

▶ Wait for at least 3 minutes until the condensers have discharged.

▶ Check that there is no voltage.

1.3.11 Risk of being burned or scalded by hot components

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

1.3.12 Risk of death from escaping flue gas

If you operate the product with an empty condensate trap, flue gas may escape into the room air.

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


5

1 Safety

1.3.13 Risk of material damage caused by using an unsuitable tool

▶ Use the correct tool to tighten or loosen screw connections.

1.3.14 Risk of material damage caused by frost

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

1.3.15 Risk of corrosion damage due to unsuitable combustion and room air

Sprays, solvents, chlorinated cleaning agents, paint, adhesives, ammonia compounds, dust or similar substances may lead to corrosion on the product and in the air/flue pipe.

▶ Ensure that the supply of combustion air is always free of fluorine, chlorine, sulphur, dust, etc.

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

▶ Ensure that the combustion air is not routed through an old floor-standing oilfired boiler chimney.

▶ 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 a combustion air supply is ensured that is technically free of chemical substances.

1.3.16 Risk of material damage caused by leak detection sprays and liquids

Leak detection sprays and liquids block the filter of the mass flow sensor on the Venturi, and thus destroy the mass flow sensor.

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

1.3.17 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)

Installation and maintenance of the boiler must only be performed by a competent person with valid accreditation from the Health and Safety Executive in accordance with the

"Gas Safety (Installation and Use) Regulations 1998" (hereinafter abbreviated to "competent person" or "heating specialist company"). The existing regulations, rules and guidelines must be observed when doing so.

Any special requirements of Local Authorities, gas undertakings or insurers must be complied with. The competent person is also responsible for inspection, maintenance and repairs to the boiler, and for checking gas volume setting and flue gas analysis.

Installers shall carryout a full site risk assessment and put into place all necessary steps and procedures to comply with Health and safety at work act and ensure safety of themselves and others with regard to manual handling and working at height requirements.

During the appliance installation (and any subsequent work, such as, the replacement of major parts ) it will be necessary to employ caution. All installers and operatives involved from unloading the appliance until it is fully mounted on the wall in its final installed location must exercise full duty of care for themselves and others with regard to safety.

When lifting and handling this appliance, operatives should employ assistance. In certain situations it may be necessary to use mechanical handling aids. Take care to avoid trip hazards, slippery or wet surfaces.

Employers and installers should refer to the HSE web site for full advice and manual handling assessment charts

(MAC) tool.

In addition where no specific instructions are given then reference shall be made, but not restricted to, all applicable and relevant British Standards and codes of practice such as the following:

– Gas Safety (Installation and Use) regulations.

– All current Building Regulations for England, Northern Ireland and Wales, (as amended). This includes Approved Codes of Practice and approved documents and

6


Safety 1

guidance for building regulations. (A to P and 7)

– The Building Standards, Scotland, and any requirements determined by the local authorities within.

– The Health and safety at work act

– COSHH Control of Substances Hazardous to Health.

– BS 7671 Requirements for electrical installations. IEE Wiring Regulations

– The Electricity at Work Regulations.

– The Water supply (water fittings) regulations 1999.

– Water bylaws 2000 (Scotland)

– BS 5854 Code of practice for flues and flue structures in buildings.

– BS EN 12828 Design of water-based heating systems.

– BS EN 806 Parts 1 - 5.

– BS 8558 Guide to the design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

– BS 6880 Code of practice for low temperature heating systems with outputs above

45 kW, Part 1, 2, and 3.

– BS 6891 Installation of low pressure gas pipe work of up to 35mm in domestic premises.

– BS 4814 Specification for: Expansion vessels using an internal diaphragm, for sealed hot water and heating systems.

– BS 7074 Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems., Part

1 and 2.

– BS 7593 Code of practice for treatment of water in domestic hot water central heating systems.

– BS 12831 Heating systems in buildings.

Method for calculating design heat load.

– BS EN 13831 Closed expansion vessels with built in diaphragm.

– EN 14336 Heating systems in buildings.

Installation and commissioning of water based heating systems.

– BS 5440 – 1 Installation of flues and ventilation for gas appliances of rated input not exceeding 70kW*

– BS 5440 – 2 Flueing and ventilation for gas appliances of rated input not exceeding

70kW*

* 1st 2nd and 3rd family gases.

– BS 5449 Forced circulation hot water systems up to 45kW.

– BS EN 6798 Installation & maintenance of gas fired hot water boilers of rated input not exceeding 70kW net.

– BS 5482 - Part 1 Domestic butane and propane gas burning installations

Institute of Gas Engineers Publications:

– IGE/UP/1B (Edition 2) Tightness testing and direct purging of small natural gas installations.

– IGE/UP/ 7 (Edition 2) Gas in timber and light steel framed buildings.

Additionally for gas boilers systems with outputs greater than 70KW.

– BS 6644 Installation of gas boilers between 60 kW and 2 MW (2nd and 3rd family gases)

– BS 5449

– IGE/UP/1 (Edition 2) Strength testing, tightness testing and direct purging of industrial and commercial gas installations.

– IGE/UP/1A (Edition 2) Strength testing, tightness testing and direct purging of small, low pressure industrial and commercial natural gas installations.

– IGE/UP/10 Installation of gas appliances in industrial and commercial premises.

Part 1 Flued appliances.

– The installation must comply with the current version of the Clean Air Act.

– I.S. 813 Domestic Gas Installations

– I.S. 820 Non Domestic Gas Installations

– Building Control Act 2007

– ETCI Regulations for installing electrical systems


7

2 Notes on the documentation

2 Notes on the documentation

2.1

Observing other applicable documents

▶

You must observe all the operating and installation instructions included with the system components.

2.2

Storing documents

▶

Pass these instructions and all other applicable documents on to the system operator.

2.3

Applicability of the instructions

These instructions apply only to:

Product article number

Article number

Gas Council

Number

0010018531 41-044-78 612 (VU GB 126/5‑5 A)

ecoTEC plus

615 (VU GB 156/5‑5 A)

ecoTEC plus

618 (VU GB 186/5‑5 A)

ecoTEC plus

618 (VU GB 186/5‑5 A

LPG) ecoTEC plus

624 (VU GB 246/5‑5 A)

ecoTEC plus

630 (VU GB 306/5‑5 A)

ecoTEC plus

630 (VU GB 306/5‑5 A


637 (VU GB 376/5‑5 A)

ecoTEC plus

825 (VUW GB 256/5‑5)

ecoTEC plus

832 (VUW GB 326/5‑5)

ecoTEC plus

832 (VUW GB 326/5‑5


835 (VUW GB 356/5‑5)

ecoTEC plus

838 (VUW GB 386/5‑5)

ecoTEC plus

0010018532 41-044-79

0010018533 41-044-80

0010018534 41-044-81

0010018535 41-044-82

0010018536 41-044-83

0010018537 41-044-84

0010018538 41-044-85

0010018353 47-044-57

0010018354 47-044-58

0010018355 47-044-59

0010016540 47-044-53

0010018356 47-044-60

2.4

Benchmark

Vaillant is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the

UK and to encourage regular servicing to optimise safety, efficiency and performance.

Benchmark is managed and promoted by the Heating and

Hotwater Industry Council.

For more information visit www.centralheating.co.uk

2.5

Local regulations

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.

8


Product description 3

4

5

6

7

8

1

2

3

3 Product description

3.1

Product design

3.1.1

Functional elements, product for heating mode only

5

4

3

2

1

Gas valve

Water pressure sensor

Venturi with mass flow sensor

Heat exchanger

Connection for the flue pipe

Flue gas measuring stub pipe

Expansion vessel

Air intake pipe

3.1.2

Functional elements, product with hot water generation

5

8

9

10

6

7

11

12

13

14

4

3

2

1

16

15

16

9 Compact thermal module

10 Ignition electrode

11 Fan

12 Automatic air vent

13 Pressure gauge

14 Internal pump

15 Bypass valve

16 Expansion relief valve

17 Diverter valve

18 Electronics box

17

18

20

19

4

5

7

8

9

1

2

3

18

6

Gas valve


Venturi with mass flow sensor

Heat exchanger

Connection for the flue pipe

Flue gas measuring stub pipe

Expansion vessel

Air intake pipe

Compact thermal module

10 Ignition electrode

11 Fan

12 Automatic air vent

13 Pressure gauge

14 Internal pump

15 Bypass valve

16 Expansion relief valve

17 Electronics box

18 Diverter valve

19 Impeller sensor (hot water)

20 Secondary heat exchanger

17

3.2

Information on the identification plate

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

Information on the identification plate

Meaning

→ "CE label" section

11

12

13

14

15

6

7

8

9

10

VU…

VUW…

Read the instructions.

Vaillant gas-fired wall-hung boiler for heating

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


9

4 Installation

3.5

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

4 Installation

4.1

Unpacking the product

1.

Remove the product from its box.

2.

Remove the protective film from all parts of the product.

4.2

Checking the scope of delivery

▶

Check that the scope of delivery is complete and intact.

4.2.1

Scope of delivery

Applicability: Product with heating mode only

Bar code with serial number,

7th to 16th digit = product article number

3.3

3.4

Note

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

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).

CE label

1

1

1

3

1

1

2

3

1

1

1

1

Number

Description

Heat generator

Installation kit containing the following:

- Product retainer

- Expansion relief valve connector

- Gas connection pipe

- Heating flow/return connection pipe

- Service valve

- Bag with small parts

Lower cover

Installation template

Condensate drain hose

Enclosed documentation

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

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

4.2.2

Scope of delivery

Applicability: Product with integrated hot water generation

1

1

Number

1

Description

Heat generator

Installation kit containing the following:

- Product retainer

10


Installation 4

1

1

1

2

4

1

2

3

1

Number

1

Description

- Expansion relief valve connector

- Gas connection pipe

- Heating flow/return connection pipe

- Cold water, hot water connection pipe

- Service valve

- Bag with small parts

Lower cover

Installation template

Condensate drain hose

Enclosed documentation

4.3

Transporting the product

4.3.1

General

▶

Hold the load as close as possible to your body. Do not twist your body – instead, reposition your feet.

▶

If the unit is being lifted by two persons, ensure your movements are coordinated during lifting.

▶

Avoid bending your upper body – do not lean forwards or to the side.

▶

Wear appropriate cut-resistant and non-slip gloves to protect yourself against sharp edges and maintain a safe and secure grip.

▶

If required, get somebody to assist you in this.

4.3.2

Unloading the box from the delivery van

▶

It is recommended that two people lift the unit together.

▶

Lift the box using the straps provided.

▶

Use safe lifting techniques – keep your back straight and bend your legs at the knee.

▶

Hold the load as close as possible to your body.

▶

If the unit is being lifted by two persons, ensure your movements are coordinated during lifting.

▶

If required, get somebody to assist you in this.

4.3.3

Transporting the box from the delivery

point to the installation site – ground floor

▶

It is recommended that two people lift the unit together.

▶

Use safe lifting techniques – keep your back straight and bend your legs at the knee.

4.4

Dimensions

3 4*

5

440

35 35

100 100

188

6* 7

9

11 10

1

2

3

4*

5

6*

7

8

12

4

5

1

2

3

6

Flue pipe wall duct

Product holder

Heating flow (22 × 1.5

diameter)

Hot water connection

(15 × 1.5 diameter)

Gas connection


Cold water connection


7

8

9

Heating return (22 × 1.5

diameter)

R1 tundish/condensate trap connection

Flue pipe connection

10 Condensate discharge connection, 19 mm diameter

11 Condensate trap


11

A

B

C

D

4 Installation

12 Drain line/heating expansion relief valve

* connection, 15 mm diameter

Only products with integrated 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

612 (VU GB 126/5‑5 A) ecoTEC plus






825 (VUW GB 256/5‑5) ecoTEC plus




338 mm

338 mm

338 mm

338 mm

372 mm

406 mm

338 mm

338 mm

372 mm

406 mm

4.5

Minimum clearances

4.6

Clearance from combustible components

It is not necessary to maintain a clearance between the product and components made of combustible materials.

4.7

Using the installation template

▶

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

4.8

Wall-mounting the product

1

C C D

1.

Check whether the wall has sufficient load-bearing capacity to bear the operational weight of the product.

2.

Check if the supplied fixing material may be used for the wall.

Conditions: The load-bearing capacity of the wall is sufficient, The fixing material may be used for the wall

▶

Wall-mount the product as described.

▶

Install the product bracket (1) on the wall.

▶

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

Conditions: The fixing material may not be used for the wall

▶

Wall-mount the product as described using the permitted fixing material provided on-site.

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).

12


4.9

Removing the front casing

Installation 5

▶

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

▶

Remove the side section as shown in the illustration.

▶

Remove the front casing as shown in the illustration.

4.10

Removing the side section

2x

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.

5 Installation

Danger!

Risk of scalding and/or risk of material damage due to incorrect installation leading to escaping water.

Stresses in supply lines can cause leaks.

▶

Install the supply lines without tension.

Caution.

Risk of material damage due to the gas leak-tightness test.

At a test pressure of >11 kPa (110 mbar), gas leak-tightness tests may cause damage to the gas valve.

▶

If, during gas leak-tightness tests, you also place the gas lines and the gas valve in the product under pressure, use a max.

test pressure of 11 kPa (110 mbar).

▶

If you cannot limit the test pressure to

11 kPa (110 mbar), close any gas isolator cocks that are installed upstream from the product before you carry out the gas leaktightness test.

▶

If, during gas leak-tightness tests, you have closed the gas isolator cock that is installed upstream of the product, relieve the gas line pressure before you open this gas isolator cock.

Caution.

Risk of material damage due to corrosion.

If non-diffusion-tight plastic pipes are used in the heating installation, this may cause air to enter the heating water and corrosion of the heat generation circuit and the heat generator.

▶

If using non-diffusion-tight plastic pipes in the heating installation, partition the system by installing an external heat exchanger between the heat generator and the heating installation.

Caution.

Risk of material damage due to heat transfer during soldering.

▶

Do not solder the connection pieces if the connection pieces are screwed to the service valves.


13

5 Installation

5.1

Installation requirements

5.1.1

Information on liquid gas operation

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

If you have a product that has been preset for operation with natural gas, you must convert it to run on liquid gas. You will need a conversion kit for this. The conversion procedure is described in the manual supplied with the conversion kit.

5.1.2

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.

5.1.3

Using the correct type of liquid gas

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

▶

Only use the gases listed on the identification plate.

5.1.4

Required preliminary work

1.

Install a stop cock in the gas line.

2.

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

3.

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

Conditions: 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.

Conditions: External expansion vessel installed

▶

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.

4.

Install a tundish with siphon for the condensate discharge and the exhaust pipe on the expansion relief valve. Lay as short a drain line as possible, at a downward gradient away from the tundish.

5.

Insulate bare pipes exposed to environmental influences to protect them from frost using suitable insulating material.

5.2

Installing the gas connection

1.

Install the gas line 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.

5.

Check the gas line for leak-tightness.

5.3

Installing the hot and cold water connection


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.

14


Installation 5

5.4

Connecting the domestic hot water cylinder


▶

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

5.5

Connecting the heating flow and heating return

min.

180

11

2

3

Internal stackpipe

Internal discharge system

Gulley Soakaway

▶

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

5.6

Connecting the condensate drain pipework

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.

The product is equipped with a condensate trap (2). (The filling height is 145 mm). The condensate trap collects the condensate that has formed in a vessel with a capacity of approximately 200 ml, and intermittently releases the contents into the discharge pipe. This minimises the risk of the discharge pipe freezing.

▶

Connect the condensate discharge (1) to condensate drain pipework (3) which has a minimum internal diameter of 19 mm (22 mm outside diameter for all external pipes) and is made from an acid-resistant material (e.g.

plastic overflow pipe).

– 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.

▶

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 drain pipework 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.


15

5 Installation

5.7

Installing the discharge pipe on the expansion relief valve

1.

Install the discharge 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.

5.8.2

Replacing the connection piece for the air/flue pipe as required

1.

Replace the connection piece for the air/flue pipe as required. The product-specific standard equipment is listed under Technical data.

2.

Remove the connection piece for the air/flue pipe.

(→ Page 16)

3.

Alternatives 1 / 2

▶

If required, install the connection piece for the air/flue pipe, 80/125 mm diameter. (→ Page 16)

3.


▶

If required, install the connection piece with offset for the air/flue pipe, 60/100 mm diameter.

(→ Page 16)

5.8.2.1 Removing the connection piece for the air/flue pipe

3.

2.

Install the discharge 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.

5.8

Flue gas installation

5.8.1

Installing and connecting the flue pipe

1.

You can find out which flue pipes may be used by consulting the enclosed flue pipe installation manual.

2.

Observe the information on positioning the opening for the flue pipe. This information can be found in the appendix.

Conditions: Installation in damp rooms

▶

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

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.

2.

1.

1.

Insert a screwdriver into the slot between the measuring stub pipes.

2.

Press the screwdriver carefully down (1.).

3.

Turn the connection piece anticlockwise (2.) as far as it will go and then remove it by pulling it upwards (3.).

5.8.2.2 Installing the connection piece for the air/flue pipe, 80/125 mm diameter

1.


(→ Page 16)

2.

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

3.

Turn the connection piece clockwise until it clicks into position.

5.8.2.3 Installing the connection piece with offset for the air/flue pipe, 60/100 mm diameter

1.


(→ Page 16)

3.

Install the flue pipe using the installation manual.

16


1

65 mm

Installation 5

▶

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

1.

Route the supply lines of the components to be connected through the cable duct provided on the underside of the product on the left.

2.

Use strain reliefs.

3.

Shorten the supply lines as necessary.

2.

Insert the alternative connection piece with offset towards the front.

3.

Use two screws (1) to secure the connection piece to the product.

5.9

Electrical installation

The electrical installation must only be carried out by a qualified electrician.

Danger!

Risk of death from electric shock!

Mains connection terminals L and N remain live even if the on/off switch is turned off:

▶

Switch off the power supply.

▶

Secure the power supply against being switched on again.

5.9.1

Opening the electronics box

30 mm max.

4.

To prevent short circuits if a strand accidentally comes loose, only strip the outer sheathing of flexible lines to a maximum of 30 mm.

5.

Ensure the inner conductor insulation is not damaged when stripping the outer sheathing.

6.

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

7.

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

8.

Screw the respective plug to the supply line.

9.

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

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

5.9.3

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.

▶

Open the electronics box as shown in the illustration.

5.9.2

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 (+/-).

1.

Make sure that the nominal mains voltage is 230 V.

2.

Provide one common electricity supply for the boiler and for the corresponding controller:

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

– Fuse protection: ≤ 3 A

3.

Open the electronics box. (→ Page 17)

4.

Connect the product using a fixed connection and a partition with a contact opening of at least 3 mm (e.g.

fuses or power switches).

5.

Route a three-core mains connection cable that complies with the relevant standards through the cable duct and into the product.

– Mains connection line: Flexible line

6.

Carry out the wiring. (→ Page 17)

7.

Remove the supplied plug from the bracket in the electronics box and screw the plug onto the mains connection cable.

8.

Close the electronics box.

9.

Make sure that access to the mains connection is always available and is not covered or blocked.


17

6 Operation

5.9.4

Installing the product in a moist environment

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. If you use the factory-installed connection cable, if installed, with an earthed plug, there is a risk of death from electric shock.

▶

Never use the factory-installed connection cable with earthed plug when installing the product in a moist environment.

▶

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

▶

Use a flexible line for the mains connection line, which is routed through the cable duct into the product.

5.9.6

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.

5.9.6.1 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 26)

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

1.

Install the components in accordance with the respective instructions.

Conditions: Components connected to relay 1

▶

Activate D.027. (→ Page 26)

Conditions: Components connected to relay 2

▶

Activate D.028. (→ Page 26)

1.


2.

Detach the plug from the PCB slot for the mains connection (X1).

3.

Unscrew the plug of the factory-installed mains connection cable, if installed.

4.

Instead of the factory-installed mains connection cable, if installed, use a suitable three-core mains connection cable which complies with the relevant standards.

5.


6.


7.

Observe the flue-gas connection that is required on a room-sealed air/flue gas installation. (→ Page 16)

5.9.7

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.

5.9.5

Connecting controllers to the electronic system

1.

Install the controller if necessary.

2.


3.


4.

Observe the connection diagram in the appendix.

Conditions: Connecting a weather compensator or a room temperature controller via eBUS

▶

Connect the controller to the eBUS connection.

▶

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

Conditions: Connecting a low-voltage controller (24 V)

▶

Remove the bridge and connect the controller to the

24 V = RT connection (X100 or X106).

Conditions: 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 controllers, change D.018 from Eco (intermittently operating pump) to Comfort (continuously operating pump). (→ Page 26)

6 Operation

6.1

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 38)

6.2

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 .

18


Start-up 7

6.3

Live Monitor (status codes)

Menu → Live Monitor

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

Status codes – Overview (→ Page 44)

Danger!

Risk of death from Legionella.

Legionella multiply at temperatures below

60 °C.

▶

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

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 in each case.

6.4

Setting the hot water temperature


Conditions: Water hardness: > 3.57 mol/m³

7.3.1

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.

▶

Set the hot water temperature to a maximum of 50 °C.

7 Start-up

7.1

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 commissioning checklist. The commissioning checklist in the appendix (→ Page 58) 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 commissioning checklist in the appendix.

▶

Fill in and sign the commissioning checklist.

7.2

Switching the product on and off

▶

Press the on/off button on the product.

◁

The basic display appears on the display.

7.3.2

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.

7.3.3

Purging

1.

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

2.

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

7.3.4

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.

7.3.5

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.

7.3

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.

7.3.6

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.


19

7 Start-up

7.3.7

Contact data

▶

If required, store your telephone number in the Appli-

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

7.3.8

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.

7.4

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.

7.5

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

Result

F.92

Meaning

See the table of fault codes in the appendix

"Successful" Combustion quality is good.

Unit configuration matches the specified gas group.

"Warning"

F.93

Combustion quality inadequate.

CO₂ content is incorrect.


Measure


None

Start check programme

P.01 and adjust the

CO₂ content with the adjusting screw in the

Venturi.

If the correct CO₂ 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.


7.6

▶

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 units are connected to the same flue gas pipe in the heating installation, ensure that none of these condensing units 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.

Note

It is not possible to perform CO₂ measurements during the gas family check.

7.7

Using check programmes

Menu → Installer level → Test programs → Check pro-

grams

Display Meaning

P.00

Purging check programme:

The internal pump is cyclically actuated.

The heating circuit and the hot water circuit are purged via the automatic air vent (the cap of the automatic air vent must be released).

1 x : Start heating circuit purging

2 x

3 x

(

(

): Start hot water circuit purging

): Restart heating circuit purging

1 x

Note

(Cancel): End purge programme

The purge programme runs for 7.5 min per circuit and then terminates.

Purging the heating circuit:

Diverter valve in heating position, actuation of internal pump for 9 cycles: 30 sec. on, 20 sec. off.

Display: Active heating circuit.

Purging the hot water circuit:

After the above-mentioned cycles have run or the right-hand selection button has been pressed again:

Diverter valve in the hot water position, actuation of the internal pump as above. Display: Active hot

water circuit.

20


Start-up 7

Display Meaning

P.01

P.02

P.06

Maximum load check programme:

After successful ignition, the product is operated at maximum heat input.

Minimum load check programme:

After successful ignition, the product is operated at minimum heat input.

Filling mode check programme:

The diverter valve is moved to the mid-position. The burner and pump are switched off (to fill or drain the product).

Total heating output kW

< 50

Water hardness at specific system volume

1)

≤ 20 l/kW

> 20 l/kW

≤ 50 l/kW

> 50 l/kW ppm

CaCO₃ mol/m³

ppm


ppm


< 300 < 3 200 2 2 0.02

> 50 to ≤ 200

> 200 to ≤ 600

> 600

200

150

2

1.5

150

2

1.5

0.02

2

2

0.02

0.02

2 0.02

2 0.02

2 0.02

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

7.8

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 system, 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 system.

▶

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

▶

If you ascertain that it contains magnetite, clean the system and apply suitable corrosion-protection measures, or fit a magnet 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 system and treat the heating water.

▶

Ensure that oxygen cannot get into the heating water.

(→ Page 26)

Checking the filling and supplementary water

▶

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

Treating the filling and supplementary water

▶

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

Provided the national regulations and technical standards 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.

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 frost and corrosion protection agents, biocides or sealants.

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)

– Fernox F3

– Sentinel X 300

– Sentinel X 400

Additives intended to remain permanently in the system

– Fernox F1

– Fernox F2

– Sentinel X 100

– Sentinel X 200

Additives for frost protection intended to remain permanently in the system

– Fernox Antifreeze Alphi 11

– Sentinel X 500

▶

If you have used the above-mentioned additives, inform the operator about the measures required.

▶

Inform the operator about the measures required for frost protection.


21

7 Start-up

7.9

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.

7.10

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.

3.

Select the check programme P.06.

◁

The diverter valve moves to the mid-position, the pumps do not run and the product does not switch to heating mode.

4.

Observe the information on treating heating water.

(→ Page 21)

5.

Check all connections and the entire system for leaks.

Conditions: Applies to: Products with integrated hot water generation

3

4

1

2

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 system and open the purging valves on the radiators so that the contaminated water can completely drain.

4.

Close the drain 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 valve.

7.11

Filling the heating installation

1

▶

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

▶

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

▶

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

▶

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

▶

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 stop valves and disconnect the filling device by removing the double non-return valve from the cold water stop valve.

Note

Both stop 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 mode.

Conditions: Applies to: Products with heating mode only

▶

Connect the filling and drainage tap in the heating installation to a heating water supply, if possible with the

22


Start-up 7

cold water valve, in accordance with the relevant standards.

▶

Open the heating water supply.

▶

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

▶

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

▶

Slowly open the filling and drainage tap 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 and drainage tap and the cold water valve.

7.14

Filling the condensate trap

1

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.

7.12

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.

7.13

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.

7.15

Gas ratio setting

7.15.1 Checking the factory-set gas ratio 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.

▶

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

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

Only Vaillant Service Solutions may perform a gas conversion.

If a gas conversion to liquid 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 Solutions (0330 1003 143).

▶

Do not start up the product.

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

▶

Proceed as described below.


23

7 Start-up

7.15.2 Checking the leak-tightness of the flue gas system and for flue gas recirculation

1.

Check the integrity of the flue gas system.

2.

If the flue gas system is longer than 2 m, we urgently recommend that you test the system for flue gas recirculation as described below.

3.

Use the air analysis point to check for flue gas recirculation.

4.

Use the flue gas measuring instrument.

5.

If you discover CO or CO2 in the fresh air, search for a leak in the flue gas system or for the flue gas recirculation.

6.

Eliminate the damage.

7.

Repeat the above-mentioned test to determine if the fresh air contains CO or CO2.

8.

If you cannot eliminate the damage, you must not start up the boiler.

7.15.3 Checking the gas flow rate

The boiler is fitted with a multifunctional automatic gas valve which ensures that the precise air/gas ratio is provided under all operating conditions. The gas flow rate has been set during production and does not require adjustment. With the front casing fitted check the gas flow rate of the boiler as follows:

▶

Start 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.

▶

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.

25

32

35

38

18

24

30

37

Nominal value for the net heat supply in kW in accordance with

BS EN 483

12

15

H gas in m³/h

Nom.

+5%

P gas in kg/h

−10% Nom. +5% −10%

1,31 1,38 1,18 0.96

1,01 0,86

1,64 1,72 1,48 1,20 1,26 1.08

1,97 2,07 1,77 1,44 1,51 1,30

2,61 2,74 2.35

1,92 2,02 1,73

3,27 3,43 2,94 2,40 2,52 2,16

4,03 4,23 3,63 2,96 3,11 2,66

2,72 2,86 2.45

2,00 2,10 1,80

3,41 3,58 3,07 2,52 2,65 2,27

3,78 3,97 3,40 2,78 2,92 2,50

4,15 4,36 3,73 3,05 3,20 2,75

Conditions: 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.

Conditions: 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 two minutes.

▶

Record the boiler maximum gas flow rate onto the

Benchmark gas boiler commissioning checklist.

7.15.4 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 isolator cock.

2

1

3.

Use a screwdriver to undo the measuring nipple screw

(1) (lower screw) at the gas valve.

4.

Connect a pressure gauge (2) to the measuring nipple

(1).

5.

Open the gas isolator cock.

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.

24


Start-up 7

– Permissible gas flow pressure for operation with

G20 natural gas: 1.3 … 2.3 kPa (13.0 … 23.0 mbar)

– Permissible gas flow pressure for operation with

G31 liquid gas: 2.3 … 4.3 kPa (23.0 … 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.

Conditions: Gas flow pressure not in the permissible range

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.

▶

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

▶


▶

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.

▶


▶

Check the measuring nipple for gas tightness.

▶


▶

Install the front casing.

▶

Disconnect the product from the power mains.

▶

You must not start up the boiler.

Conditions: 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 measuring 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.

7.15.5 Checking the CO₂ content and, if

necessary, adjusting it (air index setting)

1.


2.

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

3.

Measure the CO₂ and CO/CO₂ content at the flue gas analysis point.

4.

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

Settings Unit G20 natural gas

G31 liquid gas

CO₂ after 5 minutes in full load mode with front casing closed

CO₂ after 5 minutes in full load mode with front casing removed

Set for Wobbe index

W₀

Vol.–%

Vol.–% kWh/m³

9.2 ± 1.0

9.0 ± 1.0

14.09

O₂ after 5 minutes in full load mode with front casing closed

CO/CO₂

Vol.–%

CO value with full load ppm

4.5 ± 1.8

≤ 250

≤ 0.0031

10.4 ± 0.5

10.2 ± 0.5

21.34

5.1 ± 0.8

≤ 250

≤ 0.0026

Conditions: The CO₂ content must be adjusted

1

2

▶

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

▶

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

▶

Check the CO₂ content again.

▶

If necessary, repeat the setting process.

▶

Set the CO₂ content (value with front casing removed) by turning the screw (2).

– Higher CO₂ content: Turn anti-clockwise

– Lower CO₂ 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 liquid 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 CO₂ content again.

▶

If necessary, repeat the setting process.

▶

Press (Cancel) once the adjustments have been made.


25

8 Adapting the unit to the heating installation

▶

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.

▶


7.16

Checking function and leak-tightness

Before you hand the product over to the operator:

▶

Check the gas line, the flue gas installation, the heating installation and the hot water pipes for leaks.

▶

Check that the air/flue pipe and condensate drain pipework have been installed correctly.

▶

Check that the front casing has been installed correctly.

7.16.1 Checking the heating mode

1.

Make sure that there is a heat requirement.

2.

Call up the Live Monitor.

◁

If the product is working correctly, the display shows

S.04.

7.16.2 Checking the hot water generation


6.

Fill the heating system again with water as described in

Filling the heating installation (→ Page 22) and Purging the heating installation (→ Page 23).

7.

Re-fill the system until the system design pressure of

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

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. Further information can be obtained from Sentinel,

Betz Dearborn Ltd., Tel: 0151 420 9595, or

Fernox, Alpha– Fry technologies. Tel: 0870

8700362.

8.


1.

Open a hot water valve all the way.

2.


◁

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

7.16.3 Checking the hot water generation


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 controller which can be used to set the hot water temperature, set the 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 controller.

◁

The product adopts the set target temperature that is set on the controller.

7.17

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.


To reset the most important system parameters, use the

Appliance config. menu point.

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 40)

8.1

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).

8.1.1

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

.

26


Adapting the unit to the heating installation 8

60

65

70

75

30

35

40

45

50

55

T

Flow

(target)

[°C]

50

55

60

65

70

75

35

40

45

T

Flow

(target)

[°C]

30

Set maximum burner anti-cycling time [min]

1

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

35

5

4.0

4.0

3.5

3.0

3.0

2.5

2.0

1.5

1.5

1.0

40

10

8.5

7.5

6.5

6.0

5.0

4.5

3.5

2.5

2.0

1.0

15

12.5

11.0

10.0

45

8.5

7.5

6.0

5.0

3.5

2.5

1.0

20

16.5

15.0

13.0

11.5

9.5

8.0

6.0

4.5

2.5

1.0

50

25

20.5

18.5

16.5

14.0

12.0

10.0

7.5

5.5

3.0

1.0

Set maximum burner anti-cycling time

[min]

55

30

25.0

22.0

19.5

17.0

14.0

11.5

9.0

6.5

3.5

1.0

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

8.0

9.0

10.0

11.0

11.5

4.0

1.0

4.5

1.0

5.0

1.0

5.5

1.0

6.0

1.0

6.5

1.0

8.1.2

Resetting the remaining burner anti-cycling time

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.

1.


▶

Press .

8.2

Setting the maintenance interval

1.


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

Number of persons

1 ‑ 2

2 ‑ 3

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

8.3

Setting the pump output

1.


menu → D.014 Pump speed target value and confirm by pressing .

2.

Set the required pump output.

Conditions: Low loss header installed

▶

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

8.3.1

Remaining feed head of the pump

8.3.1.1 Pump characteristic line for VU 126, VU

156, VU 186

400

300

200

100

Heat demand

10.0 kW

15.0 kW

20.0 kW

25.0 kW

> 27.0 kW

Number of persons

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)

1500 h

1600 h

1800 h

1900 h

2600 h

2700 h

2800 h

2900 h

3000 h

3000 h

100% PWM

85%

70%

60%

53%

0

0 200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

8.3.1.2 Pump characteristic line for VU 246, VUW

256

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%


27



356

400

300

200

100% PWM

85%

70%

60%

53%

100

0

0 200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

1

8.3.1.4 Pump characteristic line for VUW 326

400

300

200

100% PWM

85%

70%

60%

53%

100

0

0 200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]


386

400

300

200

100% PWM

85%

70%

60%

53%

Minimum

with Auto

100

0

0 200 400 600 800 1000 1200 1400 1600 1800

Flow rate [l/hr]

8.4

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 13)

▶

Regulate the pressure using the adjusting screw (1).

Position of the adjusting screw

Pressure in MPa

(mbar)

Notes/application

Right-hand stop

(turned all the way down)

0.035

(350)

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

Mid-position

(5 turns to the left)

0.025

(250)

5 further turns to the left from the

0.017

(170) mid-position

▶


Default setting

If noises are produced in the radiators or radiator valves

8.5

Handing the product over to the operator

▶

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 operator's language.

▶

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

▶

Inform the operator how to handle the product.

▶

In particular, draw attention to the safety information which the operator must follow.

▶

Inform the operator of the necessity to have the product maintained according to the specified intervals.

▶

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

▶

Inform the operator 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 operator 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.

28


Troubleshooting 9

9 Troubleshooting

9.1

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 .

Conditions: 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 29)

Note

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

9.5

Preparing the repair work

1.

Decommission 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 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.

9.5.1

Procuring spare parts

The original components of the product were also certified as part of the declaration of conformity. If you do not use certified Vaillant original spare parts for maintenance or repair work, this voids the conformity of the product. We therefore strongly recommend that you fit Vaillant genuine spare parts.

Information about available Vaillant original spare parts is available by contacting the contact address provided on the reverse of this document.

▶

If you require spare parts for maintenance or repair work, use only Vaillant genuine spare parts.

9.2

Rectifying faults

▶

If fault messages (F.XX) appear, rectify the fault by referring to the table in the appendix or using the Function menu (→ Page 34) and the Check programs (→ Page 20).

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 remedy the fault and the fault recurs despite fault clearance attempts, contact customer service.

9.6

Replacing defective components

9.6.1

Replacing the burner

1.

Remove the compact thermal module. (→ Page 34)

1

9.3

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.

9.4

Resetting parameters to factory settings

1.


menu → D.096 Reset to factory settings? and confirm by pressing .

2.

Set the diagnostics code to 1, and confirm by pressing

.

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 36)


29


9.6.2

Replacing the fan

1

2

7

2

3

4

5

6

1.

Remove the air intake pipe.

2.

Remove the three plugs from the gas valve (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 cap nuts (7) and (6) on the gas valve.

Use an open-ended spanner to counterhold the opposite side of the gas valve when unscrewing.

6.

Unscrew the three screws (2) between the mixture pipe

(1) and the fan flange.

5

1

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

12. Replace the defective fan.

1

2

3

4

1

3

2

7.

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

8.

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

9.

Remove the gas valve 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.

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 line to the gas valve. Use new seals for this.

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

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

(→ Page 20)

9.6.3

Replacing the gas valve

Note

To replace the gas valve, you will need a Torx

T20. To replace the gas valve 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 before you can remove the gas valve from the retainer.

30


5

1

2

Troubleshooting 9

9.6.4

Replacing the Venturi

1

2

4

3

3

1.


2.

Remove the three plugs from the gas valve (2).

3.


4.

Unscrew the two cap nuts (5) and (4) on the gas valve.

Use an open-ended spanner to counterhold the opposite side of the gas valve (4) and (5) when unscrewing.

5.

Either remove the unit comprising the fan with gas valve

(Replacing the fan (→ Page 30)), or use an offset screwdriver or Torx T20 socket to unscrew the fixing screw of gas valve (3) from the retainer.

1.


2.


3.

Unscrew the cap nuts (3) of the gas connection pipe (2) on the gas valve.

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.

7

6

1

2

Note

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

5

4

6.

Remove the gas valve from the retainer.

7.

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

8.

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

9.

After installing the new gas valve, perform a leak-tightness test (→ Page 26), gas family check (→ Page 20) and gas ratio setting (→ Page 23).

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 restrictor (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.

8.

Ensure that you use the correct gas restrictor (colour coding and position of pins on the underside of the gas


31


restrictor). The colour of the gas restrictor must match the colour of the coding resistor on the PCB.

9.

Insert the gas restrictor for the gas group in question into the new Venturi (yellow: G20 natural gas, grey:

Liquid gas).

10. When inserting the gas restrictor, ensure that the gas restrictor 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 restrictor.

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

12. After installing the new Venturi, carry out a gas ratio setting. (→ Page 23)

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

14. Perform a gas family check. (→ Page 20)

9.6.5

Replacing the heat exchanger

1.

Drain the product. (→ Page 36)

2.

Remove the compact thermal module. (→ Page 34)

3.

Detach the condensate drain hose from the heat exchanger.

1

2

3

1

2

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.

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.

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

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

15. Install the compact thermal module. (→ Page 36)

16. Fill and purge the product and, if necessary, the heating installation. (→ Page 22)

9.6.6

Replacing the expansion vessel

1.


32

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.


Inspection and maintenance 10

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 22)

9.6.7

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

Product type number

612 (VU GB 126/5‑5 A) ecoTEC

plus

615 (VU GB 156/5‑5 A) ecoTEC

plus

618 (VU GB 186/5‑5 A) ecoTEC

plus

624 (VU GB 246/5‑5 A) ecoTEC

plus

630 (VU GB 306/5‑5 A) ecoTEC

plus

637 (VU GB 376/5‑5 A) ecoTEC

plus

825 (VUW GB 256/5‑5) ecoTEC

plus

832 (VUW GB 326/5‑5) ecoTEC

plus

835 (VUW GB 356/5‑5) ecoTEC

plus

838 (VUW GB 386/5‑5) ecoTEC

plus

1

3

4

9

14

20

6

10

13

17

◁

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

◁

The installation assistant starts.

8.

Make the system-specific settings.

3.

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

4.


9.6.8

Replacing the PCB and the display

1.


2.

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

9.7

Completing repair work

1.

Establish the power supply.

2.

Switch the product back on if this has not yet been done. (→ Page 19)

3.


4.

Open all service valves and the gas isolator cock.

5.

Check that it works correctly and is leak-tight.

(→ Page 26)

1

3.

Remove the coding resistance (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 19)

◁

After switching on, the product switches directly to the menu to select the language. The default 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

.

10 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.

Inspection and maintenance work – Overview

(→ Page 56)

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.


33

10 Inspection and maintenance

– 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.

10.1

Function menu

Menu → Installer level → Test programs → Function menu

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

Display

T.01

T.02

T.03

T.04

T.05

T.06

T.08

Test programme

Check internal pump

Check 3-way valve

Check fan

Check cylinder charge pump

Check circulation pump

Check external pump

Checking the burner

Action

Switch the internal pump on and off.

Move the diverter valve to the heating position or to the hot water position.

Switch the fan on and off.

The fan runs at maximum rotational speed.

Switch the cylinder charging pump on and off.

Switch the circulation pump on and off.

Switch the external pump on and off.

Product starts up and switches to minimum load.

The flow temperature is shown in the display.

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.

Tilt the electronics box forward.

1

2

3

10.2

Electronics self-test

Menu → Installer level → Test programs → Electronics

self-test

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

10.3

Removing the compact thermal module

Note

The compact thermal module consists of five main components:

– Speed-regulated fan,

– Gas valve including support plate,

– Venturi including mass flow sensor and gas connection pipe,

– Burner flange,

– Premix burner.

5.

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

6.

Unscrew either the cap nut on the gas valve (3) or the cap nut (4) between the corrugated gas pipe and the fixed gas pipe.

4

34


7

6

8

4

5

3

1

2

Inspection and maintenance 10

4.

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

◁

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

10.5

Checking the burner

1

7.

Remove the plugs of the ignition line (7) and of the ground 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 (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 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 wall of the heat exchanger. If you notice any signs of damage, replace the relevant insulating mat.

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.

10.6

3

Cleaning the condensate trap

2

1.

Remove the lower section of 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.

10.4

Cleaning the heat exchanger

1.

Protect the folded down electronics box against sprayed water.

10.7

Cleaning the filter in the cold water inlet


2

3

1

2

1

4

2.

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

3.

Clean the heating coil (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.

1.

Close the cold water stop valve.

2.

Drain the product on the hot water side.


35

11 Decommissioning

3.

Unscrew the cap nut (2) and the lock nut (1) from the product's casing.

2

4.

Tilt the electronics box forward.

5.

Remove the clamp (2).

6.

Remove the pipe (1) from the product.

7.

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

8.

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

9.

Refit the pipe.

10. Reinsert the clamp.

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

12. Open the cold water stop valve.

1

10.8

Installing the compact thermal module

8

1

2

7

3

6

9.

Secure the air intake pipe with the retaining screw.

10. Check the gas flow pressure.

10.9

Draining the product

1.

Close the service valves of the product.

2.

Start the check programme P.06 (diverter valve midposition).

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.

10.10 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.

Conditions: 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 32)

4.

Fill the heating installation. (→ Page 22)

5.

Purge the heating installation. (→ Page 23)

10.11 Completing inspection and maintenance work

Once you have completed all maintenance work:

▶

Check the gas flow pressure. (→ Page 24)

▶

Check the CO₂ content and, if necessary, adjust it (air index setting). (→ Page 25)

▶

If required, reset the maintenance interval. (→ Page 27)

4

5

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

3.

Reconnect the plugs (3) to (7).

4.

Connect the gas line 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 nozzle.

11 Decommissioning

11.1

Temporarily decommissioning the product

▶

Press the on/off button.

◁

The display goes out.

▶


▶

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

36


11.2

Decommissioning the product

▶

Press the on/off button.

◁

The display goes out.

▶


▶


▶

Close the cold water stop valve.

▶


12 Recycling and disposal

Disposing of the packaging

▶

Dispose of the packaging correctly.

▶

Observe all relevant regulations.

13 Customer service

To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement.

Please contact Vaillant Service Solutions for further details.

Vaillant Service Solutions: 03 30 100‑31 43

Recycling and disposal 12


37

Appendix

Appendix

A

Installer level – Overview

Setting level Values

Min.

Max.

Installer level →

Enter code

00 99

Unit Increment, select, explanation

Default setting

–

1 (competent person code 17)

–

Installer level → List of faults →

F.XX - F.XX¹

Installer level → Test programs →

Gas type 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 Cyl. 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

– – –

Deutsch, English, Français, Italiano, Dansk,

Nederlands, Castellano, Türkce, Magyar,

Pусский, Українськa, Svenska, Norsk, Polski, Čeština, Hrvatski, Slovenčina, Română,

Slovenščina, Português, Srpski

Flow temp. setpoint

DHW temperature

30

30

75

60

℃

℃

1

1

Product with hot water generation or connected domestic hot water cylinder

Comfort mode

– –

–

On, Off

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

English

Off

–

–

–

–

–

–

–

–

–

–

–

–

–

38


Appendix

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 = Extractor hood

5 = External solenoid valve

6 = External fault message

7 = Solar pump (not active)

8 = eBUS remote control (not active)

9 = Legionella protection pump (not active)

10 = Solar valve (not active)


2 = External pump


4 = Extractor hood








2 = External pump


4 = Extractor hood







Partial load only, full load only, auto

0 – 9

Default setting

2

2

2


Contact data

Default setting

–

Phone number

–

–

–

– –

On, Off

Auto

Auto

–

Installer level → Diagnostics menu →

D.XXX - D.XXX

Current value

– –

–

Installer level → Start ins. assistant →

Language

– – –

Deutsch, English, Français, Italiano, Dansk,

Nederlands, Castellano, Türkce, Magyar,

Pусский, Українськa, Svenska, Norsk, Polski, Čeština, Hrvatski, Slovenčina, Română,

Slovenščina, Português, Srpski

Filling mode: 3-way valve is in midposition

Purge programme

0

–

2

–

–

–

0 = Normal operating mode

1 = Mid-position (parallel operation)

2 = Permanent heating mode position

Automatic adaptive purging of the heating circuit and hot water circuit

Not active

Active

1

Flow temp. setpoint

30 75

℃

DHW temperature

35 60

℃

1

Product with hot water generation


English

–

–

–

–


39

Appendix

Setting level Values

Unit Increment, select, explanation

Min.

Max.

Comfort mode


Auxiliary relay

–

–

1

–

–

10

– kW

–

On, Off

Partial load only, full load only, auto


2 = External pump


4 = Extractor hood








1 10

–


2 = External pump


4 = Extractor hood








1 10

–


2 = External pump


4 = Extractor hood







Contact data

End the installation assistant?

Phone number

–

– – –

0-9

Yes, No


B Overview of diagnostics codes

Code Parameter

D.000 Heating partial load

Values or explanations

Adjustable heating partial load in kW

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

1 … 60 min D.001 Overrun time of internal heating pump for heating mode

D.002 Max. burner anti-cycling time heating at 20 °C flow temperature

D.003 Outlet temp. actual value

2 … 60 min

In °C

D.004 Measured value of hot water sensor In °C

D.005 Flow temperature target value (or return target value)

D.006 Hot water temperature target value

(only products with integrated hot water generation)

In °C, max. of the value set in D.071, limited by an eBUS controller if connected

35 … 65 ℃

Default setting

Auto

5 min

20 min

Default setting

–

Auto

2

2

2

–

–

Own setting

Not adjustable

Not adjustable

Not adjustable

Not adjustable

40


Code Parameter

D.007 Warm start temperature target value

(only products with integrated hot water generation)

Cylinder temperature target value

(only products with heating mode only)

D.008 Room thermostat at terminal RT


‑

35 … 65 ℃

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.009 Target value from external eBUS controller

D.010 Status of internal heating pump On, Off

D.011 Status of external heating pump On, Off

D.012 Status of cylinder charge pump On, Off

D.013 Status of hot water circulation pump On, Off

Default setting

D.014 Target pump speed (high-efficiency pump)

D.015 Actual pump speed (high-efficiency pump)

D.016 24 V DC room thermostat open/closed

D.017 Heating flow/return flow temperature control changeover

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 %

Heating mode off/on

D.018 Pump operating mode setting

D.019 Operating mode of 2-stage pump

0 = Auto

Control type:

0 = Flow, 1 = Return

Return: Automatic detection function for heating output inactive. Max. possible heating partial 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 controller

3 = Eco (intermittently operating pump)

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

Not relevant

0 = Flow

3 = Eco

65 °C D.020 Max. setting for cylinder target value Adjustment range: 50 - 70 °C (actoSTOR 65 °C)

D.022 Hot water requirement (via C1/C2, impeller or APC)

On, Off

D.023 Summer/winter mode (heating off/on) Heating on, heating off (summer mode)

D.025 Hot water generation enabled by eBUS controller

On, Off

Appendix

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

Not adjustable


41

Appendix

Code Parameter

D.026 Auxiliary relay control

D.027 Switching of relay 1 on the VR 40 "2 in 7" multi-functional module

D.028 Switching of relay 2 on the VR 40 "2 in 7" multi-functional module

D.033 Fan speed target value



2 = External pump


4 = Extractor hood








2 = External pump


4 = Extractor hood








2 = External pump


4 = Extractor hood







In rpm

D.034 Fan speed actual value

D.035 Position of the diverter valve

In rpm

Heating mode

Parallel operation (mid-position)

DHW mode

In l/min D.036 Hot water flow volume (impeller sensor)

D.039 Solar feed temperature Actual value in °C

Actual value in °C D.040 Flow temperature

D.041 Return temperature Actual value in °C

D.044 Digitised ionisation value

D.046 Pump type

D.047 Outside temperature (with Vaillant weather compensator)

D.050 Offset for minimum speed

Display field 0 to 1020

> 800 no flame

< 400 good flame

0 = Relay with disable facility

1 = PWM with disable facility

Actual value in °C

In rpm, setting range: 0 to 3000

D.051 Offset for maximum speed In rpm, setting range: -990 to 0

42

Default setting

2 = External pump

Own setting

2 = External pump

2 = External pump

0 = Relay with disable facility

Not adjustable

Nominal value set in factory

Nominal value set in factory

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable


Appendix

Code Parameter

D.058 Activating solar post-heating ( only products with integrated hot water generation)

D.060 Number of temperature limiter shutdowns

D.061 Number of ignition device cutoffs

D.064 Average ignition time

D.065 Maximum ignition time

D.067 Remaining burner anti-cycling time

D.068 Unsuccessful ignitions at 1st attempt

D.069 Unsuccessful ignitions at 2nd attempt

D.070 Set diverter valve position


0 = Solar post-heating deactivated

3 = DHW activation target value minimum 60 °C, thermostatic mixer valve required between product and draw-off point

Number of shutdowns

Default setting

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


1 = Parallel operation (mid-position)

2 = Permanent heating mode position

40 … 80 ℃


75 ℃

Own setting

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

D.071 Target value maximum heating flow temperature

D.072 Internal pump overrun after cylinder charging

D.073 Warm start target offset

D.074 actoSTOR anti-legionella function

Adjustable from 0-10 minutes in increments of 1 minute

Adjustable from -15 K to 5 K

0 = Off

1 = On

20 - 90 min

2 mins

0

1 = On

45 mins D.075 Max. charging time for domestic hot water cylinder without independent control system

D.076 Device Specific Number Device specific number = DSN)

Not adjustable

1 = 612 (VU GB 126/5-5)

3 = 615 (VU GB 156/5-5)

4 = 618 (VU GB 186/5-5)

9 = 624 (VU GB 246/5-5)

14 = 630 (VU GB 306/5-5)

20 = 637 (VU GB 376/5-5)

6 = 825 (VUW GB 256/5-5)

10 = 832 (VUW GB 326/5-5)

13 = 835 (VUW GB 356/5-5)

17 = 838 (VUW GB 386/5-5)

Adjustable cylinder charging output in kW D.077 Limit on cylinder charging output in kW

D.078 Limit on cylinder charging temperature in °C

D.080 Operating hours, heating

50 °C - 80 °C

Note

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

In hours (h)

75 °C

D.081 Operating hours, hot water generation

D.082 Number of burner start-ups in heating mode

D.083 Number of burner start-ups in hot water mode

D.084 Maintenance indicator: Number of hours until the next maintenance

In hours (h)

Number of burner start-ups

Number of burner start-ups

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

Not adjustable

Not adjustable

Not adjustable

Not adjustable


43

Appendix

Code Parameter

D.088 Start delay for hot water draw-off detection via impeller (only products with integrated hot water generation)

D.090 Status of digital controller


0 = 1.5 l/min and no delay,

1 = 3.7 l/min and 2 sec. delay

Recognised, not recognised

D.091 Status of DCF with external temperature sensor connected

D.092 actoSTOR module recognition

No reception

Reception

Synchronised

Valid

0 = Not connected

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

2 = Connection active

Setting range: 0 to 99 D.093 Setting the Device Specific Number

(DSN)

D.094 Delete fault history

D.095 Software version of PeBUS components

D.096 Default setting

D.098 Value of coding resistances for gas group and output range

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 resistance 1 in cable harness for output range:

8 = 612 (VU GB 126/5-5 A); 615 (VU GB 156/5-5 A); 618

(VU GB 186/5-5 A); 825 (VUW GB 256/5-5)

9 = 624 (VU GB 246/5-5 A); 832 (VUW GB 326/5-5)

10 = 630 (VU GB 306/5-5 A); 835 (VUW GB 356/5-5)

11 = 637 (VU GB 376/5-5 A); 838 (VUW GB 386/5-5) yy = Coding resistance 2 on PCB for gas group:

02 = P gas

03 = H gas

C

Status codes – Overview

Status code Meaning

Heating mode

S.00

S.01

S.02

S.03

S.04

S.05

Heating: No heat demand

Heating mode: Fan start-up

Heating mode: Pump pre-run

Heating mode: Ignition

Heating mode: Burner on

Heating mode: Pump/fan overrun

S.06

S.07

Heating mode: Fan overrun

Heating mode: Pump overrun

S.08

Heating mode: Remaining anti-cycling time

Hot water handling mode (products with integrated hot water generation)

S.10

S.11

S.13

Hot water requirement via flow sensor

DHW mode: Fan start-up

DHW mode: Ignition

Default setting

1.5 l/min and no delay

Own setting

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

44


S.22

S.23

S.24

S.25

S.26

S.27

S.28

Others

S.30


S.14

S.15

S.16

S.17

DHW mode: Burner on

DHW mode: Pump/fan overrun

DHW mode: Fan overrun

DHW mode: Pump overrun

Comfort mode, warm start or hot water handling mode with

actoSTOR or cylinder charging mode

S.20

S.21

DHW demand

DHW mode: Fan start-up

DHW mode: Pump pre-run

DHW mode: Ignition

DHW mode: Burner on

DHW mode: Pump/fan overrun

DHW mode: Fan overrun

DHW mode: Pump overrun

Hot water burner anti-cycling time

S.31

S.32

S.34

S.39

S.40

S.41

S.42

S.46

S.53

S.54

S.57

S.58

S.61

S.62

S.63

S.76

S.96

Room thermostat (RT) is blocking heating mode

Summer mode active or no heat requirement from eBUS controller

Waiting period because of fan speed deviation

Frost protection mode active

"Burner off contact" has responded (e.g. contact thermostat or condensate pump)

Comfort protection mode is active: Product running with limited heating comfort

Water pressure > 2.8 bar

Flue non-return flap return signal blocks burner operation (only in connection with VR

40 accessories) or condensate pump faulty, heat requirement is blocked

Comfort protection mode, flame loss at minimum load

Product is within the waiting period of the modulation block/operation block function as a result of low water pressure (flow/return spread too large)

Product is within the waiting period of the operation blocking function as a result of low water pressure (temperature gradient)

Waiting period, comfort safety mode

Modulation limitation due to noise/wind

Gas family check unsuccessful: The coding resistance on the PCB does not match the entered gas group (see also F.92).

Gas family check unsuccessful: CO/CO₂ val-

ues at limit. Check combustion.

Gas family check unsuccessful: Combustion quality outside permissible range (see F.93).

Check combustion.

System pressure too low. Top up water.

Return sensor test running, heating demands are blocked.


Appendix

45

Appendix


S.97

S.98

Water pressure sensor test running, heating demands are blocked.

Flow/return sensor test running, heating demands are blocked.

D Overview of fault codes

Code

F.00

F.01

F.02

F.03

F.10

F.11

F.12

F.13

F.20

F.22

F.23

F.24

F.25

F.26

F.27

F.28

F.29

F.32

F.42

Meaning

Flow temperature sensor interruption

Return temperature sensor interruption

Cause

NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC defective

NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC defective

NTC defective, NTC cable defective, defective plug connection on NTC, defective plug connection on actoSTOR electronics

Interruption cylinder charging sensor actoSTOR (NTC) only in combination with

F.91

Interruption cylinder sensor actoSTOR

(NTC) only in combination with F.91

Flow NTC short circuit

Return NTC short circuit


NTC defective, short circuit in cable harness, cable/casing


Short circuit at cylinder charging sensor

(NTC) only in combination with F.91

Product with integrated hot water generation: Short circuit warm start sensor/cylinder sensor

Product with integrated hot water generation and actoSTOR: Short circuit cylinder sensor (NTC) only in combination with F.91

Safety switch-off: Temperature limiter



Safety switch-off: Low water pressure

Incorrect earth connection between cable harness and product, flow or return NTC defective (loose connection), black discharge via ignition cable, ignition plug or ignition electrode

No or insufficient water in the product, water pressure sensor defective, cable to pump or water pressure sensor loose/not connected/defective

Safety switch-off: Temperature difference too great

Pump blocked, insufficient pump output, air in product, flow and return

NTC connected the wrong way round

Safety switch-off: Temperature rise too fast

Pump blocked, insufficient pump output, air in product, system pressure too low, non-return valve blocked/incorrectly installed

Safety switch-off: Flue gas temperature too high

Fault: Gas valve without function

Safety switch-off: Flame simulation

Break in plug connection for optional flue gas safety temperature limiter

(STB), break in cable harness

Gas valve stepper motor not connected, multiple plug on the PCB not plugged in correctly, interruption in cable harness, gas valve stepper motor defective, electronics defective

Moisture on the electronics, electronics (flame monitor) defective, gas solenoid valve leaking

Failure during start-up: Ignition unsuccessful

Gas meter defective or gas pressure monitor has triggered, air in gas, gas flow pressure too low, thermal isolator device (TAE) has triggered, condensate duct blocked, incorrect gas restrictor, incorrect spare part gas valve, fault on the gas valve, multiple plug on PCB incorrectly plugged in, break in cable harness, ignition system (ignition transformer, ignition cable, ignition plug, ignition electrode) defective, ionisation current interrupted (cable, electrode), incorrect earthing of product, electronics defective

Failure during operation: Re-ignition unsuccessful

Fan fault

Coding resistance fault (possible in combination with F.70)

Gas supply temporarily stopped, flue gas recirculation, condensate duct blocked, defective earthing of product, ignition transformer has spark failure

Plug on fan not correctly plugged in, multiple plug on PCB not correctly plugged in, break in cable harness, fan blocked, Hall sensor defective, electronics defective

Short circuit/interruption in output range coding resistance (in cable harness at heat exchanger) or gas group resistor (on PCB)

46


F.63

F.64

F.65

F.67

F.68

F.70

F.71

Code

F.49

F.52

F.53

F.54

F.56

F.57

F.61

F.62

F.72

F.73

Appendix

Meaning

Fault: eBUS

Contact fault mass flow sensor/Venturi

Combustion regulation fault

Fault in the gas supply (in combination with

F.28/F.29)

Combustion component fault

End comfort protection mode

Gas valve actuation fault

Gas valve switch-off delay

Fault: EEPROM

Fault: Electronics/NTC

Fault: Electronics temp.

Fault: Electronics/flame

Fault: Unstable flame signal

Invalid device specific number (DSN)

Flow NTC fault

Flow/return NTC fault

Water pressure sensor signal in the wrong range (too low)

Cause

Short circuit on eBUS, eBUS overload or two power supplies with different polarities on the eBUS

The mass flow sensor/Venturi is not connected electrically

–

The plug is not plugged in correctly

–

The plug is not plugged in

–

The plug is defective

–

The slot is defective (loose connection)

–

Mass flow sensor/Venturi defective

The combustion regulation has detected a fault

–

Gas flow pressure too low

–

Liquid gas coding resistance used when operating with natural gas

–

If the fault occurs again after being cleared:

–

Gas valve defective

–

Mass flow sensor/Venturi defective, wet or blocked (if the fault occurs again after being cleared): Do not wet the sensor, do not use any lubricants on the O-ring on the Venturi.

There is insufficient gas supply to operate the unit

–

Gas isolator cock(s) closed

–

Gas flow pressure is too low

–

Gas valve defective

A component in the combustion regulation is defective

–

Contact fault at the gas valve (plug not plugged in correctly or not plugged in, plug defective, slot is defective (loose connection))

–

Natural gas coding resistance used when operating with liquid gas

–

If the fault occurs again after being cleared: The gas valve is defective

Active comfort protection mode has detected a regulation fault

–

Ignition electrode highly corroded

The gas valve cannot be actuated

–

Cable harness supply line to the gas valve is defective (short to earth, short circuit)

–

Gas valve defective

–

PCB defective

Delayed shutdown of gas valve detected

–

Secondary light (ignition and monitoring electrode indicates delayed extinguishing of the flame signal)

–

Gas valve defective

–

PCB defective

Electronics defective

Flow or return NTC short circuited, electronics defective

Electronics overheating due to external influences, electronics defective

Implausible flame signal, electronics defective

Air in gas, gas flow pressure too low, incorrect air ratio, condensate duct blocked, incorrect gas restrictor, ionisation flow interruption (cable, electrode), flue gas recirculation, condensate duct

If spare parts fitted: Display and PCB replaced at same time and DSN not reset, incorrect or missing output range coding resistance

Flow temperature sensor signalling constant value:

–

Flow temperature sensor incorrectly positioned at supply pipe

–

Flow temperature sensor defective

Flow/return NTC temperature difference too great → flow and/or return temperature sensor defective

Interruption/short circuit of water pressure sensor, interruption/short circuit to GND in supply line to water pressure sensor or water pressure sensor defective


47

Appendix

Code

F.74

F.75

F.77

F.78

F.80

F.81

F.83

F.84

F.85

F.90

F.91

F.92

F.93

LED actoSTOR module

Communication fault

Meaning

Water pressure sensor signal outside correct range (too high)

Fault: No pressure change detection when starting pump

Cause

Line to water pressure sensor has a short circuit to 5 V/24 V or internal fault in the water pressure sensor

Water pressure sensor and/or pump defective, air in the heating installation, insufficient water in the product; check adjustable bypass, connect external expansion vessel to the return

No response from flue non-return flap or condensate pump defective

Fault: Flue non-return flap/condensate pump

Interruption to DHW outlet sensor at the external controller

Interruption or short circuit of secondary heat exchanger inlet sensor; only in connection with F.91

actoSTOR charging pump defective; only in combination with F.91

Fault: Flow and/or return temperature sensor temperature change

Fault: Flow/return temperature sensor temperature difference implausible

Fault: Flow and return temperature sensors incorrectly installed

Communication with actoSTOR module interrupted

UK link box is connected, but hot water NTC not bridged


Sensor plug has short to earth to the casing, short circuit in cable harness, sensor defective

Cylinder is not fully charged after specified time.

–

Check cylinder charging sensor and cylinder sensor

–

Air in the actoSTOR pump

–

Inspect cable harness for pump

–

Check the impeller sensor and/or limiter in the product

–

Diverter valve defective

–

Secondary heat exchanger blocked

–

Pump faulty

When the burner starts, the temperature change registered at the flow and/or return temperature sensor is non-existent or too small.

–

Insufficient water in product

–

Flow or return temperature sensor not in correct position at pipe

Flow and return temperature sensors returning implausible values.

–

Flow and return temperature sensors have been inverted

–

Flow and return temperature sensors have not been correctly installed

The flow and/or return temperature sensors have been installed on the same pipe/incorrect pipe

Check cable harness from product to actoSTOR module (PEBus).

If the product is to be operated without an actoSTOR module, set

D.092 = 0.

Sensor/actuator fault on actoSTOR module

Coding resistance fault

Poor combustion quality actoSTOR electronics status

No communication with the PCB

The coding resistance on the PCB does not match the entered gas group: Check the resistance, repeat the gas family check and enter the correct gas group.

Combustion regulation has detected poor combustion quality

–

Incorrect gas restrictor has been installed for the gas family (another gas family is present)

–

Recirculation

–

Mass flow sensor/Venturi defective (wet, blocked): Do not wet the sensor, do not use any lubricants on the O-ring on the Venturi.

LED on: Communication OK

LED flashing: Communication not OK

LED off: No power supply

Communication fault between display and PCB in the electronics box

48


1

Appendix

E Connection diagrams

E.1

Connection 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

X20

8

7

5

17

3

4

16

2

15

12

13

X51

X100

1

X90

X40 X51

X30

X35

X31

X20

X22

X25

X2

X24

X100

X16

2

X11

1

T2

X18

X12

X101

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

3

4

6

1

3

4

M

1

2

+24V

Hallsignal

4

5

PWM

Masse

11

12

13

10

7

8

9

14

15

16

17

18

C1

C2

24V

230V~

19

20

21

Main PCB 2 Operator control panel PCB


49

6

7

8

9

10

11

12

3

4

5

Appendix

Gas valve

Mass flow sensor

Outside temperature sensor, flow temperature sensor (optional, external), DCF receiver

Circulation pump remote control

Power coding resistor

Return temperature sensor

Flow temperature sensor

Fan

Contact thermostat/burner off

24 V DC room thermostat

17

18

19

13

14

15

16

20

21

*

Bus connection (digital room thermostat/controller)

Diverter valve


Cylinder temperature sensor

Cylinder contact "C1/C2"

Gas group coding resistor

Auxiliary relay (select via D.026)

Internal pump

Ignition electrode

Depending on product type

50


Appendix

1

2

3

E.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

X2

X24

X100

X16

2

X11

1

T2

X18

X12

X101

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

1

3

4

6

1

3

4

M

1

2

+24V

Hallsignal

4

5

PWM

Masse

11

12

13

10

7

8

9

14

15

16

17

18

C1

C2

24V

230V~

3

2

1

3

2

1

19

10

20

Main PCB

Operator control panel PCB

Gas valve

4

5

21

Mass flow sensor



51

Appendix

10

11

12

8

9

6

7

13

14





Fan




Diverter valve

19

20

21

15

16

17

18

*


Cylinder temperature sensor

Cylinder contact "C1/C2"



Internal pump

Ignition electrode


52


Appendix

1

2

3

E.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

X2

X24

X100

X16

X100

18

7

17

8

X2

14

13

11

4

12

1

5

3

2

6

X24

3

17

X16

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

X18

L

N

2

X11

1

T2

X18

X12

X101

X1

RT

L

N

*

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

18

19

15

16

17

4

5

6

20

21

Main PCB


Gas valve

4

5

24V

230V~

22

Mass flow sensor



53

Appendix

10

11

12

8

9

6

7

13

14





Fan




Diverter valve

19

20

21

15

16

17

18

22

*


Impeller sensor

Warm start sensor

Hot water sensor



Internal pump

Ignition electrode


54


Appendix

1

2

3

E.4

Connection diagram, product with integrated hot water generation, ≥ 37 kW

2

X51

X51

1

X90

X40 X51

X30

X35

X31

X20

X22

X25

X2

X24

X100

X16

2

X11

1

T2

X18

X12

X101

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

18

19

15

16

17

3

2

1

3

2

1

20

10

21

4

5

6

Main PCB


Gas valve

4

5

24V

230V~

22

Mass flow sensor



55

Appendix

10

11

12

8

9

6

7

13

14





Fan




Diverter valve

19

20

21

15

16

17

18

22

*


Impeller sensor

Warm start sensor

Hot water sensor



Internal pump

Ignition electrode


F

Inspection and maintenance work – Overview

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 in the table.

No.

Work

Inspection

(annual)

Maintenance

(At least every five years)

1

2

3

4

5

6

Check the air/flue pipe for leak-tightness and to ensure that it is fastened correctly. Make sure that it is not blocked or damaged and has been installed in accordance with the relevant Installation Manual.

Check the general condition of the product. Remove dirt from the product and from the vacuum chamber.

Visually inspect the general condition of the Thermoblock. In doing so, pay particular attention to signs of corrosion, rust and other defects. If you notice any damage, carry out maintenance work.

Check the gas flow pressure at maximum heat input. If the gas flow pressure is not within the correct range, carry out maintenance work.

Check the CO₂ content (the air ratio) of the product and, if necessary, adjust it. Keep a record of this.

Disconnect the product from the power mains. Check that the electrical plug connections and other connections are seated correctly and correct these if necessary.

Close the gas isolator cock and the service valves.

7

8

Drain the product on the water side (observe the pressure gauge). Check the pre-charge pressure of the expansion vessel, and top up the vessel if necessary (approx. 0.03 MPa/0.3 bar under the system filling pressure).

Remove the compact thermal module.

9

10

Check the insulating mats in the combustion area. If you notice any damage, replace the insulating mats. Replace the burner flange seal each time it is opened and accordingly each time maintenance work is carried out.

11

Clean the heat exchanger.

12

Check the burner for damage and replace it if necessary.

13

Check the condensate trap in the product, clean and fill this, if required.

14

Install the compact thermal module. Caution: Replace the seals.

15

Products with integrated hot water generation only: If the volume of water is insufficient or the outlet temperature is not reached, replace the secondary heat exchanger if necessary.

16

Products with integrated hot water generation only: Clean the filter in the cold water inlet. Replace the filter if impurities can no longer be removed or if the filter is damaged. In this case, also check the impeller sensor for dirt and damage, clean the sensor (do not use compressed air for this) and replace the sensor if it is damaged.

17

Open the gas isolator cock, reconnect the product to the power mains and switch the product on.

18

19

Open the service valves, fill up the product/heating installation to 0.1-0.2 MPa/1.0-2.0 bar (depending on the static height of the heating installation) and start the purging programme P.00.

Perform a test operation of the product and heating installation, including hot water generation, and purge the system once more if necessary.

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

56


No.

Work

20

Perform the gas family check.

21

Visually inspect the ignition and burner behaviour.

22 Check the CO₂ content (the air ratio) of the product again.

23

Check the product for gas, flue gas, hot water and condensate leaks, and repair if necessary.

24 Record the inspection/maintenance work carried out.

Appendix

Inspection

(annual)

X

X

X

Maintenance

(At least every five years)

X

X

X

X

X


57

Appendix

G Commissioning Checklist

Benchmark Commissioning and

Servicing Section

It is a requirement that the boiler is installed and commissioned to the completed in full.

www.centralheating.co.uk

58

© Heating and Hotwater Industry Council (HHIC)


Appendix

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

CONTROLS

ALL SYSTEMS

CENTRAL HEATING MODE

COMBINATION BOILERS ONLY

DOMESTIC HOT WATER MODE

CONDENSING BOILERS ONLY

ALL INSTALLATIONS

Optimum start control

Fitted

Fitted

Fitted

Fitted

Yes

Yes mbar

OR

OR

mbar

Yes

Yes mbar OR

AND

AND

OR

Yes Temperature

Yes

² Ratio

² Ratio

Yes

Yes

Yes

Yes mbar


59

Appendix

SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

SERVICE 01 SERVICE 02

AND

AND

² %

² %

AND

AND

² %

² %


AND

AND

² %

² %

AND

AND

² %

² %


AND

AND

² %

² %

AND

AND

² %

² %


AND

AND

² %

² %

AND

AND

² %

² %

SERVICE 09

SERVICE 10

AND

AND

² %

² %

AND

AND

² %

² %

60


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

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

Appendix

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

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.


61

Appendix

H Opening of the flue pipe

J

L

G

B

A

II

C

P

R

S

T

D, E

H

O

H

N

N

K

A

B

C

D

I

G

H

J

K

E

F

L

M

N

O

P

Q

R

S

T

H.1

Positioning of the opening of a fan-supported flue gas pipe

Installation site

Directly below an opening, air bricks, opening windows, etc., that can be opened.

Above an opening, air bricks, opening windows, etc., that can be opened.

Horizontally to an opening, air bricks, opening windows, etc., that can be opened.

Below temperature-sensitive building components, e.g. plastic gutters, down pipes or wastewater pipes

Below eaves

Below balconies or car port roofs

From vertical wastewater pipes or down pipes

From external or internal corners

Above floors, roofs or balconies

From a surface facing a terminal

From a terminal facing a terminal

From an opening in the car port (e.g. door, window) which leads into the dwelling

Vertical from a terminal on the same wall

Horizontal from a terminal on the same wall

From the wall on which the terminal has been installed

From a vertical structure on the roof

Above the roof area

Horizontal from adjacent windows on pitched or flat roofs

Above adjacent windows on pitched or flat roofs

Below adjacent windows on pitched or flat roofs

Minimum dimensions

300 mm

300 mm

300 mm

75 mm

200 mm

200 mm

150 mm

200 mm

300 mm

600 mm

1200 mm

1200 mm

1500 mm

300 mm

0 mm

N/A

300 mm

600 mm

600 mm

2000 mm

62


Appendix

I Text from BS 5440-1 on fan-supported flue gas pipes

BS 5440–1: It is recommended that the fanned flue gas system terminal is positioned as follows:

– At least 2 m from an opening in the building directly opposite, and

– So that the combustion products are not discharged directly across a property boundary.

– Dimensions D, E, F and G: These clearances may be reduced to 25 mm without affecting the performance of the boiler.

In order to ensure that the condensate vapour plume does not damage adjacent surfaces, the terminal should be extended as shown.

– Dimension H: This clearance may be reduced to 25 mm without adversely affecting the performance of the boiler. However, in order to ensure that the condensate vapour plume does not damage adjacent surfaces, a clearance of 300 mm is preferred. For IE, recommendations are given in the current issue of the IS 813.

J Opening of the flue pipe below eaves and balconies

Balcony/eaves

Gutter

Adequately secured air/flue gas pipe

The flue pipe must protrude beyond any overhang

K Technical data

Technical data – General

612 (VU GB

126/5‑5 A)

ecoTEC plus

Designated country (designation in accordance with ISO 3166)

GB (Great

Britain), IE

(Ireland)

Approved unit categories

I

2H

15 mm

Gas connection, boiler side

Flow/return heating connections, boiler side

Hot and cold water connection, boiler side

Expansion relief valve connector (min.)

Air/flue gas connection

22 mm

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 hot water generation, if applicable), G20

1.3 m³/h

615 (VU GB

156/5‑5 A)

ecoTEC plus

GB (Great

Britain), IE

(Ireland)

I

2H

15 mm

618 (VU GB

186/5‑5 A)

ecoTEC plus

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

624 (VU GB

246/5‑5 A)

ecoTEC plus

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

630 (VU GB

306/5‑5 A)

ecoTEC plus

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

637 (VU GB

376/5‑5 A)

ecoTEC plus

GB (Great

Britain), IE

(Ireland)

II

2H3P

15 mm

22 mm

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

1.7 m³/h

22 mm

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

3.7 kPa

(37.0 mbar)

2.0 m³/h

22 mm

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

3.7 kPa

(37.0 mbar)

2.6 m³/h

22 mm

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

3.7 kPa

(37.0 mbar)

3.7 m³/h

22 mm

15 mm

60/100 mm

19 mm

2.0 kPa

(20.0 mbar)

3.7 kPa

(37.0 mbar)

4.1 m³/h


63

Appendix

612 (VU GB

126/5‑5 A)

ecoTEC plus


Min. flue gas mass rate

(G20)


(G31)

Max. flue gas mass rate

1.44 g/s

5.6 g/s

Min. flue gas temperature

40 ℃

Max. flue gas temperature

70 ℃

Approved gas-fired units

C13, C33,

C43, C53

30% efficiency

108 %

NOx class

SEDBUK (2005)

SEDBUK (2009)

(G20/G31)

Boiler dimension, width

5

A

89.3 %

440 mm

Boiler dimension, height

720 mm

Boiler dimension, depth

Mounting weight

338 mm

36 kg

615 (VU GB

156/5‑5 A)

ecoTEC plus

1.44 g/s

7.0 g/s

40 ℃

70 ℃

5

A

C13, C33,

C43, C53

108 %

89.3 %

440 mm

720 mm

338 mm

36 kg

618 (VU GB

186/5‑5 A)

ecoTEC plus

1.5 kg/h

1.80 g/s

2.40 g/s

8.4 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

108.5 %

5

A

89.3 %

440 mm

720 mm

338 mm

36 kg

624 (VU GB

246/5‑5 A)

ecoTEC plus

1.9 kg/h

2.47 g/s

2.90 g/s

11.1 g/s

40 ℃

70 ℃

5

A

C13, C33,

C43, C53

109 %

89.3 %

440 mm

720 mm

338 mm

37 kg

630 (VU GB

306/5‑5 A)

ecoTEC plus

2.4 kg/h

637 (VU GB

376/5‑5 A)

ecoTEC plus

3.0 kg/h

2.78 g/s

4.08 g/s

13.9 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109 %

5

A

89.3 %

440 mm

720 mm

372 mm

38 kg

3.05 g/s

4.08 g/s

17.4 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

108.5 %

5

A

89.3 %

440 mm

720 mm

406 mm

43 kg

Designated country (designation in accordance with ISO 3166)

825 (VUW

GB 256/5‑5)

ecoTEC plus

GB (Great

Britain), IE

(Ireland)

Approved unit categories

II

2H3P

Gas connection, boiler side

15 mm

22 mm

Flow/return heating connections, boiler side

Hot and cold water connection, boiler side

G 3/4″

Expansion relief valve connector (min.)

Air/flue gas connection

15 mm

60/100 mm

Condensate drain pipework (min.)

G20 natural gas flow pressure

19 mm

2.0 kPa

(20.0 mbar)

3.7 kPa

(37.0 mbar)

2.7 m³/h

G31 propane gas flow pressure




(G20)

2.0 kg/h

1.80 g/s

832 (VUW

GB 326/5‑5)

ecoTEC plus

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)

3.7 kPa

(37.0 mbar)

3.4 m³/h

2.5 kg/h

2.47 g/s

835 (VUW

GB 356/5‑5)

ecoTEC plus

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)

3.7 kPa

(37.0 mbar)

3.8 m³/h

2.8 kg/h

2.78 g/s

838 (VUW

GB 386/5‑5)

ecoTEC plus

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)

3.7 kPa

(37.0 mbar)

4.2 m³/h

3.1 kg/h

3.05 g/s

64


Appendix

825 (VUW

GB 256/5‑5)

ecoTEC plus

2.40 g/s


(G31)

Max. flue gas mass rate

8.4 g/s

Min. flue gas temperature

40 ℃

Max. flue gas temperature

Approved gas-fired units

C13, C33,

C43, C53

30% efficiency

NOx class

70 ℃

108.5 %

5

SEDBUK (2005)

A

89.3 %

SEDBUK (2009)

(G20/G31)

Boiler dimension, width

440 mm

Boiler dimension, height

720 mm

Boiler dimension, depth

338 mm

Mounting weight

36 kg

832 (VUW

GB 326/5‑5)

ecoTEC plus

2.90 g/s

11.1 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109 %

5

A

89.3 %

440 mm

720 mm

338 mm

37 kg

Technical data – G20 power/loading G20

Nominal heat output range P at 50/30 °C


Maximum heat output for hot water generation

Maximum heat input for hot water generation

Maximum heat input, heating side

Minimum heat input

612 (VU GB

126/5‑5 A)

ecoTEC plus

3.3

… 12.9 kW

3.0

… 12.2 kW

12.2 kW

12.4 kW

12.4 kW

3.2 kW

Heating adjustment range

3 … 12 kW

615 (VU GB

156/5‑5 A)

ecoTEC plus

3.3

… 16.1 kW

3.0

… 15.4 kW

15.4 kW

15.7 kW

15.5 kW

3.2 kW

3 … 15 kW

835 (VUW

GB 356/5‑5)

ecoTEC plus

4.08 g/s

16.2 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109 %

5

A

89.3 %

440 mm

720 mm

372 mm

38 kg

618 (VU GB

186/5‑5 A)

ecoTEC plus

4.2

… 19.3 kW

3.8

… 18.5 kW

18.5 kW

18.9 kW

18.6 kW

4.0 kW

4 … 19 kW

838 (VUW

GB 386/5‑5)

ecoTEC plus

4.08 g/s

17.9 g/s

40 ℃

70 ℃

C13, C33,

C43, C53

109 %

5

A

89.3 %

440 mm

720 mm

406 mm

43 kg

624 (VU GB

246/5‑5 A)

ecoTEC plus

5.7

… 25.7 kW

5.2

… 24.4 kW

24.4 kW

630 (VU GB

306/5‑5 A)

ecoTEC plus

6.4

… 32.2 kW

5.8

… 30.4 kW

30.4 kW

637 (VU GB

376/5‑5 A)

ecoTEC plus

7.1

… 39.6 kW

6.4

… 37.6 kW

37.6 kW

24.9 kW

24.7 kW

5.5 kW

5 … 24 kW

31.0 kW

30.9 kW

6.2 kW

6 … 30 kW

38.4 kW

38.1 kW

6.8 kW

6 … 38 kW







825 (VUW

GB 256/5‑5)

ecoTEC plus

4.2

… 20.4 kW

3.8

… 19.3 kW

25.4 kW

25.9 kW

19.6 kW

4.0 kW

Heating adjustment range

4 … 19 kW

832 (VUW

GB 326/5‑5)

ecoTEC plus

5.7

… 25.7 kW

5.2

… 24.4 kW

31.8 kW

32.4 kW

24.7 kW

5.5 kW

5 … 24 kW

835 (VUW

GB 356/5‑5)

ecoTEC plus

6.4

… 32.2 kW

5.8

… 30.4 kW

35.0 kW

35.7 kW

31.0 kW

6.2 kW

6 … 30 kW

838 (VUW

GB 386/5‑5)

ecoTEC plus

7.1

… 30.1 kW

6.4

… 28.6 kW

38.7 kW

39.5 kW

28.9 kW

6.8 kW

6 … 29 kW


65

Appendix

Technical data – Power/loading G31







618 (VU GB

186/5‑5 A)

ecoTEC plus

5.5

… 19.3 kW

5.0

… 18.5 kW

18.5 kW

18.9 kW

18.6 kW

5.3 kW

624 (VU GB

246/5‑5 A)

ecoTEC plus

6.7

… 25.7 kW

6.0

… 24.4 kW

24.4 kW

24.9 kW

24.7 kW

6.4 kW

630 (VU GB

306/5‑5 A)

ecoTEC plus

9.4

… 32.1 kW

8.5

… 30.4 kW

30.4 kW

31.0 kW

30.9 kW

9.0 kW

637 (VU GB

376/5‑5 A)

ecoTEC plus

9.4

… 39.6 kW

8.5

… 37.6 kW

37.6 kW

825 (VUW

GB 256/5‑5)

ecoTEC plus

5.5

… 19.3 kW

5.0

… 19.3 kW

25.4 kW

832 (VUW

GB 326/5‑5)

ecoTEC plus

6.7

… 25.7 kW

6.0

… 24.4 kW

31.8 kW

38.4 kW

38.1 kW

9.0 kW

25.9 kW

19.6 kW

5.3 kW

32.4 kW

24.7 kW

6.4 kW







835 (VUW

GB 356/5‑5)

ecoTEC plus

9.4

… 32.1 kW

8.5

… 30.4 kW

35.0 kW

35.7 kW

30.9 kW

9.0 kW

Technical data – Heating

612 (VU GB

126/5‑5 A)

ecoTEC plus

85 ℃

Maximum flow temperature

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

Permissible total overpressure

Minimum pressure for full operation

Expansion vessel capacity

Circulation water volume

(with reference to

ΔT= 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)

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

525 l/h

1.2 l/h

0.025 MPa

(0.250 bar)

838 (VUW

GB 386/5‑5)

ecoTEC plus

9.4

… 30.1 kW

8.5

… 28.6 kW

38.7 kW

39.5 kW

28.9 kW

9.0 kW

615 (VU GB

156/5‑5 A)

ecoTEC plus

85 ℃

618 (VU GB

186/5‑5 A)

ecoTEC plus

85 ℃

624 (VU GB

246/5‑5 A)

ecoTEC plus

85 ℃

630 (VU GB

306/5‑5 A)

ecoTEC plus

85 ℃

637 (VU GB

376/5‑5 A)

ecoTEC plus

85 ℃

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

662 l/h

1.6 l/h

0.025 MPa

(0.250 bar)

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

796 l/h

1.9 l/h

0.025 MPa

(0.250 bar)

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

1,049 l/h

2.5 l/h

0.025 MPa

(0.250 bar)

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

1,307 l/h

3.1 l/h

0.025 MPa

(0.250 bar)

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

1,617 l/h

3.8 l/h

0.025 MPa

(0.250 bar)

66


Appendix

Maximum flow temperature

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

Permissible total overpressure

Minimum pressure for full operation

Expansion vessel capacity

Circulation water volume

(with reference to

ΔT= 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)

825 (VUW

GB 256/5‑5)

ecoTEC plus

85 ℃

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

830 l/h

2.0 l/h

0.025 MPa

(0.250 bar)

832 (VUW

GB 326/5‑5)

ecoTEC plus

85 ℃

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

1,049 l/h

2.5 l/h

0.025 MPa

(0.250 bar)

835 (VUW

GB 356/5‑5)

ecoTEC plus

85 ℃

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

1,307 l/h

3.1 l/h

0.025 MPa

(0.250 bar)

Technical data – Hot water handling

Lowest water volume

Water volume (at

ΔT = 30 K)


ΔT = 35 K)


ΔT = 42 K)

Permitted overpressure

825 (VUW

GB 256/5‑5)

ecoTEC plus

2.0 l/min

12.3 l/min

10.5 l/min

8.8 l/min

Required connection pressure

Hot water output temperature range

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 … 65 ℃

832 (VUW

GB 326/5‑5)

ecoTEC plus

2.0 l/min

15.2 l/min

13.0 l/min

10.9 l/min

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 … 65 ℃

Technical data – Electrics

Electric connection

Permissible connected voltage

190 … 253 V

Built-in fuse (slow-blow)

2 A

35 W

Min. electrical power consumption

Max. electrical power consumption

Standby electrical power consumption

Level of protection

612 (VU GB

126/5‑5 A)

ecoTEC plus

230 V/50 Hz

50 W

< 2 W

Test symbol/registration no.

IP X4 D

CE‑

0085CM0320

835 (VUW

GB 356/5‑5)

ecoTEC plus

2.0 l/min

16.7 l/min

615 (VU GB

156/5‑5 A)

ecoTEC plus

230 V/50 Hz

618 (VU GB

186/5‑5 A)

ecoTEC plus

230 V/50 Hz

190 … 253 V 190 … 253 V

2 A

35 W

55 W

< 2 W

IP X4 D

CE‑

0085CM0320

14.3 l/min

11.9 l/min

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 … 65 ℃

2 A

35 W

65 W

< 2 W

IP X4 D

CE‑

0085CM0320

838 (VUW

GB 386/5‑5)

ecoTEC plus

85 ℃

30 … 80 ℃

0.3 MPa

(3.0 bar)

0.08 MPa

(0.80 bar)

10 l

1,230 l/h

2.9 l/h

0.025 MPa

(0.250 bar)

838 (VUW

GB 386/5‑5)

ecoTEC plus

2.0 l/min

18.5 l/min

15.9 l/min

13.2 l/min

1.0 MPa

(10.0 bar)

0.035 MPa

(0.350 bar)

35 … 65 ℃

624 (VU GB

246/5‑5 A)

ecoTEC plus

230 V/50 Hz

630 (VU GB

306/5‑5 A)

ecoTEC plus

230 V/50 Hz

190 … 253 V 190 … 253 V

637 (VU GB

376/5‑5 A)

ecoTEC plus

230 V/50 Hz

190 … 253 V

2 A

35 W

70 W

< 2 W

2 A

45 W

80 W

< 2 W

IP X4 D

CE‑

0085CM0320

IP X4 D

CE‑

0085CM0320

2 A

55 W

115 W

< 3 W

IP X4 D

CE‑

0085CM0320


67

Appendix

825 (VUW

GB 256/5‑5)

ecoTEC plus

230 V/50 Hz

Electric connection

Permissible connected voltage

190 … 253 V

Built-in fuse (slow-blow)

2 A

35 W

Min. electrical power consumption

Max. electrical power consumption

Standby electrical power consumption

Level of protection

65 W

< 2 W

Test symbol/registration no.

IP X4 D

CE‑

0085CM0320

832 (VUW

GB 326/5‑5)

ecoTEC plus

230 V/50 Hz

190 … 253 V 190 … 253 V

2 A

35 W

85 W

< 2 W

IP X4 D

CE‑

0085CM0320

835 (VUW

GB 356/5‑5)

ecoTEC plus

230 V/50 Hz

2 A

45 W

90 W

< 2 W

IP X4 D

CE‑

0085CM0320

838 (VUW

GB 386/5‑5)

ecoTEC plus

230 V/50 Hz

190 … 253 V

2 A

55 W

120 W

< 3 W

IP X4 D

CE‑

0085CM0320

68


Index

Index

A

Air index setting................................................................... 25

Air/flue pipe ......................................................................... 16

Air/flue pipe, installed ............................................................ 5

Appliance config. ................................................................. 26

Article number ..................................................................... 10

Automatic air vent................................................................ 22

Auxiliary relay ...................................................................... 19

B

Burner anti-cycling time....................................................... 26

Burner anti-cycling time, resetting ....................................... 27

Burner anti-cycling time, setting .......................................... 26

Burner, replacing ................................................................. 29

Bypass valve, setting........................................................... 28

C

Calling up, diagnostics codes ............................................. 26

Calling up, fault memory...................................................... 29

Calling up, installer level...................................................... 18

Carrying out, inspection work .............................................. 33

Carrying out, maintenance work.......................................... 33

CE label............................................................................... 10

Check programmes ............................................................. 20

Checking the burner ............................................................ 35

Checking, burner ................................................................. 35

Checking, CO₂ content ........................................................ 25

Checking, pre-charge pressure for the internal expansion vessel .................................................................................. 36

Circulation pump ................................................................. 18

Cleaning, cold water inlet filter ............................................ 35

Cleaning, heat exchanger .................................................. 35

Clearing, fault memory ........................................................ 29

CO₂ content, checking......................................................... 25

CO₂ content, setting ............................................................ 25

Cold water connection......................................................... 14

Cold water inlet filter, cleaning ............................................ 35

Combustion air ...................................................................... 6

Comfort mode...................................................................... 19

Comfort protection mode..................................................... 29

Compact thermal module ...................................................... 6

Compact thermal module, installing .................................... 36

Compact thermal module, removing ................................... 34

Completing, inspection work ............................................... 36

Completing, maintenance work ........................................... 36

Completing, repair work ...................................................... 33

Component test ................................................................... 34

Condensate drain pipework................................................. 15

Condensate siphon ....................................................... 23, 35

Condensate trap............................................................ 23, 35

Connecting, controller ......................................................... 18

Connection dimensions ....................................................... 11

Contact details..................................................................... 20

Controller, connecting ......................................................... 18

Corrosion............................................................................... 6

Corrugated gas pipe.............................................................. 6

D

Decommissioning ................................................................ 37

Decommissioning, temporarily ............................................ 36

Diagnostics codes, calling up .............................................. 26

Discharge pipe, expansion relief valve................................ 16

Disposal, packaging ............................................................ 37

Disposing of the packaging ................................................. 37

Documents ............................................................................ 8

Draining, product ................................................................. 36

E

Electricity ............................................................................... 5

Electronics box, closing....................................................... 17

Electronics box, opening ..................................................... 17

Electronics self-test ............................................................. 34

Ending, installation assistant ............................................... 20

F

Fan, replacing...................................................................... 30

Fault codes.................................................................... 29, 46

Fault memory, calling up ..................................................... 29

Fault memory, deleting........................................................ 29

Fault messages ................................................................... 29

Filling ................................................................................... 22

Filling mode ......................................................................... 19

Flue gas route ....................................................................... 5

From the delivery point to the installation site ..................... 11

Front casing, closed .............................................................. 5

Frost ...................................................................................... 6

Function menu..................................................................... 34

G

Gas conversion ................................................................... 23

Gas family check, performing.............................................. 20

Gas ratio setting .................................................................. 23

Gas restrictor....................................................................... 31

Gas valve ............................................................................ 30

Gas valve, replacing............................................................ 30

H

Handing over to the operator............................................... 28

Handling .............................................................................. 11

Heat exchanger, cleaning.................................................... 35

Heat exchanger, replacing .................................................. 32

Heating flow......................................................................... 15

Heating partial load ............................................................. 19

Heating return...................................................................... 15

Hot water connection........................................................... 14

I

Hot water temperature......................................................... 19

Identification plate ................................................................. 9

If you smell gas ..................................................................... 4

Inspection work, carrying out............................................... 33

Inspection work, completing ................................................ 36

Installation assistant, ending ............................................... 20

Installation assistants, restarting ......................................... 20

Installation site................................................................... 5–6

Installer level, calling up ...................................................... 18

Installing, compact thermal module..................................... 36

Installing, unit connection piece with offset ......................... 16

Installing, unit connection piece, 80/125 mm diameter ....... 16

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

Internal expansion vessel, replacing ................................... 32

Isolator devices ................................................................... 36

L

Language ............................................................................ 19

Leak detection spray ............................................................. 6

Liquid gas ........................................................................ 4, 14

M

Mains connection ................................................................ 17

Maintenance interval, setting............................................... 27

Maintenance work, carrying out .......................................... 33


69

Index

Maintenance work, completing............................................ 36

Mass flow sensor, replacing ................................................ 31

Minimum clearance ............................................................. 12

Multi-functional module ....................................................... 19

O

Operating concept ............................................................... 18

P

PCB and display, replacing ................................................. 33

PCB or display, replacing .................................................... 33

Performing, gas family check .............................................. 20

Power supply....................................................................... 17

Pre-charge pressure for the internal expansion vessel, checking .............................................................................. 36

Preparing, repair work ......................................................... 29

Pressure gauge ..................................................................... 9

Product dimensions............................................................. 11

Product, draining ................................................................. 36

Product, switching off .......................................................... 36

Pump output, setting ........................................................... 27

Pump, remaining feed head ................................................ 27

Purging ................................................................................ 23

R

Regulations ........................................................................... 6

Remaining feed head, pump ............................................... 27

Removing, compact thermal module................................... 34

Removing, unit connection piece for the air/flue pipe ......... 16

Repair work, completing...................................................... 33

Repair work, preparing ........................................................ 29

Replacing the burner ........................................................... 29

Replacing, fan ..................................................................... 30

Replacing, gas valve ........................................................... 30

Replacing, heat exchanger.................................................. 32

Replacing, internal expansion vessel .................................. 32

Replacing, mass flow sensor............................................... 31

Replacing, PCB and display................................................ 33

Replacing, PCB or display................................................... 33

Replacing, unit connection piece for the air/flue pipe.......... 16

Replacing, Venturi ............................................................... 31

Resetting, burner anti-cycling time ...................................... 27

S

Safety device......................................................................... 5

Schematic drawing ................................................................ 5

Scope of delivery................................................................. 10

Self-test ............................................................................... 34

Serial number ...................................................................... 10

Service message................................................................. 29

Setting, burner anti-cycling time .......................................... 26

Setting, bypass valve .......................................................... 28

Setting, CO₂ content............................................................ 25

Setting, maintenance interval .............................................. 27

Setting, pump output ........................................................... 27

Side section, installing......................................................... 13

Side section, removing ........................................................ 13

Spare parts.......................................................................... 29

Starting, installation assistants ............................................ 20

Status codes.................................................................. 19, 44

Supply of combustion air ....................................................... 5

Switching off ........................................................................ 19

Switching off, product .......................................................... 36

Switching on ........................................................................ 19

T

Target feed temperature...................................................... 19

Telephone number, competent person ............................... 20

Test programmes ................................................................ 20

Tool ....................................................................................... 6

Treating the heating water .................................................. 21

U

Unit connection piece for the air/flue pipe, removing .......... 16

Unit connection piece for the air/flue pipe, replacing .......... 16

Unit connection piece with offset, installing......................... 16

Unit connection piece, 80/125 mm diameter, installing....... 16

Unloading the box ............................................................... 11

V

Venturi ................................................................................. 30

Venturi, replacing ................................................................ 31

Voltage .................................................................................. 5

W

Weight ................................................................................. 12

70


0020209591_00 21.05.2015

Vaillant Ltd.

Nottingham Road Belper Derbyshire DE56 1JT

Telephone 03 30 100‑34 61 Telephone (renewables) 02 07 022‑09 28

Vaillant Service Solutions 03 30 100‑31 43 Spares Technical Enquiries 177 359 66 15 [email protected] [email protected]

www.vaillant.co.uk

© These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.

Vaillant ecoTEC plus SERIES Installation And Maintenance Instructions Manual

Installation and maintenance instructions

For the competent person

Installation and maintenance instructions

ecoTEC plus

GB, IE

Benchmark Commissioning and

Servicing Section

www.centralheating.co.uk

Related manuals

Table of contents

Vaillant ecoTEC plus SERIES Installation And Maintenance Instructions Manual

Installation and maintenance instructions

For the competent person

Installation and maintenance instructions

ecoTEC plus

GB, IE

Benchmark Commissioning and

Servicing Section

www.centralheating.co.uk

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Table of contents