Vaillant ecoTEC exclusive 832, ecoTEC exclusive 838 Installation And Maintenance Instructions Manual
Page 1
For the installer
Installation and maintenance instructions
ecoTEC exclusive
Gas wall boilers with condensing appliance technology
ecoTEC exclusive 832
ecoTEC exclusive 838
GB, IE
Page 2
Contents
1 Notes on the documentation ........................... 3
1.1 Storage of the documents ...................................... 3
1.2 Safety instructions and symbols ........................... 3
1.3 Validity of the manual ............................................. 3
2 Description of the appliance ........................... 4
2.1 Design .......................................................................... 4
2.2 Type overview ............................................................ 4
2.3 CE label ........................................................................ 4
2.4 Gas council numbers ................................................ 5
2.5 Intended use ............................................................... 5
2.6 Identification plate .................................................... 5
3 Safety instructions and regulations .............. 5
3.1 Safety instructions ................................................... 5
3.1.1 Installation and setting ............................................ 5
3.1.2 If you smell gas .......................................................... 5
3.1.3 Changes to the surroundings of the heating
device ........................................................................... 5
3.2 Related documents ................................................... 6
4 Assembly ........................................................... 7
4.1 Scope of delivery ...................................................... 7
4.1.1 Transporting the appliance .................................... 7
4.2 Dimensioned drawing and dimensions for
connection .................................................................. 10
4.3 Installation site .......................................................... 11
4.4 Required minimum gaps/assembly clearances . 11
4.5 Mounting the appliance ........................................... 12
4.6 Removing the front case ......................................... 12
5 Installation ......................................................... 12
5.1 General instructions for heating system ............ 12
5.2 Gas connection .......................................................... 12
5.3 Hot water and cold water connections ............... 13
5.4 Heating connection .................................................. 14
5.5 Pressure Relief Valve ............................................... 14
5.6 Flue pipe ...................................................................... 15
5.6.1 100 mm standard flue pipe ..................................... 15
5.6.2 Optional 125 mm flue pipe ...................................... 15
5.7 Termination of the flue pipe .................................. 15
5.8 Air connection ............................................................ 16
5.9 Condensate discharge ............................................. 17
5.10 Electrical connection ................................................ 17
5.10.1 Mains connection ...................................................... 17
5.10.2 Connection of controllers, accessories and
external installation components ......................... 18
5.10.3 External electrical controllers (non eBUS) ......... 18
5.10.4 Details for the connection of an external timer
to the connection rail ............................................... 19
5.10.5 Optional plug-in timers by Vaillant ....................... 19
5.10.6 Wiring diagrams......................................................... 20
6 Start-up .............................................................. 22
6.1 Filling the installation ............................................... 22
6.1.1 Filling and venting from the heating side ........... 23
6.1.2 First flushing of the system ................................... 24
6.1.3 Filling and venting from the hot water side ....... 24
6.1.4 Filling the condense trap ........................................ 24
6.2 Checking the gas setting ......................................... 24
6.2.1 Gas pressure statement - Natural gas ................. 24
6.2.2 Checking the connection pressure (gas inlet
working pressure) ..................................................... 25
Checking CO2 content and setting if necessary
6.2.3
(setting the air figure) ............................................. 26
6.3 Checking the equipment function ......................... 26
6.3.1 Heating ........................................................................ 27
6.3.2 Hot water function .................................................... 27
6.3.3 Subsequent flushing through of the heating
system ("hot") ........................................................... 27
6.4 Handing over the appliance to the owner .......... 28
7 Adapting the appliance to the heating system
............................................................................. 29
7.1 Selection and setting the parameters ................. 29
7.2 Overview of the settable installation parameters ... 30
7.2.1 Setting the heating partial load ............................ 30
7.2.2 Setting the pump overrun time ............................. 30
7.2.3 Setting the maximum flow temperature ............. 30
7.2.4 Setting the return temperature control .............. 30
7.2.5 Setting the burner anti-cycle time ....................... 31
7.2.6 Determination of the maintenance interval/
maintenance display ................................................ 31
7.2.7 Setting the pump output ......................................... 32
7.3 Adjusting the bypass valve ..................................... 32
8 Inspection and maintenance ........................... 33
8.1 Inspection and maintenance intervals ................. 33
8.2 General inspection and maintenance
instructions ................................................................. 33
8.3 Filling/draining the heating installation .............. 35
8.3.1 Filling the unit and heating installation ............... 35
8.3.2 Draining the unit ....................................................... 35
8.3.3 Draining the entire installation .............................. 35
8.4 Servicing the compact thermal module .............. 35
8.4.1 Dismantle compact thermal module .................... 35
8.4.2 Clean the heat exchanger ....................................... 36
8.4.3 Checking the burner ................................................. 36
8.4.4 Installing the burner assembly .............................. 36
8.5 Maintaining the secondary heat exchanger ....... 37
8.6 Cleaning the condense trap ................................... 37
8.7 Checking the expansion vessel .............................. 38
8.8 Checking the gas setting ......................................... 38
8.8.1 Checking the connection pressure (gas inlet
working pressure) ..................................................... 38
Checking CO2 content and adjusting if
8.8.2
necessary .................................................................... 38
8.9 Test operation............................................................ 38
9 Troubleshooting ................................................ 39
9.1 Diagnostics ................................................................. 39
9.1.1 Status codes ............................................................... 39
9.1.2 Diagnosis codes ......................................................... 40
9.1.3 Error codes ................................................................. 43
9.1.4 Error memory ............................................................ 43
9.2 Test programs ............................................................ 44
9.3 Resetting parameter to factory settings ............ 44
ecoTEC exclusive installation and maintenance instructions / 0020017768_042
Page 3
Contents
Notes on the documentation 1
10 Replacing components ..................................... 45
10.1 Safety instructions ................................................... 45
10.2 Replacing burner ....................................................... 45
10.3 Replacing fan or gas fittings .................................. 46
10.4 Replacing primary heat exchanger ...................... 46
10.5 Replacing electronics and display ........................ 47
11 Vaillant service ................................................. 47
12 Recycling and disposal ..................................... 47
13 Technical data ................................................... 48
Appendix
EC declaration of conformity ............................................. 49
Benchmark gas boiler commissioning checklist ............ 51
1 Notes on the documentation
The following information is intended to help you
throughout the entire documentation.
Further documents apply in combination with this installation and maintenance manual.
We accept no liability for any damage caused by failure to observe these instructions.
Other applicable documents
For the owner of the system:
Operating manual no. 838402
Brief operating instructions no. 838404
Warranty card no. 0020055745
Assembly manual for flue accessories no. 834449
1.1 Storage of the documents
Please pass on this operating and installation manual
and all other valid documents to the operator of the installation in order for him or her to store it so that it is
available whenever it is required.
1.2 Safety instructions and symbols
Please observe the safety instructions in this manual for
the installation of the appliance.
The symbols used in the manual are explained below:
Danger!
d
Immediate danger to life and limb!
Danger!
e
Risk of death from electric shock!
Danger!
H
Risk of burns or scalding!
Caution!
a
Potentially dangerous situation for the product
and environment!
Note!
h
Useful information and instructions.
• Symbol for a necessary task
1.3 Validity of the manual
This installation manual applies exclusively to units with
the following part numbers:
– 0010002668
– 0010002669
The part number of the unit can be obtained from the
identification plate.
3ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 4
2 Description of the appliance
2 Description of the appliance
2.1 Design
14
13
12
11
10
9
2.3 CE label
CE labelling shows that the appliances comply with
the basic requirements of the following directives:
– Directive 90/396/EEC of the Commission with revisions
"Directive for Harmonisation of Legal Regulations
of the Member States for Gas Consumer UNits" (Gas
equipment directive)
– Directive 92/42 EEC of the Commission with revisions
1
"Directive Concerning the Efficiency of New Hot Water
Heating Boilers Fired by Liquid or Gaseous Fuels“
2
3
(Efficiency directive)
– Directive 73/23/EEC of the Commission with revisions
"Directive Concerning Electrical Operating Equipment
for Use Within Specific Voltage Limits“ (Low voltage
directive)
– Directive 89/336/EEC of the Commission with revisions
"Directive Concerning Electromagnetic Compatibility"
The units comply with the prototype described in the EU
4
Prototype Test Approval:
PIN-No. CE-0085BR0308
The units comply with the following standards:
5
– EN 483
6
– EN 625
– EN 677
7
– EN 50165
– EN 55014
8
– EN 60335-1
– EN 60529
– EN 61000-3-2
– EN 61000-3-3
Fig. 2.1 Functional elements of ecoTEC exclusive
Key to Fig. 4.2
1 Expansion vessel 8 Aqua-Sensor
2 Air intake pipe 9 Electronics box
3 Burner assembly 10 Pump
4 Ignition electrode 11 Auto air vent
5 Gas Valve 12 Pressure sensor
6 Diverter valve 13 Heat exchanger
7 Hot water heat exchanger 14 Air / flue gas duct
2.2 Type overview
Appliance
type
832 UK (Great Britain) II
838 UK (Great Britain) II
Table 2.2 Type summary
Designated country
(designation in accordance
with ISO 3166)
Approval
category
2H3P
2H3P
Type of gas Nominal heat rating
Natural gas H G20
Liquid gas propane G31
Natural gas H G20
Liquid gas propane G31
4
ecoTEC exclusive installation and maintenance instructions / 0020017768_044
Vaillant Ltd. supports the Benchmark Initiative.
h
You will find the Benchmark Logbook on the
last page of this instruction manual. It is very
important that this document be filled out
properly when installing, commissioning and
handing-over to the operator of the installation.
in kW (heating)
27 31,4
30 37,2
Hot water output
in kW
Page 5
Description of the appliance 2
Safety instructions and regulations 3
2.4 Gas council numbers
Appliance Gas council numbers
ecoTEC exclusive 832 47 044 37
ecoTEC exclusive 838 47 044 38
Table 2.1 Gas council numbers
2.5 Intended use
The Vaillant ecoTEC exclusive is a state-of-the-art appliance which has been constructed in accordance with
recognised safety regulations. Nevertheless, danger to
the life and limb of the user or third parties can still
occur or the appliance or other material assets be impaired in the event of improper use.
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities, or lack of experience and/or knowledge, unless
they have been given supervision or instruction concerning use of the unit by a person responsible for their
safety.
Children must be watched to ensure that they do not
play with the unit.
The unit is intended as a heat producer for closed hotwater central heating installations in households. Any
other use or extended use is considered to be improper.
The manufacturer or supplier is not liable for any resulting damage. The user alone bears the risk. Intended use
includes the observance of the operating and installation manual and the adherence to the inspection and
maintenance conditions.
Caution!
a
Any incorrect use is forbidden.
2.6 Identification plate
The identification plate the Valliant ecoTEC exclusive is
attached at the factory to the bottom of the appliance.
3 Safety instructions and regulations
3.1 Safety instructions
Caution!
a
To tighten or loosen bolts, only use suitable
open-ended spanners (do not use pliers or extensions etc.).
Improper use or unsuitable tools can cause
damage, such as gas or water leaks.
3.1.1 Installation and setting
Installation, setting work and maintenance and repairs
to the unit may only be carries out by an heating engineer approved at the time by the Health and Safety Executive.
3.1.2 If you smell gas
If you smell gas, the following safety instructions must
be observed:
• Do not actuate any electrical switches in the danger area
• Do not smoke in the danger area
• Do not use a telephone in the danger area
• Close the gas stop cock
• Ventilate the danger area
• Notify your gas supplier or a suitably qualified heating
engineer.
National phone number for gas emergencies: 0800 1 11 999
3.1.3 Changes to the surroundings of the heating
device
No changes must be made to the following objects:
- the heating device
- the gas, air, water and electricity supply pipes
- the exhaust pipe
- the constructional conditions that could affect the
operational reliability of the device
3.1.4 Important instructions for propane appliances
Bleeding the liquid gas tank when installing the system:
before installing the device, make sure that the gas tank
has been bled. The liquid gas supplier is responsible for
the proper bleeding of the tank. Ignition problems can
be caused if the tank is not bled properly. In such cases,
first contact the person in charge of filling the tank.
Affix tank sticker
Affix the enclosed tank sticker (propane quality) on the
tank where it is clearly visible or on the bottle cabinet, if
possible close to the filler nozzle.
Danger!
d
Only use propane in accordance with DIN
51622 or EN 437.
5ecoTEC exclusive installation and maintenance instructions / 0020017768_04
5
Page 6
3 Safety instructions and regulations
3.2 Related documents
The installation of the appliance and any associated hot
water system must be in accordance with (but not limited to) the following; COSHH regulations, Gas Safety (Installation and Use) Regulations 1998, Health and Safety
Document No. 635 (The Electricity at Work Regulations
1989), BS7671 (IEE Wiring Regulations) and the Water
Supply (Water Fitting) Regulations 1999, or The Water
Bylaws 2000 (Scotland). It should also be in accordance
with the relevant requirements of the Local Authority,
Building Regulations, The Building Regulations (Scotland), The Building Regulations (Northern Ireland) and
the relevant recommendations of the following British
Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water
central heating systems.
Institute of Gas Engineers Publication IGE/UP/7/1998:
”Guide for gas installations in timber framed housing”
BS. 5482 Pt. 1 Domestic butane and propane gas burning installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2 Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP10 Installation of gas appliances in industrial and
commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating systems.
BS. 5440: Installation and maintenance of flues and
ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases).
Part 1 Specification for installation of flues.
Part 2 Specification for installation and maintenance
of ventilation for gas appliances.
European installation directive
Caution!
a
Installation and maintenance of the unit may
only be undertaken by a competent person approved at the time by the Health and Safety
Executive in accordance with the "Gas Safety
(Installation and Use) Regulations 1998".
In IE the installation must comply with the
current Version of I.S.813 ‘Domestic Gas Installations’ and the current Building Regulations.
The current ETCI Regulations for the installation of electrical equipment must also be observed.
Caution!
a
To tighten or loosen bolts, only use suitable
open-ended spanners (do not use wrenches or
extensions etc.).
Improper use or unsuitable tools can cause
damage, (such as gas or water leaks.)
ecoTEC exclusive installation and maintenance instructions / 0020017768_046
Page 7
Assembly 4
4 Assembly
The Vaillant ecoTEC exclusive is delivered pre-assembled in a package unit.
4.1 Scope of delivery
Check the delivery for completeness and lack of damage
(see Fig. 4.1 and Table 4.1).
2
3
1
4
5
6
7
8
Fig. 4.1 Scope of delivery for ecoTEC exclusive
Item Quantity Description
1 1 Boiler
2 1 Hanging bracket
33
4 1 Installation and connection accessories
5 1 Guarantee Card
6 1 Template
7 4 Copper tails for gas and water pipework
83
9 1 Pressure relief valve/double check valve
10 1 Lower cover (packed inside boiler)
Table 4.1 Scope of supply ecoTEC exclusive
Installation and Servicing, Users and
Flue Installation Instructions
Flow and return service valve, gas service
valve
10
9
4.1.1 Transporting the appliance
Important:
a
With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a
one man lift.
General recommendations when handling
• Clear the route before attempting the lift.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible. Do not twist –
reposition feet instead.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Avoid upper body/top heavy bending - do not lean for-
ward/sideways.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip.
• Always use assistance if required.
Removal of carton from delivery van
• Recommend 2 person lift or 1 person with use of sack truck.
• If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
• Recommend secure appliance onto truck with suitable
straps.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Always use assistance if required.
Carriage of carton from point of delivery to point of
installation – ground floor.
• Recommend 2 person lift or 1 person with use of sack truck.
• If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
• Recommend secure appliance onto truck with suitable
straps.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Clear the route before attempting the lift.
• If removing boiler from truck straddle the load and tilt
forwards to facilitate secure grip.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Do not twist – reposition feet instead.
• Take care to avoid trip hazards, slippery or wet sur-
faces and when climbing steps and stairs.
• Always use assistance if required.
7ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 8
4 Assembly
Carriage of carton from point of delivery to point of
installation – first or higher floor, cellar.
• Recommend 2-person lift or 1 person with use of sack
truck.
• If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
• Recommend secure appliance onto truck with suitable
straps.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• If 2 persons performing lift, ensure co-ordinated
movements during lift.
• Avoid upper body/top heavy bending - do not lean forward/sideways.
• Clear the route before attempting the lift.
• If removing boiler from truck straddle the load and tilt
forwards to facilitate secure grip.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Do not twist – reposition feet instead.
• Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs.
• Always use assistance if required.
Carriage of carton from point of delivery to point of
installation – roofspace.
• Recommend 2-person lift.
• Ensure co-ordinated movements during lift.
• Avoid upper body/top heavy bending - do not lean forward/sideways.
• Clear the route before attempting the lift.
• Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs.
• When transferring appliance into roofspace, recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and
support appliance.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• Always use assistance if required.
• It is assumed safe access, flooring and adequate lighting are provided in the roof space.
• It is recommended a risk assessment of the roof space
area be carried out before moving the appliance into the
area to take into account access, stability of flooring, lighting and other factors, and appropriate measures taken.
Unpacking of appliance from carton.
• Recommend 2 persons unpack appliance from carton.
• Always keep working area clear.
• Recommend straps and open carton flaps, then remove items from the top including the polystyrene
packing and remove carton by sliding up over the boiler.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs.
• Keep load as close to body as possible.
• Always use assistance if required.
• Dispose of packaging in a responsible manner.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance outside packaging.
Positioning of Appliance for Final Installation – no
obstructions.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Fit bracket securely onto wall before lifting appliance
into position.
• Obtain firm grip on front and sides of appliance, lift
upwards, ensure stable balance achieved and lift upwards to position in place on bracket.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Ensure co-ordinated movements to ensure equal
spread of weight of load.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
ecoTEC exclusive installation and maintenance instructions / 0020017768_048
Page 9
Assembly 4
Positioning of Appliance for Final Installation – above
worktop, foreseeable obstructions etc.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Fit bracket securely onto wall before lifting appliance
into position.
• Obtain firm grip on front and sides of appliance, lift
upwards, onto worktop if practicable.
• Ensure stable balance achieved and lift upwards to position in place on bracket.
• If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler.
• Ensure coordinated movements during 2 person lifts
to ensure equal spread of weight of load.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Avoid upper body/top heavy bending - do not lean forward/sideways.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
Positioning of Appliance for Final Installation – within
compartment etc. restricting installation.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Fit bracket securely onto wall before lifting appliance
into position.
• Obtain firm grip on front and sides of appliance, lift
upwards, onto worktop if practicable.
• Ensure stable balance achieved and lift upwards to
drop into place onto bracket.
• If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler.
• Ensure coordinated movements during 2 person lifts
to ensure equal spread of weight of load.
• If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler.
• Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
Positioning of Appliance for Final Installation – in
roof space restricting installation.
• If appliance weight is over 25 kg always use 2 persons
to move where practical.
• Obtain firm grip on front and sides of appliance, lift
upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket.
• If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler.
• Ensure co-ordinated movements during 2 person lifts
to ensure equal spread of weight of load.
• If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler.
• Ensure safe lifting techniques are used - keep back
straight – bend using legs - when lifting load from
floor level.
• Do not twist – reposition feet instead.
• Keep boiler as close as possible to body throughout
lift to minimise strain on back.
• Always use assistance if required.
• Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance.
• It is recommended a risk assessment of the roof space
area be carried out before moving the appliance into
the area to take into account access, stability of flooring, lighting and other factors, and appropriate measures taken.
9ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 10
4 Assembly
4.2 Dimensioned drawing and dimensions
for connection
2
800
6
7
Ø 20
Fig. 4.2 Dimensions for connection (mm)
Key to Fig. 4.2
1 Flue connection
2 Mounting bracket
3 Heating return
4 Cold water connection
5 Gas connection
6 Hot water connection
7 Heating flow
480
70
100 100
Ø 20
5
4
3
Ø 20
190
R 1/2
7
20
25
180
450
ecoTEC exclusive installation and maintenance instructions / 0020017768_0410
Page 11
Assembly 4
4.3 Installation site
The site of erection of the boiler should allow proper
connection of the air/exhaust ducting. In addition, there
should be adequate room for maintenance work and air
circulation around the boiler. The boiler can be installed
in any room, however, in rooms with a bath or a shower,
the special requirements of BS 7671 (IEE Regulations),
the electro-technical stipulations of the Building Standards (Scotland) Regulations and, in IE, the current issue
of IS 813 and the current ETCI Stipulations must especially be observed.
Danger!
e
Danger of death by electric shock! If a room
sealed boiler is installed in a room with a bath
or a shower, the electrical switches and the
boiler controller, which operate at mains voltage must be mounted in locations where any
person in the bath or in the shower cannot
reach them
In the event of installation in unusual locations, special
provisions may have to be made. Detailed instructions
for this can be found in BS 5546 and in BS 6798. The
boiler must be installed on a flat vertical wall which is
adequately robust to carry the weight of the boiler.
It is possible to mount onto a wall made of flammable
material if the regulations of the Local Authority and
the legal building stipulations are fulfilled.
In this case however, the unit would have to be mounted
in a specially made enclosure. (You can also use an
existing cabinet or existing enclosure as long as it can
be modified accordingly to suit the new application.)
Further details concerning the fundamental characteristics
when modifying existing cabinets or enclosures, including
the requirements for ventilation, are described in BS 6798.
If the boiler is to be installed in a half-timbered house,
the installation must be undertaken in accordance with
the Institute of Gas Engineers Publication "IGE/UP/7
Edition 2 Gas installation in timber framed and light steel
framed buildings". Please note the following instructions
before choosing where to
install the heater:
Caution!
a
Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance must be operated independently
of the ventilation!
When choosing the place of installation and while operating the appliance, make sure that the combustion air
is free from chemical substances such as e.g. fluorine,
chlorine, sulphur, ammonia etc. Sprays, solvents and
cleaning agents, paints, adhesives etc. contain these
kinds of substances, which - in the worst case scenario can lead to corrosion, even in the exhaust system, during ambient air dependent operating of the appliance.
Particularly in hairdessing salons, lacquering and finishing workshops, cleaning facilities, etc., the appliance
must be operated independently of the ambient air. Otherwise, a separate installation room is required to guarantee that the combustion air supply is free from the
above substances.
4.4 Required minimum gaps/assembly clearances
min
165/246*
min 5
Fig. 4.3 Required minimum gaps/assembly clearances
The boiler must be mounted on a flat, vertical wall surface which is large enough for the boiler including the
required minimum space requirement and the space required for assembly (Fig. 4.3). These are shown on the
mounting template supplied with the boiler, and are:
– 5 mm on each side of the boiler
– 145 mm underneath the boiler
– 165 mm* above the boiler if using a flue pipe of 100
mm outside diameter
– 246 mm* above the boiler if using a flue pipe of 125
mm outside diameter
– 500 mm** in front of the boiler
Note!
h
If the boiler is to be installed in a timber framed
building, it should be fitted in accordance with
“IGE/UP/7 Edition 2 Gas installations in timber
framed and light steel framed buildings“.
It is not necessary to maintain a clearance between the
appliance and combustible materials or components,
since, at the rated heating power of the appliance, the
temperature here is always lower than the permitted
temperature of 85 °C.
min 5
min 145
min 500**
11ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 12
4 Assembly
5 Installation
4.5 Mounting the appliance
240
75
75
50
50
85
1
3
Fig. 4.4 Mounting the appliance
• Fix the hanging bracket (1) to the wall using the plugs
and screws (2) provided with the appliance.
• Hang the top of the appliance (3) onto the hanging
bracket using the suspension bracket.
2
23
5 Installation
Danger!
d
The Vaillant ecoTEC exclusive may only be installed by a suitably qualified heating engineer
approved at the time by the Health and Safety
Executive who also assumes the responsibility
for installing the appliance properly and fully
commissioning the appliance prior to first use,
along with demonstrating its correct use to the
end user.
5.1 General instructions for heating system
Caution!
a
Flush the heating system thoroughly before
connecting the appliance!
By doing that, residue such as welds, cinder,
hemp, putty, rust, rough dust and similar substances are removed from the pipes. Otherwise
such substances can be deposited in the appliance and cause damage.
5.2 Gas connection
4.6 Removing the front case
2
1
Fig. 4.5 Removing the front case
To disassemble the front housing of the appliance, proceed as follows:
• Release the screw (1) on the bottom of the appliance.
• Push both the clamps (2) on the bottom of the appli-
ance together so that the front cladding releases.
• Pull the housing forwards at the lower edge and re-
move the front cladding upwards.
Danger!
d
The gas installation may only be established by
an authorised engineer approved at the time by
the Health and Safety Executive. The legal directives and the local regulations for gas supply companies must be observed.
Caution!
a
Ensure stress-free assembly of the gas pipes
to avoid leakages!
Caution!
a
The gas regulating block may be tested for
leakage only with a maximum pressure of
110 mbar! The operating pressure may not
exceed 60 mbar. If these pressures are
exceeded, the gas fitting may be damaged.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0412
Page 13
Installation 5
5.3 Hot water and cold water connections
5
2
4
1
2
3
Fig. 5.1 Gas connection
The Vaillant ecoTEC exclusive is supplied for use with
natural gas G20 and can only be converted to the use
of propane gas G31 by the Vaillant service engineer or
a suitably qualified installer approved at the time by the
Health and Safety Executive.
The gas connection is to be via 20 mm Ø steel piping.
The dynamic gas connection pressure must be at least
19 – 23 mbar for natural gas and 37 mbar for propane
gas.
• The gas pipe should first be cleaned by blowing out
with compressed air. This prevents damage to the
appliance.
• Connect the compression gas service cock and 15 mm
copper outlet tail as supplied with the appliance and
tighten.
• Connect a gas supply pipe of not less than 15 mm
diameter to the copper tail.
• Tighten all connections.
(Ensure the gas supply pipework is adequately sized
such that a 20 mbar gas pressure is available at the
boiler inlet at full flow rate).
Fig. 5.2 Hot water and cold water connection
Caution!
a
Mount the hot water and cold water lines so
they are tension-free, this prevents leaks!
Flush all foreign matter from the mains supply before
connecting to the boiler.
• Connect the cold water service valve (1) to the cold
inlet water connection of the appliance with the
washer provided and tighten.
• Connect a 15 mm cold water inlet copper pipe (3) to
the cold water service valve (1) and tighten.
• Connect a 15 mm hot water outlet pipe (4) to the
outlet connection (5) of the appliance.
The Vaillant ecoTEC exclusive is set in the factory to a
nominal water quantity of 11.6 l/min. (38 kW unit) and
9.8 l/min. (32 kW unit).
13ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 14
5 Installation
5.4 Heating connection
5.5 Pressure Relief Valve
Fig. 5.3 Heating connection
Caution!
a
Mount the heating lines so they are tensionfree, this prevents leaks!
Before connecting the heating circuit to the boiler, all
pipework and radiators must be thoroughly flushed to
remove any installation debris.
• Connect the central heating flow and return service
valves to the appliance.
• Connect the 22 mm copper pipe tails to the service
valves as shown in the illustration and tighten the nuts.
• Connect the central heating pipework to the flow and
return tails.
Two additional tubes are supplied with the appliance for
top connection of the flow and return pipework within
the casing.
Fig. 5.4 Fitting the pressure relief valve
The pressure relief valve and filling loop connection is
provided within the boiler cardboard box and should be
assembled as shown below.
• Remove plug from connection.
• Fit and install the complete unit "pressure relief valve,
filling valve and flexible connection" to the connection.
• Connect the corrugated hose to the double check
valve.
• Connect the discharge pipe to the pressure relief
valve.
The discharge pipework should be as short as possible
and installed with a continuous fall away from the boiler.
The pipe should terminate in a position which ensures
that any discharge of water or steam from the valve
cannot create a hazard to persons in or about the
premises, or cause damage to any electrical components or external wiring,and the point of discharge
should be clearly visible.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0414
Page 15
Installation 5
5.6 Flue pipe
Danger!
d
Vaillant appliances are only system-certified if
genuine Vaillant flue pipes are used. Only use
genuine Vaillant flue pipes. Malfunctions can
occur if you use other accessories. These may
result in damage and injury. You will find a list
of genuine flue pipes in the Vaillant installation
manual for flue pipes. The CE mark is valid only
if the appliance is operated with Vaillant flue
pipes.
5.6.1 100 mm standard flue pipe
754
Fig. 5.5 Item No. 303933
87
65
74
48
30
A 100 mm standard flue pipe (Item No. 303933) is available. Further information can be obtained from the installation instructions for the flue pipe. Extensions are
available to increase this length to a maximum of 8 m.
90° elbows and 45° elbows are also available to increase the flexibility during installation.
5.6.2 Optional 125 mm flue pipe
A concentric flue pipe having an outside diameter of
125 mm is available, which can be extended to a length
of up to 21 m. You can also get a vertical system. Further information can be obtained from the installation
instructions for the flue pipe.
1103
70
70
15
Fig. 5.7 Item No. 303209
650
1530
880
70
550
10
1435
Fig. 5.6 Item No. 303900
880
40
Fig. 5.8 Item No. 303200
5.7 Termination of the flue pipe
The following information applies to both flue pipe systems.
a. The flue terminal must be located in such a position
that any flammable substances can be freely dissipated.
b. Water condensation (known as pluming) can also arise
at the terminal of the flue pipe. Installation sites
where these appearances may cause a problem should
be avoided.
c. If the flue terminal is less than 2 m above a balcony,
the ground or a flat roof that is accessible by persons,
a suitable protection guard should be fitted (manufactured by Tower Flue Components, Tonbridge, TN9 1TB,
Model K3, plastic-coated).
15ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 16
5 Installation
A
G
F
J
H, I
E
Fig. 5.9 Terminal Locations
BCD
A
A
A
G
Note!
h
Vertical flue pipes must not terminate within
600 mm of an opening window, an extraction
opening or any other ventilation opening.
The flue pipe must be fitted, or screened, in such a way
that ignition or damage to sections of the building are
avoided.
B
F
M
G
L
F
F
K
K
L
BS 5440–1: We recommend that the terminal of a
fan-assisted flue pipe system be positioned as follows:
a) At least 2 m from an opening in the building directly
opposite, and
b)so that the combustion products do not flow out at
right angles to a boundry.
1) Dimensions B, C and D:
These dimensions can be reduced to 25 mm without
having a negative effect on the output of the boiler.
In order to prevent the products and condensation
emission from impinging on any bordering surfaces,
the terminal should be extended as shown in Fig. 5.10.
2)Dimension F:
This dimension can be reduced to 25 mm without
having a negative effect on the output of the boiler.
In order to prevent the smoke and condensation
emission from impinging on any bordering surfaces,
however, a gap of 300 mm is recommended. For IE,
recommendations are given in the current issue of
the IS 813.
Terminal location mm
Directly under or above an opening or the horizontal
A
to an opening, a hollow ventilation tile, an opening win-
dow etc.
B Under gullies, down-pipes or drainpipes 75
C Unter gutters 200
D Under balconies 200
A From vertical drainpipes and down-pipes 25
F From external and internal corners 300
G Above the ground, a roof or a balcony 300
H Opposite another surface 600
I Opposite another termination 1200
J Next to an opening (e.g. a door, window) within a car-port 1200
K Vertically away from a terminal on the same wall 1500
L Horizontally away from a terminal on the same wall 300
M Distance away from an adjacent vertical flue pipe 500
Table 5.1 Position of the flue terminal in a fan-assisted con-
centric flue pipe
300
Note!
h
In addition, the terminal should not be located
closer than 150 mm from a wall-opening provided
for e.g. a window.
Boundary flue terminations must as a minimum comply
with Building regulation part „J“ 600 mm and should
also be in accordance with the Guide to Condensing
Boiler Installation which recommends 2.5 m from wall,
fence or boundary.
Where a plume diverter terminal is used this is measured in the direction of the flow of products.
Fig. 5.10 Flue pipe terminating under balconies or gutters
5.8 Air connection
Detailed recommendations concerning air connection
are given in BS 5440, Part 2.
A ventilation opening in the room or inner room section
where the boiler is installed is not required .
Ventilating a compartment or enclosure
The boilers have a very high energy efficiency. As a
result of this, only small heat losses are produced at the
casing of the appliance. For this reason, cabinets and
enclosures in which the boiler is fitted do not need to
have permanent ventilation openings at the top and
bottom for cooling.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0416
Page 17
Installation 5
5.9 Condensate discharge
1
2
4
a
3
Internal
stackpipe
Fig. 5.11 Condensate discharge
b
3
Internal
discharge system
c
6
5
Gulley
d
7
Soakaway
The ecoTEC exclusive units are equipped with a normal
water condensate collector where the condensate is
continuously diverted into the drain pipe.
• Connect the condensate drain (1) of the boiler to a
condensate drain pipe (2) which has a minimum internal diameter of 19 mm (22 mm outside diameter for all
external pipes) and which is made from an acid-resistant material (e.g. plastic overflow pipe).
Note!
h
The drain pipe connected to the condensate
drain of the boiler must have a constant gradient (45 mm per metre) and should be installed
and terminate within the building to prevent
the possibility of freezing up.
The condensate drain pipe should terminate in a suitable location, e.g.:
a) The drain pipe should preferably terminate in the floor
of the house in the ventilation duct (at least 450 mm
above the duct base). There must be a siphon (3) fitted
in the line (mounted in the boiler) producing a connection head of at least 75 mm of water. A ventilation
valve (4) must be fitted in the drain pipe in front of the
siphon. The connection to the ducting should not allow
overflow into another drain pipe or allow overflow from
another drain pipe into the condensate drain pipe. This
can be achieved by keeping a gap between the pipe
branches of at least 110 mm, with a duct diameter of
100 mm, and 250 mm with a duct diameter of 150 mm.
b) Connection into the domestic waste water drain pipe
(e.g. a sink or washing machine) with an external termination. The condensate drain pipe should have a
minimum diameter of 22 mm, without length restriction, and also be fitted with a siphon (3) having a con-
nection head of 75 mm (fitted within the boiler already). The connection should be made after the drain
siphon if possible. If the installation is only possible in
front of the siphon, there must be a ventilation valve
between the two siphons. This is normally provided in
a drain.
c) Draining into a gully (5) under the grid (6) and above
the water level. The external piping should be kept as
short as possible to minimise the frost risk, and should
be no longer than 3 m.
d)To the condensate absorption point (drainage ditch) (7).
The external pipe should have a maximum length of 3 m.
Further information can be obtained from "BS 6798
Specification for installation of gas–fired boilers of rated
input not exceeding 70 kW net". The condense trap (1)
must be filled with water as described in the relevant
section before the boiler is commissioned.
5.10 Electrical connection
Danger!
d
The electrical installation may only be undertaken by an authorised engineer.
Risk of fatal electric shock from touching live
connections. Always disconnect the power supply first by pulling the plug out of the wall
socket. Only after this can the installation be
undertaken. Continuous voltage is present on
the mains connection terminals L and N, even if
the main switch is turned off!
5.10.1 Mains connection
The appliance is fitted with a 1.0 m long connection
cable with mains plug. The three-pole mains plug is fitted with a 3.0 A fuse. The connection cable is wired into
the appliance in the factory.
Connection to the mains supply shall be made via the
fused 3 pin plug to an unswitched shuttered socket,
complying to the requirements of BS 1363.
17ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 18
-+789 LN 345
5 Installation
5.10.2 Connection of controllers, accessories and
external installation components
The following controllers, accessories and installation
components can be connected to the ecoTEC exclusive
(see Table 5.2).
The installation should be carried out in accordance with the
individual instruction manual. The required connections to
the electronic system of the boiler (e.g. for external controllers, external sensors etc.) should be undertaken as follows:
• Remove the front cover of the device, and lower the
electronic box forward.
• Unclip the rear cover of the electronic box and hinge
the cover upwards.
• Insert the connection lines of the components to be
connected through the cable openings (1) on the left
hand side of the underside of the appliance.
• Then insert the connection lines through the cable
openings (2) into the electronic box and cut them to
length.
-+789 LN 345
Fig. 5.13 Example for cable routing
1
2
Fig. 5.12 Opening the switchgear box rear wall
• Remove the insulation over a length of 2 - 3 cm and
insulate the cores.
• Connect the connection cable in accordance with
Table 5.2 and Fig. 5.13 to the relevant screwed terminals in the electronic system.
Caution!
a
Do not connect mains voltage to the terminals
7, 8, 9! Danger of destroying the electronics!
Note!
h
There is no provision set in the factory for
connection of an installation thermostat for
underfloor heating.
Note!
h
Make sure that the connection cables are
securely fastened in to the screw terminals.
5.10.3 External electrical controllers (non eBUS)
The boiler connections 3, 4 and 5 serve for the connection of external controllers, for example a timer and/or
a room thermostat. The connections 3 and 4 are connected to each other in the factory. If external controllers are used, this connection must be removed and the
controllers must be connected to connections 3 and 4.
The connection 5 is an additional neutral line for external neutral lines, for example for the sensor of a room
thermostat.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0418
Page 19
5.10.4 Details for the connection of an external
timer to the connection rail
20 VDC (DO NOT USE 7, 8, 9 IN UK!)
987
LN
N
L
3 A FUSE
MAINS
SUPPLY
230 V
50 Hz
Fig. 5.14 Details for the connection of timers
SWITCH
CONTACTS
L
CLOCK
N
5
3
4
ROOM
THERMOSTAT
N
Installation 5
If it is intended to connect a room thermostat in addition to a timer, the connection between the ON connection of the timer and connection 4 on the boiler must be
interrupted by the contacts of the room thermostat (see
circuit diagram Fig. 5.14).
5.10.5 Optional plug-in timers by Vaillant
Further details for the connection can be found in the
relevant instructions of the accessories. The cover on
the connection box should be replaced after all the electrical connections have been made. The cover is secured
with two clips.
Controller Item no. Connection
VRT 400 (single-circuit weather compensator) 307 409 Installation in electronics box (plug-and-play)
VRT 240 (room thermostat) 307 401 Wall mounting, terminal 3 - 4
VRT 360f (room thermostat) 0020018253 Remote controller, receiver wall mounting
VRT 360 (room thermostat) 307 406 Wall-mounted, 2-wire bus
VRT 40 (room thermostat) 300 662 Wall-mounted, 3-wire connection to terminals 7-8-9
VRT 50 (room thermostat) 0020018265 Wall-mounted, eBus
Telecommunication Item no. Connection
vrnetDIALOG 830 00 2000 3988 GSM/GPRS, wall-mounted or installation in electronics box
vrnetDIALOG 840/2 00 2000 3983 Wall-mounted, analogue telephone line up to 16 appliances
vrnetDIALOG 860/2 (Int) 00 2000 3984 Wall-mounted, GSM/GPRS, up to 16 appliances
Accessories Item no. Connection
Accessory module 2 from 7 00 2001 7744 Fitting in the electronics box
vrDIALOG 810 306 743 Visualisation and configuration software
Table 5.2 Controller and accessories
(plug-and-play)
19ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 20
5 Installation
5.10.6 Wiring diagrams
Connection eBUS accessories
X22
Cable harness compact thermal module
PWM pump
Connection accessories module
Diagnosis via eBUS,
vrnetDIALOG
External sensor
External flow or return sensor
Cable harness hydraulics
Connection for external
eBUS controller
Room thermostat 24 V:
Connection 7, 8 and 9
No bi-directional interface
(only analogue)
Caution:
Do not connect mains voltage!
Danger of damage to
the electronics!
Fig. 5.15 Connection wiring ecoTEC exclusive
Mains connection: 230 V/50 Hz
Room thermostat 230 V/50 Hz
(Remove bridge when connecting)
Heating pump
Fan
Fuse 2A, slow-response
Igniter
ecoTEC exclusive installation and maintenance instructions / 0020017768_0420
2nd pump: - circulation pump
- storage tank charging pump
- 2nd external pump
- solar pump
Page 21
Installation 5
Flow temperature
sensor (NTC)
X 20/5 red
X 20/7 black
X 20/8 blue
X 20/7 black
Gas valve
X 2/9 black
X 2/11 red
X 2/12 green
Return temperature
sensor (NTC)
X 20/18 red (24 VDC)
X 20/9 blue (Earth)
Water pressure sensor
Water
through flow
sensor
Ignition electrode
Plug connection
Fan
X 20/16 blue (Earth)
X 20/4 grey (PWM)
X 20/3 black (Hall signal)
X 20/17 red (24 VDC)
X 2/16 black A
X 2/7 pink B
X 2/15 brown C
X 2/8 blue D
Preference changeover valve
Pump
X 2/3 red (+ 5V)
X 2/2 black (Earth)
X 2/6 green (Signal)
Mains plug
X22
X31
Switchgear box
X40
X 2/4 orange
X 2/10 black
Secondary
heat exchanger
X 2/5 violet (Signal)
X 2/1 black
X41
X 2 X 20
(NTC)
Hot water outlet
(NTC)
Fig. 5.16 Electronic board layout ecoTEC exclusive
21ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 22
6 Start-up
6 Start-up
6.1 Filling the installation
Mixing additives with the heating water can result in material damage. However, up to now, no incompatibility
with Vaillant appliances has been detected with proper
use of the following products.
• When using additives, follow the additive manufactur-
er‘s instructions without exception.
Vaillant accepts no liability for the compatibility of any
additive or its effectiveness in the entire heating system.
Additives for cleaning purposes
(subsequent flushing required)
- Fernox F3
- Jenaqua 200
- Jenaqua 300
- Jenaqua 400
- Sentinel X 300
- Sentinel X 400
Additives intended to remain permanently in the system
- Fernox F1
- Fernox F2
- Jenaqua 100
- Jenaqua 110
- Sentinel X 100
- Sentinel X 200
Additives for frost protection intended to remain permanently in the system
- Fernox Antifreeze Alphi 11
- Sentinel X 500
Provided the national regulations and technical standards do not specify any higher requirements, the following applies:
• You must treat the heating water
- if the total volume of filling and top-up water exceeds thrice the nominal volume of the heating system over the service life of the system
or
- if the limits given in the following tables are not adhered to.
Heating water
qualities
Electric conductivity
at 25 °C
Appearance Free of sedimentary substances
pH-value at 25 °C 8,2-10,0
Oxygen mg/L
1) With aluminium and aluminium alloys, the ph value range is
restricted from 6.5 to 8.5.
Table 6.2 Guidelines for heating water: Salinity
Unit Low-salt saline
μS/cm < 100
1)
< 0,1 < 0,02
100-1500
8,2-10,0
1)
Caution!
a
Aluminium corrosion resulting in leakages
caused by unsuitable heating water!
Unlike materials such as steel, cast iron or copper, aluminium is reactive to alkalised heating
water (pH-value > 8,5) which results in significant corrosion.
With aluminium, ensure that the pH value of
the heating water ranges between 6.5 up to a
maximum of 8.5.
• Inform the operator of the necessary measures in
case you have used any of these additives.
• Inform the operator of the required procedures for
frost protection.
• Observe the applicable national regulations and technical standards for the treatment of filling and top-up
water.
Total heating
output
kW mol/m
< 50 No requirement or < 3
> 50 to ≤ 200
> 200 to ≤ 600
> 600
1) with systems equipped with wall-hung boiler and systems with electric heating elements
2) of the specific system volume (nominal capacity in litres/heating output; in case of multiple boiler systems the lowest individual
heating output should be used)
These data only apply up to 3x the system volume for filling and top-up water. Once this triple system volume is exceeded, the
water will have to be treated exactly the same as in case of exceeding the limit values given in table 6.2 (softening, desalination,
hardness stabilisation and desludging).
Table 6.1 Guidelines for the heating water: Water hardness
Total hardness at 20 l/kW
for the smallest boiler heating
2)
surface
3
1)
2 1,5 0,02
1,5 0,02 0,02
0,02 0,02 0,02
Total hardness at > 20 l/kW
< 50 l/kW for the smallest boiler
heating surface
mol/m3 mol/m
2 0,02
ecoTEC exclusive installation and maintenance instructions / 0020017768_0422
2)
Total hardness at > 50 l/kW
for the smallest boiler heating
surface
2)
3
Page 23
Start-up 6
Caution!
a
Risk of material damage if the heating water is
treated with unsuitable frost or corrosion protection agents!
Frost and corrosion protection agents may
cause changes in the seals, noises during heating and possibly subsequent damage.
Do not use any unsuitable frost or corrosion
protection agents.
6.1.1 Filling and venting from the heating side
1
Fig. 6.1 Auto air vent
Key
1 Auto air vent
A water pressure/filling pressure between 1.0 and 2.0
bar is required for proper functioning of the boiler.
If the heating installation operates over several floors,
it may be necessary to have higher water levels on the
pressure gauge.
• Rotate the cap of the auto air vent (1) on the pump
a couple of times to loosen it (the appliance is
ventilated automatically by the auto air vent during
continuous operation).
• Open all radiator valves in the installation.
Note!
h
The ecoTEC units are supplied with a pressure
gauge and a digital pressure display (2). Using
the pressure gauge you can perform a quick
check whether the filling pressure is within the
prescribed range or not, even when the unit is
switched off. With the unit switched on, you
can read off the exact pressure by pushing the
minus button „-“.
• Turn the rotary knobs (1) and (4) to the left hand stop
and switch the unit on using the main switch (3).
Note!
h
Use the test programme P.6 for filling the
heating system: The priority changeover valve
moves to the central position, the heating
pump is not running and the unit does not go
into heating mode, see Chapter 9.2.
Note!
h
To avoid running the system with too little water
and thus to prevent damage, your appliance has
a water pressure sensor. This signals the low
pressure level if the level falls below 0.6 bar by
the water pressure value in the display flashing.
If the water pressure falls below 0.3 bar the unit
switches off. The error message F.22 appears in
the display. Fill the system up with water before
you start up the appliance again.
Filling the heating system:
1
2
1
4
Fig. 6.2 Check the filling pressure of the heating installation
2
bar
Fig. 6.3 Filling the heating system
Proceed as follows to fill the system:
• Open all radiator valves on the system.
• Ensure that the boiler CH service valves are open.
• Check the flexible filling loop is connected.
• Locate the filling valve handle (1) and open.
bar
3
• Locate the filling valve handle (2) and open to allow
water to enter the system. Starting with the lowest
radiator, open the radiator air release until water
(clear of bubbles) is emitted.
23ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 24
6 Start-up
• Repeat this at all radiators until the complete system
is full, all air locks have been cleared and the boiler
pressure gauge reads 1.5 bar. Release any air from
the pump by slackening the centre screw. Turn off
the filling valve (2) and fully close filling valve (1).
• The boiler is equipped with an automatic air release
valve. To allow this to vent the boiler, the cap on the
top must be slackened by 1 –2 turns (This cap must be
left slackened during boiler operation to ensure any
residual air or system gases are released).
• Check the heating system and boiler connections
are sound.
Note!
h
Use the test programme P.0 to vent the boiler
and the heating system: The unit does not start
in heating mode, the heating pump switches on
and off and alternately vents the heating circuit and the hot water circuit, see Chapter 9.2.
6.1.2 First flushing of the system
Note!
h
The entire heating system must be flushed
through completely at least twice: once cold
and once hot, in accordance with the following
instructions.
• Check if all radiator thermostat valves and both
maintenance cocks on the boiler are open.
• Connect a hose to the drain valve which is located
at the lowest position in the heating system.
• Open the 1/2" KFE drain cocks and all the vent valves
on the radiators so that the water flows quickly and
completely out of the heating system and the boiler,
in order to remove the contamination caused during
the installation out of the heating system before the
boiler is started up.
• Close the 1/2” KFE drain cocks.
• Re-fill the heating system with water as described
in Section 6.1.1.
• Check that the over-pressure valve in the heating
system is functioning correctly by turning the handle
on the valve.
• Check the pressure in the heating system and top
up with water if necessary.
• Close filling valve 1 and filling valve 2.
6.1.3 Filling and venting from the hot water side
• Open the cold water stop cock on the appliance on
the inlet combination.
• Fill the hot water system by opening all the hot water
taps until water comes out.
• As soon as water comes out of all the hot water taps,
the hot water circuit is filled completely and also vented.
6.1.4 Filling the condense trap
1
Fig. 6.4 Filling the condense trap
Danger!
d
If the appliance is started up with an unfilled
condense trap, there is a danger of poisoning
by exhaust gas emission.
Fill the trap as follows:
• Unscrew the lower section of the trap (1) from the
condense trap.
• Fill the lower section of the trap (1) 3/4 full with water.
• Screw the lower section of the trap back onto the
condense trap.
6.2 Checking the gas setting
Caution!
a
Conversion from natural gas to liquid gas or
vice versa may only be undertaken by Vaillant
service personnel or a suitably qualified installer approved at the time by the Health and Safety Executive.
Note!
h
For all kind of conversions a special Vaillant
conversion kit is needed. Further information
can be obtained from Vaillant Service Solutions
(0870 6060 777).
6.2.1 Gas pressure statement - Natural gas
Natural gas:
a
Do not proceed with the adjustment or attempt
to put the unit into service if the inlet working
pressure lies outside the 19-23 mbar range.
The nominal operating pressure at the gas meter outlet
should be between 19 and 23 mbar. The gas valve within
the appliance is factory set for Natural Gas G20 and
should need no adjustment. The appliance is designed to
operate with an inlet pressure to the appliance of
ecoTEC exclusive installation and maintenance instructions / 0020017768_0424
Page 25
Start-up 6
20 mbar when the appliance is operating at the maximum heat input. The inlet working pressure to the appliance is measured at the appliance multi-functional gas
valve on the valves inlet pressure test point, see fig. 6.5.
Due to internal appliance pressure losses the reading at
the inlet of the appliance gas valve may be lower than
the design pressure of 20 mbar.
The acceptable pressure measured at the appliance gas
valve inlet is:
Natural Gas
(G20)
ecoTEC exclusive
832
ecoTEC exclusive
838
Table 6.3 Acceptable pressure measured at the appliance gas
Note!
h
Caution!
a
Caution!
a
6.2.2 Checking the connection pressure
Proceed as follows to check the connection pressure:
• Remove the front cover from the device.
• Close the gas isolation cock on the unit.
Meter outlet pressure Minimum pressure
Maximum
Design (nominal)
Minimum
Maximum
Design (nominal)
Minimum
valve inlet
In all instances the gas rate to the appliance
shall be measured.
Should the pressure recorded at the gas meter
not be between 19 mbar and 23 mbar then the
Emergency Service Provider should be contacted.
Should the pressure at the gas meter be correct but lower pressure at the gas valve than
indicated in the above table, it may indicate
blockage in the internal pipework or that the
pipework is undersized. Rectification work must
be undertaken before the appliance is commissioned.
(gas inlet working pressure)
23 mbar
21 mbar
19 mbar
23 mbar
21 mbar
19 mbar
at gas valve inlet
20 mbar
18 mbar
16 mbar
19.5 mbar
17.5 mbar
15.0 mbar
2
Fig. 6.5 Checking the gas supply pressure
• Release the sealing screw marked "in" (1) on the
gas fitting.
• Connect a digital pressure manometer or u-gauge
manometer (2).
• Open the gas isolation cock on the unit.
• Start the appliance up via P.1 (see Chapter 9.2).
• Measure the connection pressure in comparison
with atmospheric pressure.
Natural gas:
a
If the connection pressure is outside the range
19 to 23 mbar, no adjustment should be undertaken, and the unit must not be started up!
Liquid gas:
a
If the connection pressure is outside the range
25 to 45 mbar, no adjustment should be undertaken, and the unit must not be started up!
1
If the connection pressure is within the permissible
range, proceed as follows:
• Take the appliance out of operation.
• Close the gas isolation cock on the unit.
• Remove the pressure gauge and screw the sealing
screw (1) back in again.
• Open the gas isolation cock on the unit.
• Make sure that the sealing screw is not leaking.
• Put the front cover back on and turn on the device.
25ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 26
6 Start-up
If the connection pressure is not within the permissible
range and you cannot resolve the problem, inform the
gas supply authority. Proceed as follows:
Take the appliance out of operation.
• Close the gas isolation cock on the unit.
• Remove the pressure gauge and screw the sealing
screw (1) back in again.
• Make sure that the sealing screw is not leaking.
Put the front casing back on.
Do not start up the appliance!
6.2.3
Checking CO2 content and setting if necessary (setting the air figure)
• Remove the front cover.
• Activate test programme P.1 (see Chapter 9.2).
• Wait at least 5 minutes until the appliance reaches
its operating temperature.
1
2
3
- Turning to the left: higher CO
- Turning to the right: lower CO
content,
2
content,
2
Note!
h
Natural gas: Adjust only in increments of 1/8
turn and wait approx. 1 minute after each adjustment until the value stabilises.
Note!
h
Liquid gas: Adjust only in increments of 1/16
turn and wait approx. 1 minute after each adjustment until the value stabilises.
• After completion of the setting process, hinge the air
intake pipe back up.
• Check the CO
content again.
2
• If necessary, repeat the setting process.
• Press the "i" button. The "Full load mode" is turned
off. The full load mode is also exited if no button is
pushed for 15 minutes.
• Re-secure the air intake pipe with the screw (3).
• Put the front casing back on.
Settings
CO2 after 5 minutes full load
mode with front casing removed
set for Wobbe-Index W
Table 6.4 Factory gas settings
0
Natural
gas H
Tolerance
9,0 +/- 1,0 10,0 +/- 0,5 Vol.–%
12,4 22,5
Propane
Tolerance
Unit
kWh/
m3
4
Fig. 6.6 Checking/adjusting the CO2 content
• Measure the CO2 content on the flue gas measuring
nozzles (1). Compare the measured value with the
corresponding value in Table. 6.4.
• If the CO
content needs to be adjusted, release the
2
screw (3) and hinge the air intake pipe (2) through
90° to the front. Do not remove the air intake pipe!
• If necessary, set the corresponding CO
content
2
(value with removed appliance front, see Table 6.4)
by turning the screw (4) in.
6.3 Checking the equipment function
After installing and checking the gas supply pressure,
perform a function check before commissioning the appliance and handing over to the user.
• Commission the appliance in accordance with the instructions in the relevant operating manual.
• Check the gas infeed, exhaust gas installation, boiler and
heating installation and the hot water pipes for leaks.
• Check the flue pipe for proper installation.
• Check over-ignition and that the flame on the burner
is burning evenly.
• Check the function of the heating (see Chapter 6.3.1)
and the hot water preparation (see Chapter 6.3.2)
• Hand the unit over to the user.
The Vaillant ecoTEC exclusive has status codes which
indicate the operating condition of the appliance in the
display. Functional checks of the hot water and heating
operation can be undertaken using these status codes
by pushing the button "i".
ecoTEC exclusive installation and maintenance instructions / 0020017768_0426
Page 27
Fig. 6.7 Function check
6.3.1 Heating
• Switch on the appliance.
• Make sure that there is a heat demand for heating
(set the room thermostat or the weather-controlled
controller to "demand").
• Press "i" to activate the status indicator.
Fig. 6.8 Display during heating mode
As soon as there is a heat demand, the appliance goes
through the status displays "S. 1" to "S. 3", until the appliance is running properly in normal operation and the
display "S. 4" appears.
6.3.2 Hot water function
• Switch on the appliance.
• Turn on a hot water tap fully.
• Press "i" to activate the status indicator.
When the hot water function is working correctly the
display shows "S.14".
Start-up 6
Fig. 6.9 Display during hot water preparation
6.3.3 Subsequent flushing through of the heating
system ("hot")
• Allow the appliance to run until both the appliance
and the heating system have reached their operating
temperature.
• Check the heating system for leaks.
• Connect a hose to the drain valve which is located at
the lowest position in the heating system.
• Shut off the appliance, open the drain valve and all
vent valves on the radiators and allow the water to
flow out of the heating system and the boiler quickly
and fully.
• Close the drain valve.
• Re-fill the heating system with water (see Chapter 6.1.1).
• Drain water out of the system until a system pressure
of 1.0 bar is reached. (The ideal measured value on the
pressure gauge is 0.5 bar plus an extra amount corresponding to the highest point of the system above the
boiler. A height of 10 m corresponds to a pressure increase on the pressure gauge of around
1 bar. The pressure must not be less than 1 bar on any
installation.)
If the system is to be protected by an inhibitor, it
should be added at this stage in accordance with the
manufacturer's instructions.
Further information can be obtained from Sentinel,
Betz Dearborn Ltd., Tel.: 0151 420 9595, or from Fernox, Alpha–Fry technologies, Tel.: 0870 8700362.
• Re-mount the enclosure of the boiler.
• Attach the bottom cover to the boiler by sliding the
front edge of the cover into the lip at the bottom front
edge of the appliance chassis.
• Carefully push the rear of the bottom cover upwards
until the spring retaining clips engage at the side of
the appliance. It may be necessary to adapt the bottom cover by removing the easy break sections.
27ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 28
6 Start-up
6.4 Handing over the appliance to the owner
• Set the controller for the maximum radiator temperature to the required temperature.
• Set the controller for the maximum hot water temperature to the required temperature.
• Instruct the operator in the safe and efficient operation of the boiler, paying particular attention to the
functions of:
– the ON/OFF switch of the boiler,
– the controller for the maximum radiator tempera-
ture,
– the controller for the maximum hot water tempera-
ture (only on combination boilers),
– the pressure gauge.
• Make the operator acquainted with the operation of
any external controllers.
• Explain to the operator the importance of regular
maintenance by a competent heating engineer. It is
strongly recommended that a maintenance contract
be taken out to ensure regular maintenance. Further
information can be obtained from Vaillant Service Solutions (0870 6060 777).
• Enter the operating pressure of the central heating
system, the heat feed (in kW) and the temperature difference between the flow and return in the Benchmark gas boiler commissioning checklist.
If the appliance is not installed and commissioned in accordance with manufacturer's instructions this can lead
to invalidation of the guarantee (Note: Your legal rights
remain unaffected by this.)
• Leave the operating and installation instructions with
the operator of the appliance.
• Go through the operating manual with the operator
and answer any questions.
• Draw special attention to the safety instructions,
which the operator must follow.
• Instruct the operator about the methods used for
combustion air supply and flue conducting. In particular, point out that these measures must not be altered.
• Inform the operator that the instruction manuals
should be kept near the appliance.
Note!
h
When you have finished the installation, attach
the sticker supplied (835593) to the front case
of the appliance in the user’s language.
Caution!
a
The front cover should only be removed
- for initial installation access
- for servicing
- for testing
For continuous and safe operation the front
cover must be fitted together with a correctly
fitted and sealed flue system.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0428
Page 29
Adapting the appliance to the heating system 7
7 Adapting the appliance to the heat-
ing system
The ecoTEC exclusive units are fitted with a digital information and analysis system.
7.1 Selection and setting the parameters
In the diagnostic mode, you can change the various parameters required to match the boiler to the heating
system.
Table 7.1 shows only those diagnostic points where modifications are possible. All the other diagnostic points
are only required for diagnosis and fault rectification
(see Chapter 8).
Using the following description you can select the relevant parameters :
• Press the "i" and "+" buttons simultaneously.
The display shows "d.0".
• Scroll to the desired diagnosis number with the "+" or
"–" buttons.
• Press the "i" button.
The display shows the relevant diagnosis information.
• If necessary, use the "+" or "–" keys to change the
value (display flashes).
• Save the new value by holding down the "i" button for
approx. 5 seconds until the display no longer blinks.
You can end the diagnosis mode as follows:
• Press the keys "i" and "+" simultaneously or do not
press any key for about 4 minutes.
The current pressure in the heating system appears in
the display again.
+
~ 5 s
+
Fig. 7.1. Setting the parameters
29ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 30
7 Adapting the appliance to the heating system
7.2 Overview of the settable installation parameters
The following parameters can be set to match the
appliance to the heating system and to suit the
customers requirements:
Display Meaning Adjustable parameters
d.0 Heating partial load ecoTEC exclusive 832
ecoTEC exclusive 838
d.1 Pump overrun time for heating operation
(starts after completion of heat demand)
d.2 Max. blocking time heating at 20°C feed
temperature
d.14 Pump speed target value Target value internal pump in % - possible set-
d.17 Heating flow/return regulation changeover 0 = flow, 1 = return 0
d.18 Pump mode (return flow) 0 = return, 1 = nonstop, 2 = winter 0
d.26 Changeover option relay to electronic 1 = circulation pump
d.71 Target value max. heating flow temperature 40 to 85 °C 75 °C
d.84 Maintenance indicator: Number of hours
until the next maintenance
Table 7.1 Adjustable parameters
27 kW
30 kW
2 - 60 min 5 min
2 - 60 min 20 min
tings: Auto, 53, 60, 70, 85, 100 %
2 = Ext. pump (default)
3 = storage charging pump
4 = vapour extraction hood
5 = external throttle
6 = ext. fault signal (without maintenance display)
0 to 3000h and „-“
(300 corresponds to 3000 h, „-“ = deactivated)
Default
setting
22 kW
27 kW
Auto
2
-
Appliance-specific
setting
Note!
h
You can enter your settings in the end column
after setting the appliance-specific parameters.
Note!
h
The diagnosis points d.17, d.71 and d.84 are located in the 2nd. diagnosis level, see Chapter
9.1.2
7.2.1 Setting the heating partial load
The units are set in the factory to a possible heat load
but not yet to the maximum value. Under diagnosis
point "d.0" you can set a value which corresponds to
the required output in the heating system in kW.
7.2.2 Setting the pump overrun time
The pump overrun time for the heating operation is set in
the factory to a value of 5 minutes. It can be set under
diagnosis point "1" within the range two minutes to
60 minutes. Under diagnosis point "d.18" you can set the
overrun behaviour of the pump to a different mode.
Overrun: After completion of the heat demand the heating
pump continues to run for the time set under "d.1".
Continuous: The internal heating pump is switched
on when the rotary knob for setting the heating feed
temperature is not in the left-hand stop position and the
heat demand is released by an external controller.
Winter: The internal heating pump is switched on when
the rotary knob for setting the heating feed temperature
is not in the left-hand stop position.
7.2.3 Setting the maximum flow temperature
The maximum feed temperature for the heating is set in
the factory to 75 °C. Under diagnosis point "d.71" it can
be set to between 40 und 85 °C.
7.2.4 Setting the return temperature control
When connecting underfloor heating or wall heating to
the appliance which does not have its own temperature
regulation, the temperature regulation mode can be
changed from feed temperature regulation (factory setting) to return temperature regulation under diagnosis
point "d.17".
ecoTEC exclusive installation and maintenance instructions / 0020017768_0430
Page 31
Adapting the appliance to the heating system 7
7.2.5 Setting the burner anti-cycle time
T
(target)
Feed
[°C]
20 2,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 45,0 50,0 55,0 60,0
25 2,0 4,5 9,2 14,0 18,5 23,0 27,5 32,0 36,5 41,0 45,0 50,0 54,5
30 2,0 4,0 8,5 12,5 16,5 20,5 25,0 29,0 33,0 37,0 41,0 45,0 49,5
35 2,0 4,0 7,5 11,0 15,0 18,5 22,0 25,5 29,5 33,0 36,5 40,5 44,0
40 2,0 3,5 6,5 10,0 13,0 16,5 19,5 22,5 26,0 29,0 32,0 35,5 38,5
45 2,0 3,0 6,0 8,5 11,5 14,0 17,0 19,5 22,5 25,0 27,5 30,5 33,0
50 2,0 3,0 5,0 7,5 9,5 12,0 14,0 16,5 18,5 21,0 23,5 25,5 28,0
55 2,0 2,5 4,5 6,0 8,0 10,0 11,5 13,5 15,0 17,0 19,0 20,5 22,5
60 2,0 2,0 3,5 5,0 6,0 7,5 9,0 10,5 11,5 13,0 14,5 15,5 17,0
65 2,0 1,5 2,5 3,5 4,5 5,5 6,5 7,0 8,0 9,0 10,0 11,0 11,5
70 2,0 1,5 2,0 2,5 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5
75 2,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0
Table 7.2 Effective burner anti-cycle time
The burner is electronically locked for a specific time
after each time it is switched off ("re-start interlock")
to avoid frequent switching on and off of the burner
(energy losses).
The burner anti-cycle time is only activated for the
heating operation. Hot water operation during a burner
anti-cycle time does not affect the timer.
The individual anti-cycle time can be matched to the
hydraulic and thermal properties of the heating installation. In the factory the burner anti-cycle time is set to
a value of 20 minutes. It can be varied under diagnosis
Set maximum burner anti-cycle time [min]
1 5 10 15 20 25 30 35 40 45 50 55 60
7.2.6 Determination of the maintenance interval/
maintenance display
The electronics of the ecoTEC exclusive allow you to
determine the maintenance intervals for the appliance.
This function serves to provide a signal that, after a
specific, adjustable, number of burner operating hours,
the boiler needs to be serviced. The service signal SEr is
shown in the display of the ecoTEC exclusive alternately
with the current pressure after expiry of the set number
of burner operating hours. The display also appears on
the VRT 360 and 400 (accessories).
point "d.02" within the range 2 minutes to 60 minutes.
The individual effective anti-cycle time is calculated
from the momentary target feed temperature and the
set maximum burner anti-cycle time.
The timer can be reset or cancelled by actuating the
appliance main switch. The remaining burner anti-cycle
time left after switching off by the controller in heating
operation can be called up under diagnosis point "d.67".
The individually effective burner anti-cycle times with
Heat demand
32 kW
38 kW
Table 7.3 Guide values for operating hours
Number of
persons
3 - 4
4 - 6
4 - 6
4 - 8
Burner operating hours to the next
inspection/service (dependent
upon the type of appliance)
2.800 h
2.900 h
3.000 h
3.100 h
respect to the feed temperature and the maximum set
burner anti-cycle time can be taken from Table 7.2.
The operating hours to the next service can be set under
diagnosis point "d.84". Guide values can be taken from
Table 7.3; these values correspond to an approximate
operating time for the appliance of one year.
The operating hours can be set in steps of ten from
0 to 3000 h.
If there is no number in the diagnosis point "d.84", but
there is the symbol "-", then the "maintenance display"
is not active.
Note!
h
After the set number of hours have expired, the
service interval must be entered in the diagnosis mode again.
31ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 32
7 Adapting the appliance to the heating system
7.2.7 Setting the pump output
The ecoTEC exclusive is fitted with a speed controlled
pump which sets itself to the hydraulic conditions and
the heat demand of the heating system.
Under certain conditions the output of the pump can be
set, in five steps to 53, 60, 70, 85 or 100% of the maximum pump output using the diagnosis system. This
switches the speed control off.
Caution!
a
When using an flow header we recommend turning off the speed control and setting the pump
output to 100%.
400
300
Lift [mbar]
200
100
0
0 200 400 600 800 1000 1200 1400 1600
Volumeflow [l/h]
Fig. 7.2 Characteristic pump line for ecoTEC exclusive 832 and 838
Key to Fig. 7.2
1 at 27 kW
2 at 30 kW
2
1
1800
7.3 Adjusting the bypass valve
The appliances have a bypass valve.
The pressure can be adjusted between 170 and 350 mbar.
Approx. 250 mbar is preset (mid-position). The pressure
changes by approx. 10 mbar each time the adjusting
screw is rotated. By turning right, the pressure increases and turning left decreases it.
1
Fig. 7.3. Setting the by-pass valve
• Regulate the pressure using the setting screw (1).
Position of the setting
screw
Right-hand stop
(turned all the way
down)
Pressure
(mbar)
350
Notes/application
If the radiators do not get properly hot in the works setting
Mid-position (5 turns
to the left)
5 further turns to
the left from the
mid-position
Table 7.4 Setting value for the bypass valve
250 Default setting
170
If noises in the radiators or
radiator valves are produced
ecoTEC exclusive installation and maintenance instructions / 0020017768_0432
Page 33
Inspection and maintenance 8
8 Inspection and maintenance
8.1 Inspection and maintenance intervals
Regular maintenance and service is recommended to
ensure permanent safe and efficient operation of the
boiler. The frequency of maintenance and service depends upon the individual installation conditions and
upon the use the appliance is put to. An inspection must
be performed once a year.
Danger!
d
It is a legal requirement that all maintenance
work be only performed by trained personnel
approved at the time by the Health and Safety
Executive.
Inspection and maintenance work which is improperly carried out can lead to injury and material damage.
In order to ensure all the functions of the Vaillant appliance over a long period, only genuine Vaillant spare
parts may be used when undertaking maintenance, service and repair work. Any spare parts which might be required are contained in the current Vaillant spare parts
catalogues. Further information can be obtained from
Vaillant Customer Service Centres.
8.2 General inspection and maintenance instructions
Only genuine Vaillant spare parts may be used for inspections, maintenance and repair work to ensure the
perfect long-term working order of all functions of your
Vaillant appliance and to prevent the allowed series condition from being changed.
Any spare parts which might be required are listed in
the relevant current spare parts catalogues. Information
can be obtained from Vaillant Service Solutions
(08706060777).
• Close the maintenance cocks (if fitted) in the heating
flow and return and the cold water inlet valve on the
inlet combination.
• Remove the front cover from the device.
Always perform the following steps after performing
any maintenance work:
• Open the heating flow and return and the cold water
inlet valve.
• Refill the device, if necessary, with hot water up to
a pressure of between 1.0 and 2.0 bar and vent the
heating system.
• Open the gas shut-off cock.
• Re-connect the appliance to the electrical mains by
inserting the plug into the wall plug socket and switch
the main switch on.
• Check the appliance for gas and water leaks.
• If necessary, refill and re-vent the heating system.
• Reapply the front cover to the device.
• Check all the functions of the appliance.
Safety instructions
Note!
h
If it is necessary to keep the main switch on for
certain inspection and maintenance, this is indicated in the description of the maintenance task.
Danger!
d
The supply terminals of the device are under
voltage even if the mains switch is off.
Always perform the following steps prior to maintenance
work:
• Switch off the mains switch.
• Disconnect the device from the mains supply by
pulling the power plug or de-energising the device by
means of a separator with a contact opening of at
least 3 mm (e. g. fuses or circuit breakers).
• Close the gas shut-off valve.
33ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 34
8 Inspection and maintenance
No. Activity
1 Check the air/gas flue system and ensure it is not blocked, damaged and is fitted correctly. x
Measure the gas rate during operation (see chapter ‚Start-up‘). If the gas rate
2
is lower than the minimum gas rate follow the maintenance instructions (column 2).
Column 1
Inspection
must be
carried out
once a year
x
Column 2
Maintenance
Check combustion by measuring CO and CO
is outside the tolerances follow the maintenance instructions (column 2). If a flue gas analyser
3
is not available check the ignition and burner flame picture through the sight glass, if incomplete
combustion is evident perform the maintanance instructions (column 2).
4 Isolate the appliance from the electrical mains supply, close the gas and water service valves. x
Visually inspect the general heat exchanger area for signs of corrosion, sooting or other forms
5
of damage. If damage is evident perform the tasks in the maintenance column 2.
Remove the burner module (as described in section 8.4) if maintenance schedule is required
from steps 2, 3 or 5 above. Clean the primary heat exchanger. Fit a new burner door seal kit
6
(spareparts no. 0020026401 - observe the assembly instructions enclosed with the seal kit).
Refit the burner module and tighten the nuts.
7 Check all the appliances electrical connections and make adjustments if necessary. xx
8 Check/re-pressurise the expansion vessel as necessary. xx
9 Check the appliance generally, check for dirt/dust and clean if necessary. xx
10 Check and clean the condense trap and flexible condensate hose. xx
11 Open the gas and water service valves, re-establish the electrical supply and turn on the boiler. xx
Perform a test operation of the appliance including the heating and hot water systems and
12
bleed the system if necessary.
Re-pressurise the appliance/system up to between 1.0 - 2.0 bar (depending on the static height
13
of the system).
values, compare to table 6.1. If the measurement
2
x
x
x
xx
xx
Measure the gas rate during operation and ensure it is within the tolerances specified
14
(see chapter ‚Start-up‘).
Re-check the combustion by measuring the CO and CO
Ensure that the measurement is within the tolerances. If a flue gas analyser is not available
15
check the ignition and burner flame picture visually through the sight glass.
16 Check the boiler for leaks of any kind, rectify as necessary. xx
17 Complete the gas commissioning checklist (Benchmark). xx
Table 8.1 Maintenance steps
values, (compare to table 6.1).
2
ecoTEC exclusive installation and maintenance instructions / 0020017768_0434
x
x
Page 35
8.3 Filling/draining the heating installation
Inspection and maintenance 8
8.3.1 Filling the unit and heating installation
The filling of the appliance and the heating system is described in Section 6.1.
8.3.2 Draining the unit
• Close the maintenance cocks (if fitted) on the appliance.
• Open the drain valves on the maintenance cocks.
8.3.3 Draining the entire installation
• Attach a hose to the filling/draining cock on the syst
• Bring the open end of the hose to an appropriate
drain point.
• Check that the maintenance cocks of the boiler are
open.
• Open the filling/drain cock.
• Open the bleed valves on the radiators.
Start at the highest radiator and then work from the
top to the bottom.
• When the water has drained out of the
tem, close the bleeding valves on the radiators and
close the filling/drain cock again.
8.4 Servicing the compact thermal module
8.4.1 Dismantle compact thermal module
The compact thermal module consists of a speed-controlled fan, the gas fitting, the gas mixer pipe for the fan
pre-mix burner and the pre-mix burner itself. These four
individual parts form the compact thermal module component.
Danger!
d
Danger of explosion through gas leakage!
The mixer tube between the gas control unit
and burner must not be opened. It can only be
guaranteed that this component is gas-tight
after it has been inspected at the factory.
Danger!
d
There is danger of being burned or scalded at
the compact thermal module and at all components carrying water. Only carry out work on
these components once they have cooled down.
Proceed as follows to dismount it:
• Turn the appliance off on the main switch.
• Isolate the unit from the electrical mains.
• Cut off the gas supply to the device.
• Close the maintenance cocks on the appliance.
• Remove the front cover from the device.
• Swing off the electronic box.
heating sys-
em.
1
2
3
4
5
6
Fig. 8.1 Dismantling compact thermal module
• Remove the screw (3) and remove the air inlet pipe (1)
from the inlet spigot on the gas fi
• Separate the gas supply pipe (6) on the gas fitting.
Secure the gas corrugated pipe against twisting by
bracing the pipe on the wrench surface while loosening the union nut.
Caution!
a
Damage to the gas pipe!
Under no circumstance may the compact
thermal module be suspended from the flexible
corrugated gas pipe.
• Pull the two plugs of the ignition und grounding lines
off the ignition electrode (4).
• Only ecoTEC exclusive 832: Pull the cable plug off the
fan motor and the cable off the gas fitting.
Only ecoTEC exclusive 838: Open the mains coupling
to the fan.
• Undo the five nuts (2).
• Pull the entire compact thermal module (5) off the
heat exchanger.
• After dismantling the burner and the heat exchanger,
check for damage and dust and, if necessary, clean
the components as described below.
tting.
35ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 36
8 Inspection and maintenance
8.4.2 Clean the heat exchanger
Caution!
a
Protect the electronics box turned down
against sprayed water.
1
2
3
4
Fig. 8.2 Clean the heat exchanger
• Remove the compact thermal module (see Chapter 8.4.1).
• Clean the pipes (3) of the heat exchanger (4) using
regular vinegar. Flush with water. The water flows out
of the heat exchanger through the water condense trap.
• After a soaking time of approx. 20 minutes, flush away
the dirt particles that have come loose with a powerful
water jet. Avoid pointing the water jet directly at the
insulating surface (2) on the back of the heat exchanger.
8.4.4 Installing the burner assembly
1
2
Fig. 8.4 Replacing silicone gaskets
• Insert the new graphite seals (1) in the burner flange.
Danger!
a
The two seals (1 - fig. 8.4) on the burner assembly
(must be replaced each time the module is
removed (for example during maintenance).
The burner flange insulation (2 - fig. 8.4) on
the compact thermal module (SP no. 21-0734)
may not show any signs of damage; otherwise
it must also be replaced.
1
2
8.4.3 Checking the burner
Fig. 8.3 Checking burner
The burner (1) is maintenance-free and needs no cleaning.
• Check the burner surface for damage, replace the
burner if necessary.
• After checking/replacing the burner, dismantle the
compact thermo module as described in Section 8.4.4.
1
Fig. 8.5 Installing compact thermal module
• Place the entire compact thermal module (5) onto the
integral condensation heat exchanger.
• Tighten the five nuts (2) across the diagonal until the
burner door fits closely and uniformly onto the mating
surfaces.
• Insert the ignition cable and the earth cable of the
ignition electrode (4).
3
4
5
6
ecoTEC exclusive installation and maintenance instructions / 0020017768_0436
Page 37
Inspection and maintenance 8
• Only ecoTEC exclusive 832: Insert the cables on the
fan motor and the cable on the gas fitting.
Only ecoTEC exclusive 838: Close the mains coupling
to the fan.
• Connect the gas supply (6) with a new gasket to the
gas fitting. Use the spanner flat at the flexible gas line
to hold the gas line.
Caution!
a
Open the gas supply and check the appliance
for gas leaks using a leak testing spray. Pay
particular attention to the gas fitting (6).
• Check that the blue gasket in the air intake pipe (1)
is correctly located in the gasket seat.
• Insert the air intake pipe on the suction nozzles and
secure the pipe with the retaining screw (3).
8.5 Maintaining the secondary heat exchanger
Danger!
d
All water conducting components present a
danger of burning and scalding. Only carry out
work on these components once they have
cooled down.
Caution!
a
Protect the electronics box turned down
against sprayed water.
• Release the clamp (1) on the preference changeover
valve.
• Release the clamps (2) and (3) on the secondary heat
exchanger.
• Remove the secondary heat exchanger to the side.
• Flush the secondary heat exchanger thoroughly with
clean water.
• When re-assembling, use new O rings and flat seals,
the part numbers can be obtained from the parts
catalogue.
8.6 Cleaning the condense trap
1
Fig. 8.7 Cleaning the condense trap
Note!
h
When removing the secondary heat exchanger,
protect the opening in the appliance from dirt
contamination!
1
2
3
4
Fig. 8.6 Cleaning the secondary heat exchanger
• Isolate the appliance from the house electricity circuit
(see Chapter 8.2) and close the gas supply.
• Close the maintenance cocks -if fitted- and the cold
water inlet valve on the inlet combination, and drain
the appliance.
• Release the nut (4) on the secondary heat exchanger.
Danger!
d
If the device is operated with empty condense
trap, there is risk of poisoning through emitting
flue gases.
Therefore, fill the trap with water again after
each cleaning operation.
• Unscrew the lower section (1) of the water condense trap.
• Clean the bottom of the trap by flushing it out with
water.
• Fill the lower section with water until about 10 mm
below the upper edge.
• Fasten the lower section onto the condense trap again.
37ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 38
8 Inspection and maintenance
8.7 Checking the expansion vessel
8.8 Checking the gas setting
8.8.1 Checking the connection pressure
(gas inlet working pressure)
To check the connection pressure proceed as described
in Chapter 6.1.2.
8.8.2 Checking CO
1
To check the air figure proceed as described in Chapter
6.2.2.
8.9 Test operation
Always perform the following checks after completing
any inspection/maintenance task:
• Commission the appliance in accordance with the
necessary
instructions in the relevant operating manual.
content and adjusting if
2
Fig. 8.8 Checking the expansion vessel
Note!
h
This check need not be performed every year a check every three years is sufficient.
• The maintenance cocks of the central heating system
must be closed.
• Release the pressure from the appliance.
• Remove the valve cover from the filling connection
of the expansion vessel.
• Check that the internal pressure in the expansion
vessel is between 0.75 and 0.9 bar. If the pressure
is less than this, the vessel must be pumped up again
using an air pump.
• Refit the valve cover.
• Re-pressurise the boiler and the heating system.
Fig. 8.8 Function check
• Check the appliance for gas and water leaks.
• Check the flue system for leaks and that it is fixed
properly.
• Check over-ignition and that the flame on the burner
is burning evenly.
• Check the function of the heating (see Chapter 6.3.1)
and the hot water preparation (see Chapter 6.3.2)
• Document the inspection/maintenance tasks performed in the form provided in the inspection or
maintenance contract.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0438
Page 39
Troubleshooting 9
9 Troubleshooting
Note!
h
If you wish to contact the Vaillant Service Team,
please refer to the error code displayed (F.xx)
and the appliance status (S.xx) if possible.
9.1 Diagnostics
9.1.1 Status codes
The status codes that you can see on the display provides information about the current operating condition
of the appliance.
Fig. 9.1 Display of status codes
The display of the status codes can be viewed as follows:
• Press the "i" button.
The display shows the status code, e.g. S.4 for
"Burner mode - Heating".
The display of the status codes can be ended as follows:
• Press the "i" button or
• Do not press any button for about 4 minutes.
The current filling pressure in the heating system
appears in the display again.
Display Meaning
Heating mode
S.0 No heat required
S.1 Fan start
S.2 Water pump flow
S.3 Ignition
S.4 Burner mode
S.5 Fan and water pump return water
S.6 Fan return flow
S.7 Water pump return water
S.8 Burner lock after heating mode
Hot water function
S.10 Hot water switch on
S.11 Fan start
S.13 Ignition
S.14 Burner mode
S.15 Fan and water pump return water
S.16 Fan return flow
S.17 Water pump return water
Storage tank charging/heat retention mode
Page 20 Water pump flow
S.21 Fan start
S.23 Ignition
S.24 Burner mode
S.25 Fan and water pump return water
S.26 Fan return flow
S.27 Water pump return water
S.28
Other:
S.30
S.34 Antifrost mode active
S.36
S.42
S.53
S.54
S.96
S.97
S.98
Table 9.1 Status codes
Burner lock after recharging/heat retention
(cycle suppression)
Room thermostat blocks heating operation
(terminal 3’-4’ open)
Summer mode active or eBUS controller or timer
S.31
blocks heating operation
Heat exchanger antifreeze active, as fan speed
S.32
variation is too high. Appliance is within the waiting
time of the operation block function
Target value specification of room thermostat
< 20 °C , i.e. the external regulator is blocking
the heating operation
S.41 Water pressure >2.9bar
Exhaust gas diverter return signal blocks burner
operation (only in connection with accessories) or
condensate pump faulty, heat demand is blocked
Appliance is within the waiting period of the
modulation block/operation block function due to
water shortage (flow-return spread too large)
Appliance is within the waiting period of the
operation block function due to water shortage
(temperature gradient)
Return sensor test running, heating demands
are blocked
Water pressure sensor test running, heating
demands are blocked
Flow/return sensor test running, heating
demands are blocked
39ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 40
9 Troubleshooting
9.1.2 Diagnosis codes
In the diagnosis mode, you can change certain parameters or display more information.
The diagnosis information is divided into two diagnosis
levels. The 2nd diagnosis level can be reached only after
entering a password.
Caution!
a
The access to the 2nd diagnosis level may only
be used by a qualified heating engineer.
1st diagnosis level
• Press the "i" and "+" buttons simultaneously.
The display shows "d.0".
• Scroll to the desired diagnosis point of the 1st diagno-
sis level using the buttons "+" or "–". (see Table 9.2).
• Press the "i" button.
The display shows the relevant diagnosis information.
• If necessary, use the "+" or "–" keys to change the
value (display flashes).
• Save the new value by holding down the "i" button for
approx. 5 seconds until the display no longer blinks.
You can end the diagnosis mode as follows:
• Press the "i" and "+"
buttons simultaneously or
• Do not press any button for about 4 minutes.
The current pressure in the heating system appears in
the display again.
2nd diagnosis level
• Scroll as described above in the 1st. diagnosis level to
diagnosis number d.97
• Change the displayed value to 17 (password) and save
this value.
You are now in the 2nd diagnosis level in which all information from the 1st diagnosis level (see Table 9.2) and
the 2nd diagnosis level (see Table 9.3) is displayed.
Scroll and change values and exit diagnosis mode as
described in the first diagnosis level.
Note!
h
If you push the buttons "i" and "+" within
4 minutes of leaving the 2nd diagnosis level,
you can directly access the 2nd diagnosis level
without having to re-enter the password.
ecoTEC exclusive installation and maintenance instructions / 0020017768_0440
Page 41
Display Meaning Display value/adjustable value
d.0 Heating partial load adjustable heating partial load in kW
d.1 Water pump return time for heating mode 2 - 60 minutes (factory setting: 5)
d.2 Max. blocking time heating at 20°C feed temperature 2 - 60 minutes (factory setting: 20)
d.3 Measured value for the hot water outlet temperature in °C
d.4 Measured value for the hot start sensor in °C
Feed temperature target value (or return tempera-
d.5
ture target value, if return flow regulation selected)
d.6 Set hot water temperature 35 to 65 °C
d.7 Set hot water retention temperature
Feed target temperature from external analogue
d.9
regulator to terminal 7-8-9/eBus
d.10 Status internal heating pump 1 = on, 0 = off
d.11 Status external heating pump 1 to 100 = on, 0 = off
d.12 Cylinder charging pump 0 = off, 1 - 100 = on
d.13 Circulation pump 0 = off, 1 - 100 = on
in °C, max. of the value set in d.71
limited by an eBUS controller, if fitted)
40 to 65 °C
15 °C left, then 40 °C up to value set in d.20 (max. 70 °C)
in °C, minimum from ext. eBus target value and target
value terminal 7
Troubleshooting 9
d.15 Pump speed actual value Actual value internal pump in %
d.16 Room thermostat 24 V
d.22 Hot water demand 1 = on, 0 = off
d.23 Summer mode (heating on/off) 1 = heating on, 0 = heating off (summer mode)
Storage tank charging /hot water charging via
d.25
eBUS controller released
d.30 Control signal for both gas valves 1 = on, 0 = off
d.33 Fan speed target value in rpm/10,
d.34 Fan speed actual value in rpm/10,
d.35 Position of the preference changeover valve 0 = heating; 100 = hot water; 40 = centre position
d.36 Through-flow sensor hot water actual value in l/min
d.40 Flow temperature actual value in °C
d.41 Return flow temperature actual value in °C
d.44 Digitalised ionisation voltage Display range 0 to 102, >80 no flame, <40 good flame display
External temperature (with weather-controlled
d.47
Vaillant controller)
d.67 Remaining burner locking time in minutes
d.76 Appliance variant (device specific number) 00 to 99
d.90 Digital regulator status
DCF status with connected external probe with
d.91
DCF77 receiver
d.97 Activation of the 2nd diagnosis level Password: 17
on terminal 3‘ and 4‘
DC
0 = Room thermostat open (no heat request)
1 = Room thermostat closed (heat request)
1 = yes, 0 = no
actual value in °C
1 = identified, 0 = unidentified (eBUS Address ≤ 10)
0 = no reception, 1 = reception, 2 = synchronised, 3 = valid
d.98 Telephone installer Programmable telephone number
d.99 Language variant Available languages: 0 = German, 1 = English, 2 = Dutch
Table 9.2 Diagnosis codes in the 1st. diagnosis level
41ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 42
9 Troubleshooting
Display Meaning Display value/adjustable value
d.14 Pump speed target value
d.17 Heating flow/return regulation changeover 0 = flow, 1 = return (factory setting: 0)
d.18 Pump mode (return flow) 0 = overrun 1 = continuous, 2 = winter (Factory setting: 0)
d.26 Changeover option relay to electronic
d.27 Changeover relay 1 on the accessories module
d.28 Changeover relay 2 on the accessories module
d.50 Offset for minimum fan speed in rpm/10, adjustment range: 0 to 300
d.51 Offset for maximum fan speed in rpm/10, adjustment range: -99 to 0
d.58 Activation solar post-heating
d.60 Number of temperature limiting shutdowns amount
d.61 Number of fuel automatic system faults number of successful ignitions in the last attempt
d.64 Average ignition time in seconds
d.65 maximum ignition time in seconds
d.68 Unsuccessful ignitions at the first attempt number
d.69 Unsuccessful ignitions at the second attempt number
d.70 Setting the priority changeover valve position
d.71 Target value max. heating flow temperature Adjustment range in °C 40 to 85 (Factory setting: 75)
d.72 Pump overrun time after heat retention function Adjustment range in sec: 0, 10, 20 to 600 (Factory setting: 80)
d.73 Offset for hot start target value Setting range: -15 K to +5 K (Factory setting: depending upon variant)
d.80 Operating hours heating in h
d.81 Operating hours hot water function in h
d.82 Hystereses in heating mode number/1001) (3 equals 300)
d.83 Hystereses in hot water function number/1001) (3 equals 300)
Maintenance indicator: Number of hours until the
d.84
next maintenance
d.93 DSN appliance variant setting setting range: 0 to 99
d.96 Default setting 1 = Resetting adjustable parameters to factory setting
1)
In the diagnosis codes 80 to 83 5 digit figure values are stored. When selecting e.g. d.80 only the first two digits of the figure value are displayed
(e.g.10). By pressing the „i“ key, the display switches over to the last three figures (e.g. 947). The operating hours counter of the heating in this case
would be 10947 h. Pressing the „i“ again causes the display to switch back to the diagnosis point that was called up.
target value internal pump in % - possible settings:
0=Auto, 1=53, 2=60, 3=70, 4=85, 5=100 % (Factory setting: Auto)
1 = circulation pump
2 = external pump
3 = storage charging pump
4 = vapour extraction hood
5 = external throttle
6 = external fault signal (without maintenance display)
1 = circulation pump (factory setting)
2 = ext. pump
3 = storage charging pump
4 = flue gas flap/extractor hood
5 = external gas valve
6 = external error message
1 = circulation pump
2 = ext. pump (factory setting)
3 = storage charging pump
4 = Flue gas flap/extractor hood
5 = External gas valve
6 = External error message
setting range: 0 to 3
0 = solar post-heating deactivated (factory setting)
3 = activation drinking water target value min = 60 °C for
solar post-heating
0 = normal mode (factory setting)
1 = centre position
2 = permanent heating position
1)
1)
setting range: 0 to 3000h and „-“ for deactivated
factory setting: „-“ (300 corresponds to 3000h)
Table 9.3 Diagnosis codes in the 2nd diagnosis level
ecoTEC exclusive installation and maintenance instructions / 0020017768_0442
Page 43
Troubleshooting 9
9.1.3 Error codes
The error codes displace all other displays when errors
occur.
You can exit the error memory display as follows:
• Press the "i" button or
• Do not press any button for about 4 minutes.
If many errors occur simultaneously, the relevant error
codes are displayed alternately for approx. 2 seconds
each.
The current heating flow temperature appears in the
display again.
9.1.4 Error memory
The last ten errors are saved in the appliance error
memory.
• Press the "i" and "-" buttons simultaneously.
• Scroll back in the error memory with the "+" button.
Code Meaning Cause
F.0 Interruption feed temperature sensor (NTC):
F.1 Interruption return temperature sensor (NTC):
F.10 Short-circuit in feed temperature sensor
F.11 Short-circuit in return temperature sensor
F.13 Short-circuit on heat retention storage tank sensor
F.20 Safety temperature limiter actuated
F.22 Dry fire
Water shortage, temperature spread between
F.23
flow and return probe too large
F.24 Water shortage, temperature rise too quick
F.25 Interruption in cable harness Cable harness faulty
F.27 External light: Gas solenoid valve defective, flame detector defective
Appliance does not start: Attempts to ignite
F.28
during start failed
Flame goes off during operation and subsequent
F.29
ignition attempts failed
F.32 Speed deviation Fan
F.49 eBUS undervoltage
F.61 Gas valve control faulty
F.62 Gas valve shutoff delay defective Gas fitting leaking, electronics defective
F.63 EEPROM faulty Electronics defective
F.64 Electronics/sensor fault Short-circuit in flow or return sensor or electronics defective
F.65 Electronics temperature too high Electronics too hot due to external effect, electronics defective
F.67 Flame monitor input signal is outside the limits (0 or 5 V) electronics defective
F.70 No valid appliance variant for display and/or electronics
Table 9.4 Error codes
NTC faulty, NTC cable faulty, faulty plug connection on NTC,
faulty plug connection on the electronics
NTC faulty, NTC cable faulty, faulty plug connection on NTC,
faulty plug connection on the electronics
Sensor plug has mass short to the casing, short-circuit in
wiring loom, sensor faulty
Sensor plug has mass short to the casing, short-circuit in
wiring loom, sensor faulty
Sensor plug has mass short to the casing, short-circuit in
wiring loom, sensor faulty
Flow probe not connected thermally correct or defective,
appliance does not shut down
Too little water in the appliance, water shortage switch defective,
cable to pump or water shortage switch defective, pump blocked
or defective, pump output too low
Pump blocked or defective, pump output too low, flow and return
sensor swapped over
Pump blocked, low output from the pump, air in appliance, system
pressure too low
Faults in the gas supply such as:
- Gas meter or gas pressure detector defective
- Air in gas
- Gas flow pressure too low
- Main gas cock closed
Faults in the gas fitting, wrong gas setting, igniter (ignition
transformer, ignition cable, ignition plug) defective, ionisation
current stopped (cable, electrode), faulty earthing in appliance,
electronics defective
Gas supply temporarily stopped, ignition transformer has spark
failure, faulty earthing of appliance
Fans blocked, plug not inserted correctly on fan, hall sensor
defective, fault in cable harness, electronics defective
Short-circuit on eBUS input, eBUS overload or two power
supplies with different polarities on the eBUS
Short-circuit to mass in cable harness to the gas valves,
installation fault on gas valve (short-circuit, mass short in the coils)
electronics faulty
Spare part case: Display and electronics changed at the same
time appliance variant not re-set
43ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 44
9 Troubleshooting
Code Meaning Cause
F.71 Constant value feed NTC Feed NTC faulty
F.72 Flow and/or return sensor fault Flow and/or return sensor is faulty (tolerance too great)
Signal water pressure sensor in the wrong range
F.73
(too low)
Signal water pressure sensor in the wrong range
F.74
(too high)
No sudden change in pressure was detected on
F.75
turning on the pump
F.76 Interruption in cable harness Cable harness faulty
Condensate pump or return signal from accessory
F.77
module heating
con No communication with the printed circuit board
Table 9.4 Error codes (continuation)
Line to water pressure sensor is interrupted or has
a short-circuit to 0V or water pressure sensor faulty
Line to water pressure sensor has a short-circuit at 5V / 24V
or internal fault in water pressure sensor
Water pressure sensor or/and pump defective
Too little water in the appliance; check adjustable bypass;
Connect expansion vessel in return;
Air in the appliance
Condensate pump faulty or return signal from the exhaust
gas flap has responded
Communication fault between the display and the printed
circuit board in the switchgear box
9.2 Test programs
Special functions can be triggered in the appliances by
activating various test programs.
These programs are given in detail in the Table 9.5.
• The test programmes P.0 to P.6 will be started when
"Power ON" is turned on and the "+" button is
pressed for 5 seconds simultaneously. The display
shows "P.0".
• Press the "+" key to start counting the test pro-
gramme number upwards.
• Press the "i" to operate the appliance now and to
start the test programme.
• Press "i" and "+" simultaneously to exit the test pro-
grams. You can also exit the test programs by not
pressing any button for 15 minutes.
Display Meaning
Bleeding test program The heating circuit and
the hot water circuit are bled via the automatic
P.0
bleeding valve (the cap of the automatic bleeding
valve must be released).
Test programme where the appliance is operated
P.1
in full load after successful ignition.
Test program where the appliance is operated with
P.2
minimum gas volume (ignition gas volume) after
successful ignition.
9.3 Resetting parameter to factory settings
Besides the option to reset individual parameters manually to the factory settings specified in Tables 9.2 and 9.3,
you can also reset all parameters simultaneously.
• Change the value in the 2nd diagnosis level under di-
agnosis point "d.96" to 1 (see Section 9.1.2).
The parameters of all adjustable diagnosis points now
correspond to the factory settings.
Test function for the safety temperature limiter (STL):
The burner is switched on with maximum output,
P.5
the temperature controller is switched off so that the
burner heats until the software STL responds by reaching the STL temperature on the flow or return sensor.
Filling/draining programme:
P.6
The preference changeover valve moves to the centre
position. The burners and pump are switched off.
Table 9.5 Test programmes
ecoTEC exclusive installation and maintenance instructions / 0020017768_0444
Page 45
Replacing components 10
10 Replacing components
The tasks listed below in this section may be carried out
only by a heating engineer approved at the time by the
Health and Safety Executive.
• Only use genuine spare parts for repairs.
• Make sure the parts are correctly fitted and that their
original position and alignment are retained.
10.1 Safety instructions
Danger!
d
Each time the components are replaced, comply
with the safety instructions below for your own
safety and to avoid damage to the appliance.
• Take the appliance out of operation.
Note!
h
Isolate the appliance from the electrical mains
by pulling the plug out of the wall plug socket!
• Close the gas cock in the gas supply pipe, the mainte-
nance cocks and -if fitted-in- the heating flow and
return.
• Close the cold water inlet valve on the inlet combi-
nation.
• Empty the appliance if you want to replace water-
bearing components of the appliance!
• Make sure that no water drips on live components
(e.g. electronic box etc.)!
• Use only new gaskets and O-rings!
• After completing the work, check for gas leaks and
perform a function check (see Chapter 6)!
10.2 Replacing burner
Danger!
d
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Dismantle the compact thermo module as described in
Section 8.4.1.
1
Fig. 10.1 Replacing burner
• Release the 4 screws (1) on burner, and remove the
burner.
• Mount the new burner with a new gasket. Make sure
that the nose on the burner window grips onto the
gasket in the groove in the burner.
• Install the compact thermo module as described in
Chapter 8.4.4.
• After completing the work, check for gas leaks and
perform a function check (see Chapter 6)!
45ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 46
10 Replacing components
10.3 Replacing fan or gas fittings
Danger!
d
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Disconnect the appliance from the mains as described
in Chapter 10.1, and close the gas cock in the gas
supply pipe.
1
2
3
4
Fig. 10.2 Dismantling fan with gas valve
• Remove the screw (2) and remove the air inlet pipe (1)
from the inlet spigot on the gas fi
• Release the gas supply pipe (4) on the gas valve.
• Pull out the plug from the gas valve.
• Only ecoTEC exclusive 832: Pull out the plug from the
fan printed circuit board.
Only ecoTEC exclusive 838: Open the coupling of the
mains input.
• Release the four screws (3) on the compact thermo
module .
• Remove the complete "gas fitting/fan" unit.
5
Fig. 10.3 Gas fitting/fan screwed joint
• Release both fixing screws (5) on the gas fitting and
remove the fan from the gas fitting.
• Replace the defective component.
tting.
Caution!
a
Mount the gas valve and the fan in the same
position as before.
• Screw the fan to the gas fitting. Use the new seals.
• Re-install the complete "gas fitting/fan" unit in
reverse sequence.
• After completing the work, check for gas leaks and
perform a function check (see Chapter 6)!
10.4 Replacing primary heat exchanger
Danger!
d
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Disconnect the appliance from the mains as described
in Chapter 10.1, and close the gas cock in the gas
supply pipe.
• Close the maintenance cocks - if fitted - in the heating
flow and return and drain the appliance.
• Dismantle the compact thermo module as described
under 8.4.1.
6
5
4
3
Fig. 10.4 Replacing primary heat exchanger
• Remove the clamps (4) on the trap (3), release the
fittings on the trap and remove the trap from the primary heat exchanger.
• Remove the adaptor nuts of the trap from the primary
heat exchanger.
• Release the return connection (6) and the feed
connection (5) on the primary heat exchanger.
• Release the three screws (2) on the primary heat
exchanger and remove the primary heat exchanger
from the appliance.
• Mount the new primary heat exchanger in reverse
order and replace the seals.
• Fill and bleed the appliance and if needed, the plant
after installing the new primary heat exchanger.
• After completing the work, check for gas and water
leaks and perform a function check (see Chapter 6)!
1
2
ecoTEC exclusive installation and maintenance instructions / 0020017768_0446
Page 47
Replacing components 10
Vaillant service 11
Recycling and disposal 12
10.5 Replacing electronics and display
Danger!
d
Before replacing the component, comply with
the safety instructions in Section 10.1.
• Comply with the assembly and installation manuals
provided with the spare parts.
Replacing display or electronics
If you are replacing only one of the two components,
the parameter adjustment functions automatically. On
turning on the appliance, the new component takes over
the previously set parameters from the components
that are not replaced.
Replacing display and electronics
When replacing both components (spare part case),
after being turned on, the appliance goes to fault and
displays the error message F.70.
• In the second diagnosis level, under the diagnosis
point "d.93" enter the number of appliance variant
according to Table 10.1 (see Chapter 9.1.2).
The electronics is now set to the appliance type and the
parameters of all adjustable diagnosis points correspond
to the factory settings.
11 Vaillant service
To ensure regular servicing, it is strongly recommended
that arrangements are made for a Maintenance
Agreement. Please contact Vaillant Service Solutions
(0870 6060 777) for further details.
12 Recycling and disposal
Both your Valliant ecoTEC exclusive and its packaging
consist mainly of recyclable raw materials.
The Vaillant ecoTEC exclusive and all accessories and
the packaging must not be disposed of in the household
waste. Make sure that the old appliance and any accessories and the transport packaging are disposed of in
the proper way.
Appliance Number of the appliance variant
ecoTEC exclusive 832 4
ecoTEC exclusive 838 5
Table 10.1 Numbers of the appliance variants
47ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 48
13 Technical data
13 Technical data
ecoTEC exclusive 832 838 Unit
Nominal heat output range P at 40/30 °C 11,0 - 29,3 12,1 - 32,4 kW
Nominal heat output range P at 50/30 °C 10,8 - 28,7 11,9 - 31,8 kW
Nominal heat output range P at 60/40 °C 10,5 - 27,9 11,5 - 30,9 kW
Nominal heat output range P at 80/60 °C 10,2 - 27,0 11,2 - 30,0 kW
Hot water output 31,4 37,2 kW
Maximum load in hot water function 32 38 kW
Maximum thermal load on heating-side 27,6 30,6 kW
Minimum thermal load 10,4 11,4 kW
Heating
Max. flow temperature 90 90 °C
Setting range max. feed temperature (factory setting: 75°C) 40 - 85 40 - 85 °C
Permissible total over-pressure 3 3 bar
Circulation water volume (with reference to T = 20 K) 1161 1290 l/h
Condensate volume approx. (pH value 3,5 - 4,0)
at heating operation 50 °C flow/30 °C return
Residual feed head pump (at nominal circulation water volume) 250 (300) 250 mbar
hot water handling
Least water volume 1,5 1,5 l/min
Water volume (at T = 35 K) 12,9 15,2 l/min
Maximum pressure 10 10 bar
Required connection pressure 0,35 0,35 bar
Hot water discharge temperature range 35 - 65 35 - 65 °C
General
Gas connection 15 15 mm
Heating connection 22 22 mm
Hot and cold water connection 15 15 mm
Exhaust spigot (parallel adaptor) 60/100 60/100 mm
Designation Venturi 051 051 –
Category II
Connection pressure (gas flow pressure) natural gas, G20 20 20 mbar
Connection pressure (gas flow pressure) propane, G31 37 37 mbar
Connection value at 15 °C and 1013 mbar G20
(if necessary with reference to hot water preparation) G31
Exhaust gas mass flow min./max. 4,8/14,4 5,3/17,2 g/s
Exhaust gas temperature min./max. 40/78 40/82 °C
Exhaust gas connection approval C
SEDBUK classification E = 91,1 / Class „A“ E = 91,1 / Class „A“ –
NOx class 5 5 –
Appliance dimensions - Height
- Width
- Depth
Installation weight approx. 44 46 kg
Electrical connection 230/50 230/50 V/Hz
Built-in fuse 1 x 2 A slow-acting 1 x 2 A slow-acting –
Electrical power consumption min./max. 40/95 40/110 W
Power consumption at rest 5 5 W
Level of protection IP x4 D IP x4 D –
Test marks/registration number CF 0085 BR 0308 CF 0085 BR 0308 –
Table 13.1 Technical data
2,8 3,1 l/min
2H 3P
3,4
2,49
, C33, C43, C53, C83, B23, B33C13, C33, C43, C53, C83, B23, B33–
13
800
480
450
II
2H 3P
4,0
2,95
800
480
450
–
m
kg/h
mm
mm
mm
3
/h
ecoTEC exclusive installation and maintenance instructions / 0020017768_0448
Page 49
Appendix
Appendix
EC declaration of conformity
49ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 50
ecoTEC exclusive installation and maintenance instructions / 0020017768_0450
Page 51
Installation,
Installation,
Commissioning and
Commissioning and
Service Record
Service Record
51ecoTEC exclusive installation and maintenance instructions / 0020017768_04
Page 52
Please affix the label from the
rear cover of the control box
over this area.
Page 53
0020008345-06
SERVICE INTERVAL RECORD
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below .
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service
as described in the boiler manufacturer’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.
SERVICE 1 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 3 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 5 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Ye s No
SERVICE 2 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 4 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 6 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Ye s No
Signature
SERVICE 7 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 9 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
Signature
SERVICE 8 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 10 Date
Energy Efficiency Checklist completed? Ye s No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
Page 54
Page 55
Page 56
0020017768_04 GBIE 112009 — Subject to alterations
Loading...