Vaillant ecoTEC exclusive 832, ecoTEC exclusive 838 Installation And Maintenance Instructions Manual
For the installer
Installation and maintenance instructions
ecoTEC exclusive
Gas wall boilers with condensing appliance technology
ecoTEC exclusive 832
ecoTEC exclusive 838
GB, IE
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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