Vaillant ecoTEC plus 806 VU GB 806/5-5, ecoTEC plus 1006 VU GB 1006/5-5, ecoTEC plus 1206 VU GB 1206/5-5 Installation And Maintenance Instructions Manual
For the competent person
Installation and maintenance instructions
ecoTEC plus
VU GB .../5‑5
GB, IE
Installation and maintenance instructions
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40 D-42859 Remscheid
Tel. +49 21 91 18‑0 Fax +49 21 91 18‑2810
info@vaillant.de www.vaillant.de
Contents
2 Installation and maintenance instructions ecoTEC plus 0020134823_04
Contents
1 Safety .................................................................... 4
1.1 Action-related warnings ......................................... 4
1.2 Intended use.......................................................... 4
1.3 General safety information .................................... 4
1.4 Regulations (directives, laws, standards).............. 6
2 Notes on the documentation .............................. 7
2.1 Observing other applicable documents ................. 7
2.2 Storing documents................................................. 7
2.3 Applicability of the instructions .............................. 7
2.4 Benchmark............................................................. 7
3 Product description............................................. 7
3.1 Design of the product............................................. 7
3.2 Information on the identification plate.................... 8
3.3 CE label ................................................................. 8
4 Installation............................................................ 8
4.1 Unpacking the product........................................... 8
4.2 Checking the scope of delivery.............................. 8
4.3 Product dimensions and connection
dimensions............................................................. 9
4.4 Minimum clearances and installation
clearances ............................................................. 9
4.5 Clearance from combustible components ............. 9
4.6 Using the installation template............................... 9
4.7 Wall-mounting the product................................... 10
4.8 Removing/installing the front casing.................... 10
4.9 Removing/fitting the upper casing ....................... 10
4.10 Removing/installing the side section (as
required) .............................................................. 11
5 Installation.......................................................... 11
5.1 Gas installation .................................................... 11
5.2 Hydraulics installation.......................................... 12
5.3 Flue gas installation ............................................. 14
5.4 Electrical installation ............................................ 15
6 Operation............................................................ 17
6.1 Operating concept of the product ........................ 17
6.2 Live Monitor (status codes) ................................. 17
6.3 Test programmes................................................. 17
7 Start-up ............................................................... 18
7.1 Auxiliary service equipment:................................ 18
7.2 Carrying out the initial start-up............................. 18
7.3 Checking and treating the heating water/filling
and supplementary water .................................... 18
7.4 Switching on the product ..................................... 19
7.5 Running the installation assistants ...................... 19
7.6 Restarting the installation assistants ................... 19
7.7 Calling up appliance config. and diagnostics
menu.................................................................... 19
7.8 Using check programmes.................................... 19
7.9 Reading off the filling pressure ............................ 20
7.10 Preventing low water pressure ............................ 20
7.11 Filling and purging the heating installation .......... 20
7.12 Flushing the heating installation for the first
time ("cold") ......................................................... 21
7.13 Filling the condensate trap .................................. 21
7.14 Checking and adjusting the gas ratio setting ....... 21
7.15 Checking leak-tightness ...................................... 24
7.16 Thoroughly flushing the heating installation
("hot")................................................................... 24
8 Adapting the unit to the heating
installation.......................................................... 25
8.1 Calling up diagnostics codes ............................... 25
8.2 Setting the heating partial load ............................ 25
8.3 Setting the pump overrun and pump operating
mode.................................................................... 25
8.4 Setting the maximum flow temperature ............... 25
8.5 Setting the return flow temperature control ......... 25
8.6 Burner anti-cycling time ....................................... 26
8.7 Setting the maintenance interval ......................... 26
8.8 Setting the pump output....................................... 26
8.9 Handing the product over to the operator............ 26
9 Inspection and maintenance ............................ 26
9.1 Observing inspection and maintenance
intervals ............................................................... 27
9.2 Procuring spare parts .......................................... 27
9.3 Using the function menu...................................... 27
9.4 Carrying out electronics self-tests ....................... 28
9.5 Removing the gas-air mixture unit....................... 28
9.6 Cleaning the heat exchanger............................... 29
9.7 Checking the burner ............................................ 30
9.8 Replacing the ignition and ionisation
electrodes ............................................................ 30
9.9 Cleaning the condensate trap.............................. 30
9.10 Installing the gas-air mixture unit ......................... 30
9.11 Draining the product ............................................ 31
9.12 Completing inspection and maintenance work .... 31
10 Troubleshooting ................................................ 31
10.1 Contacting your service partner........................... 32
10.2 Calling up service messages ............................... 32
10.3 Reading off the fault codes .................................. 32
10.4 Querying the fault memory .................................. 32
10.5 Resetting the fault memory.................................. 32
10.6 Performing diagnostics ........................................ 32
10.7 Using check programmes .................................... 32
10.8 Resetting parameters to factory settings ............. 32
10.9 Preparing the repair work .................................... 32
10.10 Replacing defective components......................... 33
10.11 Completing repair work........................................ 35
11 Decommissioning.............................................. 35
11.1 Decommissioning the product ............................. 35
12 Recycling and disposal..................................... 35
13 Customer service............................................... 35
Appendix ............................................................................ 36
A Installer level menu structure – Overview....... 36
B Overview of diagnostics codes........................ 38
C Inspection and maintenance work –
Overview............................................................. 40
Contents
0020134823_04 ecoTEC plus Installation and maintenance instructions 3
D Status codes – Overview .................................. 41
E Overview of fault codes .................................... 42
F Connection diagram .......................................... 44
G Initial start-up checklist..................................... 45
G.1 Initial start-up checklist ........................................ 45
H Commissioning Checklist ................................. 48
I Opening of the flue pipe.................................... 51
I.1 Positioning of the opening of a fan-supported
flue gas guiding.................................................... 51
I.2 Text from BS 5440-1 on fan-supported flue
gas guiding .......................................................... 52
I.3 Opening of the flue pipe below eaves and
balconies.............................................................. 52
J Treating the heating water................................ 52
K Technical data.................................................... 53
Index ................................................................................... 55
1 Safety
4 Installation and maintenance instructions ecoTEC plus 0020134823_04
1 Safety
1.1 Action-related warnings
Classification of action-related warnings
The action-related warnings are classified in
accordance with the severity of the possible
danger using the following warning signs and
signal words:
Warning symbols and signal words
Danger!
Imminent danger to life or risk of
severe personal injury
Danger!
Risk of death from electric shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental
damage
1.2 Intended use
There is a risk of injury or death to the user or
others, or of damage to the product and other
property in the event of improper use or use
for which it is not intended.
The product is intended as a heat generator
for closed heating installations and for hot
water generation.
Depending on the gas-fired boiler type, the
products referred to in these instructions
must only be installed and operated in conjunction with the air/flue pipe accessories listed in the other applicable documents.
Intended use includes the following:
– observance of accompanying operating,
installation and servicing instructions for
the product and any other system components
– installing and fitting the product in accord-
ance with the product and system approval
– compliance with all inspection and main-
tenance conditions listed in the instructions.
Intended use also covers installation in accordance with the IP class.
Any other use that is not specified in these
instructions, or use beyond that specified in
this document shall be considered improper
use. Any direct commercial or industrial use
is also deemed to be improper.
Caution.
Improper use of any kind is prohibited.
1.3 General safety information
1.3.1 Risk caused by inadequate
qualifications
The following work must only be carried out
by competent persons who are sufficiently
qualified to do so:
– Installation
– Disassembly
– Installation
– Start-up
– Maintenance
– Repair
– Decommissioning
1.3.2 Risk of death due to blocked or
leaking flue gas routes
Installation errors, damage, tampering, unauthorised installation sites or similar can cause
flue gas to escape and result in a risk of poisoning.
What to do if you smell flue gas in the property:
▶ Open all accessible doors and windows
fully to provide ventilation.
▶ Switch off the product.
▶ Check the flue gas routes in the product
and the flue gas diversions.
1.3.3 Risk of poisoning and burns caused
by escaping hot flue gases
▶ Only operate the product if the air/flue pipe
has been completely installed.
▶ With the exception of short periods for
testing purposes, only operate the product
when the front casing is installed and
closed.
1.3.4 Risk of death due to explosive and
flammable materials
▶ Do not use or store explosive or flammable
materials (e.g. petrol, paper, paint) in the
installation room of the product.
Safety 1
0020134823_04 ecoTEC plus Installation and maintenance instructions 5
1.3.5 Danger caused by improper
operation
Improper operation may present a danger to
you and others, and cause material damage.
▶ Carefully read the enclosed instructions
and all other applicable documents, particularly the "Safety" section and the warnings.
▶ Only carry out the activities for which in-
structions are provided in these operating
instructions.
1.3.6 Risk of death from escaping gas
What to do if you smell gas in the building:
▶ Avoid rooms that smell of gas.
▶ If possible, open doors and windows fully
and ensure adequate ventilation.
▶ Do not use naked flames (e.g. lighters,
matches).
▶ Do not smoke.
▶ Do not use any electrical switches, mains
plugs, doorbells, telephones or other communication systems in the building.
▶ If it is safe to do so, close the emergency
control valve or the main isolator.
▶ If possible, close the gas isolator cock on
the product.
▶ Warn other occupants in the building by
yelling or banging on doors or walls.
▶ Leave the building immediately and ensure
that others do not enter the building.
▶ Notify the gas supply company or the Na-
tional Grid +44 (0) 800 111999 by telephone once you are outside of the building.
1.3.7 Risk of death due to lack of safety
devices
The schematic drawings included in this document do not show all safety devices required for correct installation.
▶ Install the necessary safety devices in the
system.
▶ Observe the applicable national and inter-
national laws, standards and guidelines.
1.3.8 Risk of injury during transport due
to a high product weight.
▶ Make sure that the product is transported
by at least two people.
1.3.9 Risk of death from electric shock
There is a risk of death from electric shock if
you touch live components.
Before commencing work on the product:
▶ Disconnect the product from the power
supply by switching off all power supplies
(electrical partition with a contact opening
of at least 3 mm, e.g. fuse or line protection switch).
▶ Secure against being switched back on
again.
▶ Wait for at least 3 minutes until the capa-
citors have discharged.
▶ Check that there is no voltage.
1.3.10 Risk of being burned or scalded by
hot components
▶ Only carry out work on these components
once they have cooled down.
1.3.11 Risk of death from escaping flue
gas
If you operate the product with an empty condensate siphon, flue gas may escape into the
room air.
▶ In order to operate the product, ensure that
the condensate siphon is always full.
1.3.12 Risk of scalding from hot water
There is a risk of scalding at the hot water
draw-off points if the hot water temperatures
are greater than 60 °C. Young children and
elderly persons are particularly at risk, even
at lower temperatures.
▶ Select a moderate set target temperature.
1.3.13 Risk of material damage caused by
using an unsuitable tool
▶ Use the correct tool to tighten or loosen
screw connections.
1 Safety
6 Installation and maintenance instructions ecoTEC plus 0020134823_04
1.3.14 Risk of material damage caused by
frost
▶ Do not install the product in rooms prone
to frost.
1.3.15 Risk of corrosion damage due to
unsuitable combustion and room
air
Sprays, solvents, chlorinated cleaning
agents, paint, adhesives, ammonia compounds, dust or similar substances may lead
to corrosion on the product and in the air/flue
pipe.
▶ Ensure that the supply of combustion air is
always free of fluorine, chlorine, sulphur,
dust, etc.
▶ Ensure that no chemical substances are
stored at the installation site.
▶ If you are installing the product in
hairdressing salons, painter's or joiner's
workshops, cleaning businesses or similar
locations, choose a separate installation
room in which the room air is technically
free of chemical substances.
1.4 Regulations (directives, laws,
standards)
▶ Observe the national regulations, stand-
ards, guidelines and laws.
Notes on the documentation 2
0020134823_04 ecoTEC plus Installation and maintenance instructions 7
2 Notes on the documentation
2.1 Observing other applicable documents
▶ You must observe all the operating and installation in-
structions included with the system components.
2.2 Storing documents
▶ Pass these instructions and all other applicable docu-
ments on to the system operator.
2.3 Applicability of the instructions
These instructions apply only to:
Product article number
Article number
Gas Council
Number
806 (VU GB 806/5‑5)
0010010767 41-044-68
1006 (VU GB 1006/5‑5)
0010010780 41-044-69
1206 (VU GB 1206/5‑5)
0010010791 41-044-70
2.4 Benchmark
Vaillant is a licensed member of the Benchmark Scheme.
Benchmark places responsibilities on both manufacturers
and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the
manufacturer’s instructions by a competent person approved
at the time by the Health and Safety Executive and that it
meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be
provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark
Code of Practice which is available from the Heating and
Hotwater Industry Council who manage and promote the
Scheme.
Benchmark is managed and promoted by the Heating and
Hotwater Industry Council.
For more information visit www.centralheating.co.uk
3 Product description
3.1 Design of the product
3.1.1 Functional elements (806/5‑5)
1
2
3
4
6
5
7
8
10
9
12
13
14
15
16
11
1 Connection for the flue
pipe
2 Fan
3 Gas valve
4 Connection for air in-
take pipe
5 Flue gas pressure
cartridge
6 Return temperature
sensor
7 Water pressure sensor
8 Electronics box
9 Integrated condensation
heat exchanger
10 Pressure gauge
11 Flow temperature
sensor
12 Safety overheat cut-off
device
13 Ignition electrode
14 Automatic air vent
15 Monitoring electrode
4 Installation
8 Installation and maintenance instructions ecoTEC plus 0020134823_04
3.1.2 Functional element (1006/5‑5 and 1206/5‑5)
1
2
3
6
7
5
4
8
10
9
12
13
14
15
16
11
1 Connection for the flue
pipe
2 Fan
3 Gas valve
4 Supply air connector
5 Flue gas pressure
cartridge
6 Return temperature
sensor
7 Water pressure sensor
8 Electronics box
9 Integrated condensation
heat exchanger
10 Pressure gauge
11 Flow temperature
sensor
12 Safety overheat cut-off
device
13 Ignition electrode
14 Automatic air vent
15 Monitoring electrode
3.2 Information on the identification plate
The identification plate is mounted on the underside of the
product in the factory.
Information on the
identification plate
Meaning
Serial number for identification; 7th to 16th digits =
product article number
VU… Vaillant gas-fired wall-hung boiler for
heating
ecoTEC plus Product description
H, G20 – 20 mbar
(2.0 kPa)
Gas group and gas connection pressure
as set at the factory
Cat. (e.g. II
2H3P
) Unit category
Types (e.g. C33) Gas-fired boiler types
PMS (e.g. 6 bar
(0.6 MPa))
Permissible total overpressure
T
max.
(e.g. 85 °C) Max. flow temperature
230 V 50 Hz Electric connection
Information on the
identification plate
Meaning
(e.g. 260) W Max. electrical power consumption
IP (e.g. X4D) Level of protection
Heating mode
P Nominal heat output range
Q Heat input range
Note
Make absolutely sure that the product is compatible with the gas group at the installation site.
3.3 CE label
The CE label shows that the products comply with the basic
requirements of the applicable directives as stated on the
identification plate.
The declaration of conformity can be viewed at the manufacturer's site.
4 Installation
4.1 Unpacking the product
1. Remove the product from its box.
2. Remove the protective film from all parts of the product.
4.2 Checking the scope of delivery
▶ Check that the scope of delivery is complete and intact.
4.2.1 Scope of delivery
Number
Description
1
Hanging bracket
1
Heat generator
1
Condensate trap
1 Condensate drain hose
1
Installation template
1
Enclosed documentation
1
Enclosed unit fastening
1
Bag with small parts
1
Gas connection piece
1
Service valve (1 1/2 inches), red handle
1
Service valve (1 1/2 inches), blue handle
1
Bag with seals for service valves
1
Expansion relief valve, 6 bar
1
R 1 straight-through gas valve
Installation 4
0020134823_04 ecoTEC plus Installation and maintenance instructions 9
4.3 Product dimensions and connection
dimensions
287
190
673
603
480
175
138
172 172
70
22
482
Ø25
49
G 1 1/4
960
477
680,5
1
2
3
4
5
6
7
1 Wall duct for flue pipe
2 Flue pipe connection
3 Hanging bracket
4 Heating flow
5 Condensate trap con-
nection
6 Gas connection
7 Heating return
4.4 Minimum clearances and installation
clearances
CC
AB
A 350 mm (110/160 mm
diameter flue pipe)
At least 450 mm for
cascade design
B 400 mm
C Optional approx. 200
mm
D Clearance of 600 mm
in front of the product
for easy access during
maintenance work
▶ When using the accessories, observe the minimum clear-
ances/installation clearances.
Note
A lateral clearance is not required, however
you can also remove the side sections if there
is sufficient space at the side (approx. 200
mm) in order to facilitate maintenance or repair work.
▶ Where units are installed in cascade, observe the gradi-
ent of the flue pipe (approx. 50 mm/m).
4.5 Clearance from combustible components
It is not necessary to ensure that there is a clearance
between the product and combustible components, as the
temperature of the product will never exceed the maximum
permissible temperature of 85 °C at its nominal heat output.
The same applies to the external air guiding of the concentric
flue pipe.
4.6 Using the installation template
1. Position the installation template vertically over the in-
stallation site.
2. Secure the template to the wall.
3. Mark on the wall all the points required for your installa-
tion.
4. Remove the installation template from the wall.
5. Drill all the holes required.
6. Make any perforations necessary.
4 Installation
10 Installation and maintenance instructions ecoTEC plus 0020134823_04
4.7 Wall-mounting the product
Conditions: The load-bearing capacity of the wall is sufficient, The fixing
material may be used for the wall
▶ Wall-mount the product as described.
Conditions: The load-bearing capacity of the wall is not sufficient
▶ Ensure that wall-mounting apparatus on-site has a suf-
ficient load-bearing capacity. Use individual stands or
primary walling, for example.
▶ Do not wall-mount the product if you cannot provide
wall-mounting apparatus with a sufficient load-bearing
capacity.
Conditions: The fixing material may not be used for the wall
▶ Wall-mount the product as described using the permitted
fixing material provided on-site.
1
1. Install the hanging bracket (1) on the wall.
2. Suspend the product on the hanging bracket from
above using the suspension bracket.
4.8 Removing/installing the front casing
4.8.1 Removing the front casing
2
1
1. Undo the bolt (1).
2. Push in both retaining clips (2) so that the front casing
is released.
3. Pull the front casing forwards at the bottom edge.
4. Lift the front casing upwards from the bracket.
4.8.2 Installing the front casing
1. Place the front casing on the upper brackets.
2. Push the front casing onto the product until both retaining clips (2) snap into place at the front casing.
3. Secure the front casing by tightening the bolt (1).
4.9 Removing/fitting the upper casing
4.9.1 Removing the upper casing
2
1
1. Unscrew the screws (2).
2. Pull out the upper casing (1) towards the front.
4.9.2 Installing the upper casing
1. From above, place the upper casing (1) on the product.
2. Use the screws (2) to secure the upper casing (1).
Installation 5
0020134823_04 ecoTEC plus Installation and maintenance instructions 11
4.10 Removing/installing the side section (as
required)
4.10.1 Removing the side section
Caution.
Risk of material damage caused by mech-
anical deformation.
Removing both side sections may cause
mechanical distortion in the product, which
may cause damage to the piping, for example, and potentially result in leaks.
▶ Always remove only one side section –
never both side sections at the same time.
1. Tilt the electronics box forward.
2. Remove the upper casing. (→ Page 10)
3. Hold on to the side section so that it cannot fall, and
unscrew the lower front and upper central screws from
the side section.
4. Tilt the side section slightly to the side and pull it out
towards the front.
4.10.2 Installing the side section
1. Push the side section into the bracket. When doing so,
and to prevent leaks, ensure that all straps on the side
section engage with the back wall.
2. Slide the side section to the rear.
3. Secure the side section using two screws in the front
lower area and in the upper central area.
4. Install the upper casing. (→ Page 10)
5. Fold up the electronics box.
5 Installation
Danger!
Risk of explosion or scalding caused by
incorrect installation.
Stresses in the supply line can cause leaks.
▶ Make sure there is no voltage in the sup-
ply lines when they are installed.
Caution.
Risk of damage caused by contaminated
lines.
Foreign bodies, such as welding remnants,
sealing residue or dirt in the water pipes, may
cause damage to the boiler.
▶ Flush the heating installation thoroughly
prior to installation.
Seals made of rubber-like materials may be subject to plastic
deformation, which can lead to pressure losses. We recommend using seals made of a paste-like fibre material.
5.1 Gas installation
5.1.1 Performing the gas installation
Caution.
Risk of material damage caused by incor-
rect gas installation.
Excessive test pressure may cause damage
to the gas valve.
▶ When checking the entire gas installation
for leak-tightness, the maximum permissible pressure at the gas valve is 7.5 kPa
(75 mbar).
Caution.
Risk of material damage caused by the
incorrect gas type.
Using the wrong gas type may cause a fault
shutdown of the product. Furthermore, ignition and combustion noise may occur in the
product.
▶ Only use the gas types in accordance with
the identification plate.
5 Installation
12 Installation and maintenance instructions ecoTEC plus 0020134823_04
▶ Remove the residues from the gas line by blowing
through the gas line beforehand.
▶ Make sure that the existing gas meter is capable of
passing the rate of gas supply required.
▶ Install an approved gas isolator cock on the product us-
ing the gas connection piece.
▶ Install the gas line on the gas isolator cock without ten-
sion.
▶ Purge the gas line before start-up.
▶ Check that the gas connection is leak-tight (→ Page 24).
5.2 Hydraulics installation
Caution.
Risk of material damage due to high tem-
peratures.
Plastic pipes in the heating installation may
become damaged by overheating if a fault
occurs.
▶ When using plastic pipes, install a max-
imum thermostat on the heating flow.
Caution.
Risk of material damage due to corrosion.
If non-diffusion-tight plastic pipes are used in
the heating installation, this may cause air to
enter the heating water and lead to corrosion
of the heat generation circuit and the product.
▶ If using non-diffusion-tight plastic pipes
in the heating installation, separate the
system by installing an external heat exchanger between the product and the
heating installation.
Caution.
Risk of material damage due to heat trans-
fer during soldering.
▶ Only solder connection pieces if the con-
nection pieces are not yet screwed to the
service valves.
The product should be connected using a Vaillant pump
group (accessories).
– Modulating pump
This pump group has a connection option for an expansion
vessel (right-hand connection) and an expansion relief valve
(left-hand connection). You can find information about available accessories from the Vaillant price list or from the contact address provided on the reverse of this document.
▶ When installing the pump group, observe the installa-
tion sequence for the insulation and the hydraulic pipes (
Pump group installation instructions).
▶ Note that the boiler pump must always be fitted in the
return line. Otherwise, this may lead to a malfunction in
the product.
When connecting several products in cascade operation, you
must install a non-return flap from the cascade connection
set in the flow line of each individual product.
A non-return flap from a third-party manufacturer must have
no more than 30 mbar pressure loss for a volume flow of
4.5 m³/h.
5.2.1 Connecting the heating flow and heating
return
1
1. In each case, insert a flat seal into the service valve
(Vaillant accessories).
2. Screw the service valves onto the flow and return con-
nection (1) of the pump group.
3. Screw the service valves to the customer's installation.
– Diameter of the heating line: 1 1/4″
Installation 5
0020134823_04 ecoTEC plus Installation and maintenance instructions 13
5.2.2 Installing an expansion vessel
1
▶ Install an expansion vessel on the connection (1) in the
return.
– Connection to the pump group: 1/2″
Conditions: Using a system separation
– Large expansion vessel: ≥ 10 l
5.2.3 Hydraulic connection
Ø 1 1/4"
For the hydraulic connection to the heating installation, we
strongly recommend that you use a low loss header or a
plate heat exchanger for the hydraulic system partition. In
addition, we recommend that you install a dirt filter in the
system before the low loss header or the plate heat exchanger. For the maintenance of the plate heat exchanger,
we recommend that you install cleaning connections on
the heating side so that the plate heat exchanger can be
backwashed during maintenance work.
To this end, various plate heat exchangers and low loss
headers are available as accessories, depending on the output of a product or the cascade system. The pressure loss is
adjusted to the pump groups that are offered as an accessory. The minimum volume of circulating water is guaranteed
in the unit circuit thanks to the original accessories, provided
the maximum pressure losses are not exceeded in the piping.
Select the plate heat exchanger according to output.
Depending on your choice of pump group, the following remaining feed heads are available in the unit supply:
Power Description Remaining feed
head
80 kW Modulating pump 0.042 MPa
(0.420 bar)
100 kW Modulating pump 0.026 MPa
(0.260 bar)
120 kW Modulating pump 0.024 MPa
(0.240 bar)
If you are using a plate heat exchanger to hydraulically partition the system, the following pressure losses must be maintained (rated water volume when ΔT=20 K):
Power Pressure loss
< 120 kW 86 mbar
(0.086 bar)
In conjunction with the hydraulic cascade
< 240 kW 96 mbar
(0.096 bar)
< 360 kW 76 mbar
(0.076 bar)
< 480 kW 82 mbar
(0.082 bar)
< 600 kW 87 mbar
(0.087 bar)
< 720 kW 92 mbar
(0.092 bar)
5.2.4 Connecting the condensate trap
Condensate forms in the product during combustion. The
condensate drain pipework routes the condensate to the
waste water connection.
The product is equipped with a condensate trap. The filling
height is 145 mm. The condensate trap collects any condensate that forms and feeds it into the condensate drain
pipework.
▶ Place the condensate trap on the underside of the
product on the condensate drain pipe and secure it using
the retaining clips.
▶ Leave installation space of at least 180 mm below the
condensate trap so that you can clean the condensate
trap in the event of maintenance work.
▶ Check the connection for leak-tightness.
5 Installation
14 Installation and maintenance instructions ecoTEC plus 0020134823_04
5.2.5 Connecting the condensate drain pipework
min.
180
2
1
3
▶ When making the condensate pipe connections ensure
that there is adequate branch ventilation and that there
can be no backflow of water into the boiler via the condensate pipe work.
▶ Check if a neutralising unit is required in accordance with
national regulations.
▶ Observe the local regulations on neutralising the con-
densate.
Note
You can obtain neutralisation with or without a
condensate pump as an accessory.
▶ If required, guide the drain hose (1) from the automatic
air vent into the tundish.
Note
The condensate drain pipework must have a
continuous fall (45 mm per metre) and should
whenever possible terminate at a suitable
drain point within the heated envelope of the
building that will remain frost free under long
periods of low external temperatures.
You can find further information in BS 656: "Specification for
installing and maintaining gas-fired boilers with a nominal
heat loading greater than 70 kW but less than or equal to
300 kW". Before the boiler is started up, the condensate
trap (1) must be filled with water as described in the relevant
section.
5.2.6 Connecting the expansion relief valve
Note
The product is delivered with a 6 bar expansion
relief valve, which must be installed on the
product and must be guided to a secure, but visible, point. The discharge pipe on the expansion
relief valve must have a minimum diameter of 18
mm and must only be used for this purpose.
1. Ensure that all components that are installed in the
heating installation are suitable for a max. operating
pressure of 6 bar.
1
Danger!
Risk of scalding!
Heating water that leaks from the exit point of
the expansion relief valve may cause severe
burns.
▶ Install the expansion relief valve drain to a
professional standard.
2. Connect the expansion relief valve (1).
Note
When selecting the expansion relief valve,
note the max. operating pressure of the heating installation.
5.3 Flue gas installation
5.3.1 Air/flue pipes that can be connected
▶ When installing the air/flue pipe, observe the provisions
of the applicable national regulations.
Note
All products feature an 110/160 mm diameter
air/flue gas connection as standard.
You can find out which air/flue pipes may be used by consulting the enclosed "Air/flue pipe installation manual".
5.3.2 Installing the air/flue pipe
Caution.
Risk of poisoning due to escaping flue
gas.
Mineral-oil-based greases can damage the
seals.
▶ Instead of grease, use only water or com-
mercially available soft soap to aid installation.
Installation 5
0020134823_04 ecoTEC plus Installation and maintenance instructions 15
Danger!
Risk of personal injury and material dam-
age due to unapproved air/flue pipes.
Vaillant boilers are certified only with Vaillant
original air/flue pipes. The use of other accessories may cause personal injury and material damage, as well as operating faults. For
installation type B23P, third-party accessories are also permitted (see the technical data
in the appendix).
▶ Only use Vaillant original air/flue pipes.
▶ If third-party accessories are permitted
for B23P, ensure that the flue pipe connections are properly routed, sealed and
secured against slipping out.
1. Install the flue pipe using the installation manual.
2. When installing the air/flue pipe, observe the provisions
of the applicable national regulations.
3. Route the flue pipe with a downward gradient so that
the condensate that accumulates can easily flow into
the condensate trap provided for it.
5.4 Electrical installation
5.4.1 Opening/closing the electronics box
5.4.1.1 Opening the electronics box
2
1
3
1. Remove the front casing. (→ Page 10)
2. Tilt the electronics box (1) forward.
3. Undo the clips (3) from the brackets.
4. Fold up the cover (2).
5.4.1.2 Closing the electronics box
1. Close the cover (2) by pushing downwards on the electronics box (1).
2. Ensure that all the clips (3) audibly click into the brackets.
3. Tilt the electronics box upwards.
5.4.2 Establishing the power supply
Caution.
Risk of material damage due to high con-
nected voltage.
At mains voltages greater than 253 V, electronic components may be damaged.
▶ Ensure that the rated voltage of the mains
is 230 V (+10%/-15%) ~ 50 Hz.
1. Observe all valid regulations.
2. Open the electronics box. (→ Page 15)
3. Provide one common electricity supply for the boiler
and for the corresponding controller:
– Power supply: Single-phase, 230 V, 50 Hz
– Fuse protection: ≤ 3 A
4. Connect the product using a fixed connection and a
partition with a contact opening of at least 3 mm (e.g.
fuses or power switches).
5. Use a flexible line for the mains feed line, which is
routed through the cable duct into the product.
6. Carry out the wiring. (→ Page 16)
7. Observe the connection diagram (→ Page 44).
8. Screw the supplied ProE plug to a suitable, flexible
three-core mains connection cable which complies with
the relevant standards.
9. Close the electronics box. (→ Page 15)
10. Make sure that access to the mains connection is al-
ways available and is not covered or blocked.
5 Installation
16 Installation and maintenance instructions ecoTEC plus 0020134823_04
5.4.3 Carrying out the wiring
Caution.
Risk of material damage caused by incor-
rect installation.
Mains voltage at the incorrect plug terminals
on the ProE system may destroy the electronics.
▶ Do not connect any mains voltage to the
eBUS terminals (+/-).
▶ Only connect the mains connection cable
to the terminals marked for the purpose.
1. Route the supply lines of the components to be connected through the cable duct provided on the underside of
the product.
2. Use the strain reliefs provided.
3. Shorten the supply lines as necessary.
4. To prevent short circuits if a strand accidentally comes
loose, only strip the outer sheathing of flexible lines to a
maximum of 30 mm.
5. Ensure the inner conductor insulation is not damaged
when stripping the outer sheathing.
6. Only strip inner conductors just enough to establish
good, sound connections.
7. To avoid short circuits resulting from loose individual
wires, fit conductor end sleeves on the stripped ends of
the conductors.
8. Screw the respective ProE plug to the supply line.
9. Check whether all conductors are sitting mechanically
securely in the terminals of the ProE plug. Remedy this
if necessary.
10. Plug the ProE plug into the associated PCB slot.
11. Secure the cable in the electronics box using the strain
reliefs.
5.4.4 Connecting the pump group
X18
230 V
X22
1. Open the electronics box. (→ Page 15)
2. Carry out the wiring. (→ Page 16)
3. Use the strain reliefs provided.
4. Plug the ProE plug for the mains power cable into slot
X18.
5. Plug the ProE plug for the control cable into slot X22.
6. Close the electronics box. (→ Page 15)
5.4.5 Installing the controller
▶ Install the controller if necessary.
5.4.6 Connecting controllers to the electronic
system
1. Open the electronics box. (→ Page 15)
2. Carry out the wiring. (→ Page 16)
3. If you connect a weather compensator or room thermostat to the product via eBUS, bridge the input 24 V = RT
(X100 or X106) if no bridge exists.
4. If you use a low-voltage controller (24 V), connect this
instead of the bridge 24 V = RT (X100 or X106).
5. When connecting a maximum thermostat (contact thermostat) for underfloor heating, connect this instead of
the bridge (Burner off) at the ProE plug.
6. Close the electronics box. (→ Page 15)
7. In order to achieve the Comfort pump operating mode
(continuously running pump) for multi-circuit controllers,
change D.018 Pump operating mode (→ Page 25) from
Eco (intermittent pump) to Comfort.
8. If a system separation is installed, set the pump to
Comfort D.018 and set the pump output to at least
4 (85%, D.014). This also applies for installing in
cascade.
Operation 6
0020134823_04 ecoTEC plus Installation and maintenance instructions 17
5.4.7 Connecting additional components
You can use the multi-functional module to actuate two additional components.
The following components can be actuated:
– Circulation pump
– External pump
– Cylinder charge pump
– Extractor hood
– External solenoid valve
– External fault signal
– Solar pump (not active)
– eBUS remote control (not active)
– Legionella protection pump (not active)
– Solar valve (not active).
5.4.7.1 Using the VR 40 ("2 in 7" multi-functional
module)
1. Install the components in accordance with the respect-
ive instructions.
2. Select D.027 (→ Page 25) to actuate relay 1 on the
multi-functional module.
3. Select D.028 (→ Page 25) to actuate relay 2 on the
multi-functional module.
5.4.7.2 Using the flue non-return flap
For cascade operation, you must provide a flue non-return
flap for each product. Either use only electrical flue non-return flaps or use only mechanical flue non-return flaps for all
products in a cascade.
The electrical flue non-return flap is actuated by the VR 40
multi-functional module. The installation instructions for the
VR 40 describe how the flue non-return flap is activated. The
mechanical flue non-return flap has an integrated siphon,
which must be filled with water before starting up the unit.
You can omit the flue non-return flap if you can ensure that
the flue gas installation is operated completely under negative pressure.
Conditions: Operating with natural gas
▶ For smooth operation with natural gas and a flue non-
return flap, use diagnostics code D.050 (→ Page 25) to
increase the fan speed in partial load operation to 1500
rpm.
Conditions: Operating with liquid gas
▶ You must never raise the speed under D.050
(→ Page 25) any higher because a higher speed is
already being used when operating with liquid gas.
5.4.8 Actuating the circulation pump according
to requirements
1. Connect the wiring in the same way as described
in "Connecting controllers to the electronic system
(→ Page 16)".
2. Connect the supply line for the external button using
terminals 1 (0) and 6 (functional drawing) on the X41
edge connector, which is supplied with the controller.
3. Plug the edge connector into the PCB slot X41.
6 Operation
6.1 Operating concept of the product
The operating concept and the read-off and setting facilities
of the operator level are described in the operating instructions.
An overview of the read-off and setting facilities of the installer level can be found in the section "Overview of the
menu structure – Installer level" (→ Page 36).
6.1.1 Calling up the installer level
Caution.
Risk of material damage caused by incor-
rect handling.
Incorrect settings at installer level may cause
damage and operating faults to the heating
installation.
▶ You must only access the installer level if
you are an approved competent person.
Note
The installer level is protected against unauthorised access using a password.
1.
Press and ("i") simultaneously.
◁ The following menu appears in the display.
2.
Scroll using the or button, until the menu point
Installer level appears.
3. Press (OK) to confirm your selection.
◁ In the display, the text Enter code appears along
with the value 00.
4.
Use or to set the value 17 (code).
5. Press (OK) to confirm your selection.
◁ The installer level appears with a selection of menu
points.
6.2 Live Monitor (status codes)
Menu → Live Monitor
Status codes in the display provide information on the product's current operating status.
Status codes – Overview (→ Page 41)
6.3 Test programmes
As well as the installation assistants, you can also call up the
test programmes for start-up, service and troubleshooting.
Menu → Installer level Test programs
There you will find the Check programs (→ Page 19), in
addition to the Function menu, an Electronics self-test
and the Gas family check.
7 Start-up
18 Installation and maintenance instructions ecoTEC plus 0020134823_04
7 Start-up
7.1 Auxiliary service equipment:
The following test and measuring equipment is required for
start-up:
– CO2measuring instrument
– Digital or U tube manometer
– Flat blade screwdriver, small
– 2.5 mm Allen key
7.2 Carrying out the initial start-up
Initial start-up must be carried out by a customer service
technician or an authorised competent person using the
first-commissioning-checklist and the start-up checklist.
The first-commissioning-checklist and the start-up checklist
(→ Page 48) in the appendix for the installation instructions
must be filled out and stored carefully along with the product
documentation.
Initial start-up checklist (→ Page 45)
▶ Carry out the initial start-up using the checklist and the
start-up checklist in the appendix.
▶ Fill out and sign the checklists.
7.3 Checking and treating the heating
water/filling and supplementary water
Caution.
Risk of material damage due to poor-qual-
ity heating water
▶ Ensure that the heating water is of suffi-
cient quality.
▶ Before filling or topping up the system, check the quality
of the heating water.
Checking the quality of the heating water
▶ Remove a little water from the heating circuit.
▶ Check the appearance of the heating water.
▶ If you ascertain that it contains sedimentary materials,
you must desludge the system.
▶ Use a magnetic rod to check whether it contains mag-
netite (iron oxide).
▶ If you ascertain that it contains magnetite, clean the sys-
tem and apply suitable corrosion-protection measures, or
fit a magnet filter.
▶ Check the pH value of the removed water at 25 °C.
▶ If the value is below 8.2 or above 10.0, clean the system
and treat the heating water.
▶ Ensure that oxygen cannot get into the heating water.
Checking the filling and supplementary water
▶ Before filling the system, measure the hardness of the
filling and supplementary water.
Treating the filling and supplementary water
▶ Observe all applicable national regulations and technical
standards when treating the filling and supplementary
water.
Provided the national regulations and technical standards
do not stipulate more stringent requirements, the following
applies:
You must treat the heating water in the following cases:
– If the entire filling and supplementary water quantity dur-
ing the operating life of the system exceeds three times
the nominal volume of the heating installation, or
– If the guideline values listed in the following table are not
met, or
– If the pH value of the heating water is less than 8.2 or
more than 10.0.
Total
heating
output
Water hardness at specific system volume
1)
≤ 20 l/kW
> 20 l/kW
≤ 50 l/kW
> 50 l/kW
kW
ppm
CaCO₃
mol/m³ppm
CaCO₃
mol/m³ppm
CaCO₃
mol/
m³
< 50 < 300 < 3 200 2 2 0.02
> 50
to ≤ 200
200 2 150 1.5 2 0.02
> 200
to ≤ 600
150 1.5 2 0.02 2 0.02
> 600 2 0.02 2 0.02 2 0.02
1) Nominal capacity in litres/heating output; in the case of multiboiler systems, the smallest single heating output is to be used.
Caution.
Risk of material damage if the heating
water is treated with unsuitable additives.
Unsuitable additives may cause changes in
the components, noises in heating mode and
possibly subsequent damage.
▶ Do not use any unsuitable frost and cor-
rosion protection agents, biocides or sealants.
No incompatibility with our products has been detected to
date with proper use of the following additives.
▶ When using additives, follow the manufacturer's instruc-
tions without exception.
We accept no liability for the compatibility of any additive or
its effectiveness in the rest of the heating system.
Additives for cleaning measures (subsequent
flushing required)
– Fernox F3
– Sentinel X 300
– Sentinel X 400
Additives intended to remain permanently in the
system
– Fernox F1
– Fernox F2
– Sentinel X 100
– Sentinel X 200
Additives for frost protection intended to remain
permanently in the system
– Fernox Antifreeze Alphi 11
– Sentinel X 500
▶ If you have used the above-mentioned additives, inform
the operator about the measures that are required.
Loading...