For the installer
Instructions for installation and servicing
ecoTEC plus
Wall hung open vent condensing boiler
GB
Contents
Contents Page
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notes on the documentation . . . . . . . . . . . . 4
1.1.1 Other instructions supplied
with this appliance . . . . . . . . . . . . . . . . . . . . .
1.1.2 Retention of documents . . . . . . . . . . . . . . . . 4
1.1.3 Safety instructions and symbols . . . . . . . . . 4
1.2 ecoTEC plus boilers . . . . . . . . . . . . . . . . . . . . 4
1.3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 General information . . . . . . . . . . . . . . . . . . . .
1.4.1 Gas category . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Gas safety (installation and use) regulations 5
1.4.3 Gas testing and certification . . . . . . . . . . . . 5
1.4.4 Control of substances hazardous to health 5
1.4.5 Insulation pads . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.7 Manual handling guidance. . . . . . . . . . . . . . .
1.4.8 Gas leak or fault . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.9 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.10 Sheet metal parts. . . . . . . . . . . . . . . . . . . . . .
1.4.11 Sealed components . . . . . . . . . . . . . . . . . . . . 5
1.4.12 Electrical supply failure . . . . . . . . . . . . . . . . .
1.4.13 Protection against freezing . . . . . . . . . . . . . 6
1.4.14 Boilers installed in a compartment or
cupboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.15 Boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.16 Condensate drain . . . . . . . . . . . . . . . . . . . . . . 6
1.4.17 Pluming from flue terminal . . . . . . . . . . . . . .
1.4.18 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.19 Maintenance and servicing . . . . . . . . . . . . . .
1.4.20 Technical data . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.21 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Statutory requirements . . . . . . . . . . . . . . . . .
1.6 Regulations, rules and guidelines . . . . . . . . 7
1.7 CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Benchmark. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 Gas council numbers . . . . . . . . . . . . . . . . . . . 7
2 Boiler specifications. . . . . . . . . . . . . . . . . . . .
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Page
3.17.4 Water make up . . . . . . . . . . . . . . . . . . . . . . . . 16
3.17.5 Filling a sealed water system . . . . . . . . . . . .
4
4 Boiler installation sequence . . . . . . . . . . . . . 17
4.1 Boiler location. . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Sheet metal parts. . . . . . . . . . . . . . . . . . . . . .
4.1.2 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Timber frame buildings . . . . . . . . . . . . . . . . . 17
5
4.1.4 Contents included with delivery. . . . . . . . . .
5
4.2 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Other flue options . . . . . . . . . . . . . . . . . . . . . 18
4.3 Fitting the boiler hanging bracket . . . . . . . .
4.3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Removing the front casing . . . . . . . . . . . . . . 19
4.3.3 Gas connection . . . . . . . . . . . . . . . . . . . . . . . .
5
4.3.4 Water connections . . . . . . . . . . . . . . . . . . . . . 20
4.3.5 Condensate trap and syphonic drain . . . . .
5
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
4.3.6 Installing the flue system . . . . . . . . . . . . . . . 20
4.4 Electrical connections . . . . . . . . . . . . . . . . . .
5
4.4.1 Connections to main supply . . . . . . . . . . . . . 22
4.4.2 Wiring system . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.3 Electrical board layout. . . . . . . . . . . . . . . . . .
4.4.4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6
4.4.5 External electrical controls. . . . . . . . . . . . . .
4.4.6 Connection details for external time switches
6
and boiler terminal strip . . . . . . . . . . . . . . . . 25
6
4.4.7 Vaillant optional plug in timer accessories.
6
4.4.8 Connection details using the
6
VR 65 control centre . . . . . . . . . . . . . . . . . . .
4.4.9 Thermostatic radiator valves . . . . . . . . . . . . 25
7
5 Commissioning (Part I) . . . . . . . . . . . . . . . . . 26
5.1 Preliminaries - all systems . . . . . . . . . . . . . . 26
7
5.1.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2 Initial Lighting . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3 Ignition problems . . . . . . . . . . . . . . . . . . . . . . 27
8
5.1.4 Flue problems . . . . . . . . . . . . . . . . . . . . . . . . . 27
8
5.1.5 Testing - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9
6 Natural Gas to LPG conversion . . . . . . . . . . 28
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3 General requirements . . . . . . . . . . . . . . . . . . 10
3.1 Preliminary remarks for
room sealed appliances . . . . . . . . . . . . . . . . .
3.2 Related documents. . . . . . . . . . . . . . . . . . . . .
3.3 Installation site . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1 Flue termination . . . . . . . . . . . . . . . . . . . . . . .
3.5.2 Internal flue installation . . . . . . . . . . . . . . . . 12
3.6 Air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Cupboard or compartment ventilation . . . . 12
3.8 Domestic hot water cylinder. . . . . . . . . . . . .
3.9 Condensate drain . . . . . . . . . . . . . . . . . . . . . . 13
3.10 Heating system controls . . . . . . . . . . . . . . . . 13
3.11 Draining tap. . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 Safety valve. . . . . . . . . . . . . . . . . . . . . . . . . . .
3.13 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.14 Pump specification. . . . . . . . . . . . . . . . . . . . .
3.15 Cleanser and inhibitor . . . . . . . . . . . . . . . . . . 13
3.16 Open vented water system . . . . . . . . . . . . . .
3.17 Sealed water Systems . . . . . . . . . . . . . . . . . . 16
3.17.1 Safety valve. . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17.2 Expansion vessel. . . . . . . . . . . . . . . . . . . . . . .
3.17.3 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
11
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13
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16
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16
7 Functional checks commissioning (part II) .
7.1 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Domestic hot water . . . . . . . . . . . . . . . . . . . .
(If optional accessories are fitted). . . . . . . .
7.1.2 Pump exercise programme . . . . . . . . . . . . . .
7.1.3 Final flush of the heating system (hot) . . . .
7.2 Hand over to the user . . . . . . . . . . . . . . . . . . 30
7.3 Vaillant warranty. . . . . . . . . . . . . . . . . . . . . . .
8 Inspection and maintenance. . . . . . . . . . . . .
8.1 Initial inspection . . . . . . . . . . . . . . . . . . . . . . .
8.1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . .
8.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.3 Functional check of boiler operation . . . . . .
8.1.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.5 Spark electrode. . . . . . . . . . . . . . . . . . . . . . . .
8.1.6 Removing the burner . . . . . . . . . . . . . . . . . . .
8.1.7 Combustion chamber and heat exchanger..
8.1.8 Condensate drain . . . . . . . . . . . . . . . . . . . . . . 35
1.9 Inner casing panel seal check. . . . . . . . . . . .
8.
8.1.10 Checking the expansion vessel (if fitted) . .
8.1.11 Re commissioning the boiler. . . . . . . . . . . . .
8.1.12 Test operation . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Servicing ecoTEC plus2
29
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36
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Contents Page
9 Combustion analysis . . . . . . . . . . . . . . . . . . . 37
9.1 Check CO
content. . . . . . . . . . . . . . . . . . . . . 37
2
Contents
10 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . .
10.1 Logical fault finding procedure. . . . . . . . . . .
10.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1.2 Diagnostic codes. . . . . . . . . . . . . . . . . . . . . . .
10.1.3 Fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Resetting parameter to factory settings . . 44
11 Parts replacement . . . . . . . . . . . . . . . . . . . . . 44
111.1 Safety instructions. . . . . . . . . . . . . . . . . . . . .
11.2 Replacing the burner . . . . . . . . . . . . . . . . . . .
11.3 Replacing the gas valve. . . . . . . . . . . . . . . . .
11.4 Replacing the fan . . . . . . . . . . . . . . . . . . . . . . 44
11.5 Replacing the heat exchanger . . . . . . . . . . . 45
11.6 Replacing the condense trap and siphonic
drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.7 Replacing electronics and display . . . . . . . . 46
12 Recycling and disposal. . . . . . . . . . . . . . . . . .
12.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . . 46
14 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
EC declaration of conformity . . . . . . . . . . . . 47
Benchmark gas boiler commissioning
checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service interval record . . . . . . . . . . . . . . . . . 49
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Installation and Servicing ecoTEC plus 3
Installation and Servicing ecoTEC plus4
1 Introduction
1 Introduction
1.1 Notes on the documentation.
To ensure clarity of information in instructions a
new European standard of advice and symbols is
being introduced. To ensure compliance with this
new standard the following details are included.
The following information is intended to help you
throughout the boilers entire instruction pack.
We assume no liability for any damage caused by
non-observance of these instructions.
1.1.1 Other instructions supplied with this
appliance.
For the owner:
Instructions for use no. 0020020829
Short operating instructions no. 838404
Warranty card with return envelope no. 802922
For the installer/service engineer:
Flue installation instructions no. 834449
The instructions for any accessories and controllers
used also apply.
The Benchmark gas boiler commissioning checklist
(in the installation manual) should be completed by the
installer and/or the commissioning engineer.
If, after reading these instructions, you have any
questions on the operation of the boiler, please contact
either your installer or Vaillant Technical Department.
1.1.2 Retention of documents
Please retain this literature and all related documents
so that they are available whenever they are required.
If you move please pass on the documents to the
buyer.
1.1.3 Safety instructions and symbols
Please observe the safety instructions in this literature
for the operation of the appliance.
Danger!
Immediate risk of serious injury or death!
Danger!
Risk of death from electric shock!
Danger!
Risk of burns or scalding!
Caution!
Potentially dangerous situations for the
product and environment.
Note!
Useful information and instructions.
•Symbol for a necessary task
Note!
This boiler must be installed and serviced by a
competent person in accordance with the Gas
Safety (Installation and Use) Regulations 1998.
In the UK ‘CORGI’ registered installers
undertake the work in compliance with safe
and satisfactory standard.
1.2 ecoTEC plus boilers
The ecoTEC plus boilers are designed to provide
central heating from a fully pumped open-vented
or sealed water system. The central heating water
temperature can be adjusted on the boiler.
The domestic hot water can only be adjusted on the
boiler if it is installed with a Vaillant uniSTOR unvented
cylinder and relevant controls. Once the controls
are set the boiler operates automatically. A frost
protection programme is also included.
Please read these instructions and follow them
carefully for the correct and economical use of your
boiler.
These instructions are applicable to the following
ecoTEC plus boilers, available in Natural Gas.
All ecoTEC plus boilers can be converted to LPG.
APPLIANCE MAXIMUM OUTPUT
ecoTEC plus 415 15kW
ec
oTEC plus 418 18kW
ecoTEC plus 428 28kW
ecoTEC plus 438 38kW
1.3 General notes
The boiler has been designed for use with a openvented central heating system, and comes fully
tested and assembled. The boiler is easily mounted
on any internal wall and can be installed with either a
horizontal or vertical RSF (room sealed fan assisted)
flue. The boiler uses a standard flue system (100 mm
or 125 mm outside diameter). Flue extensions and
additional bends and elbows are available for the
flue system to increase the flexibility. If desired, an
inhibitor may be used in the system. Guidance on the
use of inhibitors is contained in these instructions.
The boiler has a built in diagnostic system which
indicates the operational status of the boiler. This
feature provides key information to aid commissioning
and fault finding. The data badge is fitted to the
combustion chamber cover of the boiler. See text of
General Requirements for installation requirements or
notes.
The Valliant ecoTEC plus boilers have 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 damaged in the
event of improper use. The appliances are designed for
central heating systems. Any other use or extended
use is considered to be use other than intended. The
manufacturer/supplier is not liable for any resulting
damage. Intended use includes the observance of the
operating and installation manual and the adherence
to the inspection and maintenance conditions.
Caution!
Any incorrect use is forbidden.
The appliances must be installed by a competent
person, who is responsible for adhering to the existing
regulations, rules and guidelines.
Introduction 1
1.4 General information
Thank you for choosing a Vaillant boiler. The
information given in this booklet will enable you to
obtain the best performance from your boiler.
The Benchmark logbook should be completed by the
installer and/or commissioning engineer and handed to
the user.
1.4.1 Gas category
The boiler is supplied factory set for use on Natural
Gas (G20). The ecoTEC plus boilers can be field
adjusted for use on LPG (propane G31), see section
7 for instructions or contact Vaillant Service, 0870
6060 777.
1.4.2 Gas safety (installation and use) regulations
In your own interests and that of safety, it is the Law
that ALL gas appliances are installed by a competent
person in accordance with the current issue of the
above regulations.
1.4.3 Gas testing and certification
The boiler is tested and certificated for safety and
performance. It is, therefore, important that no
alteration is made to the boiler.
1.4 4 Control of substances hazardous to health
Under Section 6 of The Health and Safety at Work Act
1974, we are required to provide information on
substances hazardous to health.
The adhesives and sealants used in this appliance are
cured and give no known hazard in this state.
1.4.5 Insulation pads
These can cause irritation to skin, eyes and the
respiratory tract.
If you have a history of skin complaint you may be
susceptible to irritation. High dust levels are usual only
if the material is broken.
Normal handling should not cause discomfort, but
follow normal good hygiene and wash your hands
before eating, drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe
irritation to the skin seek medical attention.
1.4.6 Spare parts
Only original Vaillant spare parts may be used.
1.4.7 Manual handling guidance
During the appliance installation and the replacement
of the heat exchanger it will be necessary to employ
aution and assistance whilst lifting as the appliance
c
or component exceeds the recommended weight for a
one man lift.
In certain situations it may be required to use a
mechanic
Take care to avoid trip hazards, slippery or wet
surfaces.
al handling aid.
Danger
Smell of gas. Risk of poisoning and explosion
due to a malfunction
1.4.8 Gas leak or fault
If you smell gas or suspect a gas leak:
• Do not switch lights on or off.
• Do not use any other electrical switches.
• Do not use a telephone in the hazardous area.
• Do not use naked flames, such as matches or
cigarette lighters.
• Do not smoke.
• Turn off the gas supply at the gas meter.
• Open the windows and doors.
• Warn other residents.
• Get out of the house.
• Consult your gas supplier, service agent or other
competent person.
1.4.9 Clearances
If fixtures are positioned close to the boiler, space
must be left as shown in fig 4.1. Enough space must
also be left in front of the boiler to allow for servicing.
1.4.10 Sheet metal parts
This boiler contains metal parts (components) and care
should be taken when handling and cleaning, with
articular regard to edges.
p
1.4.11 Sealed components
Under no circumstances must the User interfere with
any sealed component as this could result in a
tentially dangerous situation arising.
po
Danger
This boiler must be earthed.
1.4.12 Electrical supply failure
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when
the electrical supply is restored.
Reset any external controls to resume normal
operation of the central heating.
If the boiler does not resume normal operation.
(The burner fails to ignite after five attempts).
The overheat thermostat may have operated.
Automatic ignition can only take place after you
manually reset the fault, refer to section 5.1.3. to reset.
Installation and Servicing ecoTEC plus 5
Installation and Servicing ecoTEC plus6
1 Introduction
1.4.13 Protection against freezing
The boiler has a built in frost protection programme as
long as the electricity and gas are left switched on.
This device operates the burner and system pump
when the temperature inside the boiler falls to 3°C.
Any other exposed areas of the system should be
otected by a separate frost thermostat.
pr
If the mains electricity and gas are to be turned off for
any long periods during severe weather, it is
ecommended that the whole system, including the
r
, should be drained to avoid the risk of freezing.
boiler
Make sure that, if fitted, the immersion heater in the
cylinder is switched off.
If you have a sealed water system contact your
tallation/ servicing company as draining, refilling
ins
and pressurising MUST be carried out by a competent
son.
per
As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
onditions this may be due to the forming of ice in the
c
condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe. The
boiler should then restart. Contact your installation/
ervicing company if the fault persists.
s
1.4.14 Boilers installed in a compartment or
cupboard
If the boiler is fitted into a compartment or cupboard it
does not require ventilation openings.
Do not use the compartment or cupboard for storage.
1.4.15 Boiler casing
Do not remove or adjust the casing in any way, as
orrect-fitting may result in incorrect operation or
inc
ailure to operate at all.
f
1.4.19 Maintenance and servicing
For the continued efficient and safe operation of the
it is recommended that it is checked and
boiler
serviced at regular intervals. The frequency of
servicing will depend upon the installation conditions
and usage, but in general, once a year should be
enough.
this appliance is installed in a rented property there
If
is a duty of care imposed on the owner of the property
by the current issue of the Gas Safety (Installation and
Use) Regulations, Section 35.
Servicing/maintenance should be carried out by a
ompetent person in accordance with the rules in force
c
in the countries of destination.
To obtain service, please call your installer or Vaillant
Service Solutions (0870 6060 777).
Please be advised that the installation engineer on
completion of commissioning and servicing should
complete the ‘Benchmark’ logbook.
All CORGI Registered Installers carry a CORGI ID
card, and have a registration number. Both should be
recorded in your boiler Logbook. You can check your
installer is CORGI registered by calling CORGI direct
on: - 01256 372300.
1.4.20 Technical data
Al dimensions are given in millimetres (except as
noted). The data label is positioned on the combustion
chamber cover. The Seasonal Efficiency Domestic
Boilers UK (SEDBUK) is:
All ecoTEC plus boilers : Class ‘A’.
The value is used in the UK Government’s Standard
Assessment Procedure (SAP) for energy rating of
dwellings. The test data from which it has been
calculated has been certified by B.S.I.
1.4.16 Condensate drain
The condensate drain must not be modified or blocked.
1.4 .17 Pluming from flue terminal
All condensing boilers produce a plume of water
vapour from the flue terminal. This is due to the
high efficiency and hence low flue gas temperature.
This may increase in wet, damp weather but this is
completely normal and indicates that the boiler is
operating correctly.
1.4.18 Cleaning
This appliance contains metal parts and care should
be taken when handling and cleaning with particular
regard to edges.
The boiler casing can be cleaned using a mild liquid
detergent with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as
you may damage the paint work.
1.4.21 Guarantee
Vaillant provide a full two year parts and labour
warranty for your appliance.
The appliance must be installed by a suitably
competent person in accordance with the gas
safety (installation and Use) Regulations 1998, and
the manufacture's instructions. In the UK ‘CORGI’
registered installers undertake the work in compliance
with safe and satisfactory standards.
Terms and conditions apply to the warranty, details of
which can be found on the warranty registration card
included with this appliance.
Failure to install and commission this appliance in
compliance with the manufacture's instructions may
invalidate the warranty (this does not affect your
statutory rights).
Introduction 1
1.5 Statutory requirements
The appliance is suitable only for installation in GB and
IE and should be installed in accordance with the rules
in force. In GB the installation of the boiler must be
carried out by a competent person as described in the
following regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The
Building Regulations, The Building Regulations
(Scotland), The Building Regulations (Northern
Ireland).
The Water Fittings Regulations or Water bye laws in
Scotland. The Health and Safety at Work Act, Control
of Substances Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference
should be made to the relevant British Standard Code
of Practice. In IE, the installation must be carried out
by a competent person and installed in accordance
with the current edition of I.S.813 “Domestic Gas
Installations”, the current Building Regulations and
reference should be made to the current ETCI rules for
Electrical Installation.
In GB the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part
1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2,
BS7593, BS7671.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
Note: For further information, see the current issue of
the
uilding Regulations, approved document L1 ( in the
B
UK) and the current issue of the following:
1) Central heating system specification (CheSS)
2) Controls for domestic central heating system and
hot water. BRECSU.
Certification
This boiler certificated to the current issue of EN 483
for performance and safety.
It is important that no alteration is made to the boiler,
without permission, in writing, from Vaillant.
Any alteration that is not approved by Vaillant, could
invalidate the warranty and could also infringe the
current issue of the Statutory Requirements.
1.6 Regulations, rules and guidelines.
This boiler meets the requirements of Statutory
Instrument, No. 3083 The Boiler (Efficiency)
Regulations, and therefore is deemed to meet the
requirements of Directive 92/42/EEC on the efficiency
requirements for new hot water boilers fired with liquid
or gaseous fuels.
Type test for purposes of Regulation 5 certified by:
Notified body 0087.
Product/production certified by: Notified body 0086.
1.7
The CE mark on this appliance shows compliance with:
- Directive 90/396/EEC on the approximation of the
laws of the Member States relating to appliances
burning gaseous fuels.
- Directive 73/23/EEC on the harmonisation of the
Laws of the Member States relating to electrical
equipment designed for use within certain voltage
limits.
- Directive 89/336/EEC on the approximation of the
Laws of the Member States relating to
electromagnetic compatibility.
1.8 Benchmark
Vaillant Ltd. support the Benchmark initiative.
At the rear of the installation manual, you will
find a Benchmark gas boiler commissioning
checklist. It is very important that this is
completed correctly at the time of installation,
commissioning and hand over to the user.
1.9 Gas council numbers
Appliance Gas council numbers
ecoTEC plus 415 41-044-53
ecoTEC plus 418 41-044-54
ecoTEC plus 428 41-044-55
ecoTEC plus 438 41-044-57
CE mark
Installation and Servicing ecoTEC plus 7
Installation and Servicing ecoTEC plus8
2 Boiler specifications
2 Boiler specifications
2.1 Technical data
Description Unit ecoTEC plus 415 ecoTEC plus 418 ecoTEC plus 428 ecoTEC plus 438
Maximum CH heat input (net) kW 15.3 18.9 28.6 38.4
CH heat output (80/60 °C) kW 5
CH heat output (50/30 °C) kW 5.3 - 16.2 5.3 - 20.0 5.7 - 30.6 6.8 - 41.0
SEDBUK Band A A A A
S
AP Seasonal Efficiency % 90.5 90.4 90.6 90.8
NOx Class 5 5 5 5
"lP
rating" IPX4D IPX4D IPX4D IPX4D
Inlet gas working pressure
required (natural gas)
Gas supply (G20) Gross CV (s.t.) MJ/
Maximum gas rate M3/h 1.61 2.0 3.02 4.06
Minimum gas rate M
Burner % CO2 (Case on) % 9.3 + 0.2 - 0.5 9.3 + 0.2 - 0.5 9.3 + 0.2 - 0.5 9.0 + 0.2 - 0.5
Gas connection (compression) mm 15 15 15 15
W
ater connections (compression) mm 22 22 22 22
Condensate drain (internal
diameter)
Fuse ratings fan supply PCB A 3.15 AT 3.15 AT 3.15 AT 3.15 AT
Main PCB A 12
Minimum flow rate of water
through the boiler
Weight kg 3.1 3.1 3.3 3.3
Electrical supply V~/
External fuse A 3 3 3 3
P
ower input W 60 60 60 60
C
ase height mm 600 600 600 600
Case width mm 3
Case depth mm 334 334 334 334
mbar 20 20 20 20
3
m
3
/h 0.53 0.53 0.56 0.71
mm 19
L/min. 10.8 12.9 20.3 27.2
HZ
.0 - 15.0 5.0 - 18.6 5.3 - 28.2 6.3 - 38.0
37.8 37.8 37.8 37.8
min. 19 min. 19 min. 19 min.
5 mAT 125 mAT 125 mAT 125 mAT
2
30/~50 230/~50 230/~50 230/~50
75 375 375 375
48
26
33
176
160
340
113
375
133
3
0
15mm GAS
CONNECTION
5
3
161
610
1
2
3
7
4
5
6
OUTSIDE
WALL
F
ACE
BOILER
C
L
FLUE
C
L
FLUE
C
L
FLUE
C
L
FLUE
C
L
BOILER
C
L
56
2.1.2 Dimensions
6
2
1
3
4
5
7
Boiler specifications 2
Fig. 2.1 Dimensions in mm
Legend:
1 Heating return pipe Ø 22
2 Heating flow pipe Ø 22
3 Gas connection Ø 15
4 Hanging bracket
5 Flue hole - flue system 303 933
6 Flue pipe connection
7 Condensate drain outlet connection (Ø 21)
2.1.3 Installation
Fig. 2.2 Function elements of boiler
Legend:
1 Flue pipe connection
2 Fan
3 Gas valve
4 Electronics box
5 Burner module
6 Ignition electrode
7 Condense trap
Installation and Servicing ecoTEC plus 9
Installation and Servicing ecoTEC plus10
3 General requirements
3 General requirements
3.1 Preliminary remarks for room sealed
appliances
This appliance should only be installed with a Vaillant
flue system.
Install the flue system as detailed in the separate flue
installation instructions supplied with this boiler.
3.2 Related documents
The installation of the boiler must be in accordance
with the relevant requirements of 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 pipe work 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”.
IGE/UP1: Soundness testing and purging of industrial
and commercial gas installation. IGE/UP2: Gas
installation pipe work, 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!
The appliance must be installed and serviced
by a competent person as stated in the Gas
Safety (Installation and Use) Regulations 1998.
In IE, the installation must be in accordance
with the current edition of I.S.813
‘Domestic Gas Installations’, the current
Building Regulations and reference should be
made to the current ETCI rules for electrical
installation.
Caution!
When tightening or slackening screwed
connections always use suitable open-ended
spanners (not pipe wrench, or extensions, etc.).
Incorrect use and/or unsuitable tools can lead
to damage being caused (e.g. gas or water
leakage)!
3.3 Installation site
The location chosen for the boiler must permit
the provision of a satisfactory flue termination.
The location must also provide adequate space
for servicing and air circulation around the boiler.
The boiler may be installed in any room, although
particular attention is drawn to the requirements of
BS 7671 (IEE Regulations), the electrical provisions of
the Building Standards (Scotland) Regulations, and in
IE the current edition of IS 813 and the current ETCI
rules, in respect of the installation of a boiler in a room
containing a bath or shower.
Note!
If a room sealed boiler is installed in a room
with a bath or shower, electrical switches or
boiler controls using the mains power supply
must be placed at locations that cannot be
reached by the person in the bath or shower.
If the boiler is installed in an unusual location, special
procedures may be necessary and BS 5546 and BS
6798 give detailed guidance on this aspect. The boiler
must be mounted on a flat, vertical wall, which must be
sufficiently robust to take the weight of the boiler. The
boiler may be installed on a combustible wall, subject
to the requirements of the Local Authorities and
Building Regulations.
A compartment used to enclose the boiler must be
designed and constructed specifically for this purpose.
(An existing cupboard or compartment may be used
provided that it is modified for the purpose). Details
of essential features of cupboard/compartment design
including airing cupboard installations are given in BS
6798. If the boiler is to be fitted in a timber framed
building, it should be fitted in accordance with Institute
of Gas Engineers Publication IGE/UP/7/1998 “Guide
for Gas Installation in Timber Framed Housing”. Please
note the safety instructions below before deciding
where to install the boiler:
Caution
Do not !install the appliance in rooms prone
to frost. In rooms with aggressive steam
or dust, the appliance must be operated
independent of the ambient air.
When choosing the place of installation and while
operating the appliance, make sure that the air
supply is free of chemical substances containing
fluorine, chlorine, sulphur etc. Sprays, solvents and
cleaning agents, paints, adhesives etc. contain the
kind of substances that can lead to corrosion even in
the exhaust system when the appliance is operated
depending on the ambient air in the worst case
scenario. Particularly in hair-cutting salons, lacquering
and finishing, cleaning facilities, the appliance must be
operated independent of the ambient air! Otherwise,
a separate installation room is required to guarantee
that the air supply is free of the above mentioned
substances.
65
13
30
405 - 610
48
3.4 Gas supply
1435
10
550
880
40
70
1103
70
15
1530
880
650
70
754
87
65
30
74
48
The gas supplier should ensure the availability of an
adequate supply of gas. A gas meter may only be
connected to the service pipe by the supplier of gas or
their contractor. An existing meter should be checked
to ensure that it is capable of passing the rate of gas
supply required. Installation pipes should be fitted in
accordance with BS 6891. In IE the current edition of
IS 813. Pipe work from the meter to the boiler must be
of an adequate size. Do not use pipes of a smaller size
than the boiler gas connection (15 mm). The complete
installation must be checked for leaks and purged as
described in BS 6891.
Danger!
Vaillant appliances are certified only for
use with genuine Vaillant flue pipes.
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.
General requirements 3
3.5 Flue options
There are various flue systems to choose from, as
follows:
60/100 standard horizontal air/flue duct, see fig 3.1.
60/100 telescopic horizontal air/flue duct, see fig 3.2.
60/100 Vertical air/flue duct and terminal, see fig 3.3.
80/125 horizontal air/flue duct, see fig 3.4.
80/125 Vertical air/flue duct and terminal, see fig 3.5.
Flue extensions are available to extend the length,
both 90° bends and 45° elbows are also available.
efer to flue system installation instructions for full
R
details.
When extension pipes are used the flue system must
be designed to have a continuous fall to the boiler
of at least 3° to allow condensate to run out via the
drain.
Fig. 3.3 Art. No. 303900
Fig. 3.4 Art. No. 303209
Fig. 3.1 Art. No. 303933
Fig. 3.2 Art. No. 303936
Installation and Servicing ecoTEC plus 11
Fig. 3.5 Vertical Flue System Art. No. 303200
Installation and Servicing ecoTEC plus12
3 General requirements
3.5.1 Flue termination
The following details refer to both flue systems.
a. The terminal must be located where the combustible
substances can escape freely at all times.
b. A plume of water vapour will sometimes be visible
from the flue terminal. Positions where this could be
a nuisance should be avoided.
c. If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people
have access then a suitable terminal guard must be
provided and fitted (made by Tower Flue Components,
Tonbridge, TN9 1TB, Model K3, plastic coated).
Fig. 3.6 Flue termination
Note!
In addition, the terminal should not be nearer
than 150 mm to an opening in the building
fabric formed for the purpose of
accommodating a built-in element such as a
window.
BS 5440–1: It is recommended that the fanned flue
terminal should be positioned as follows:
a) at least 2 m from an opening in the building directly
opposite, and
b) so that the products of combustion are not directed
to discharge across a boundary.
1) Dimensions B, C and D: These clearances may be
reduced to 25 mm without affecting the
performance of the boiler. In order to ensure
that the condensate plume does not affect adjacent
surfaces the terminal should be extended as shown
in Fig. 3.7.
2) Dimension F:
This clearance may be reduced to 25 mm without
affecting the performance of the boiler. However,
in order to ensure that the condensate plume does
not affect adjacent surfaces a clearance of 300 mm
is preferred. For IE, recommendations are given in
the current edition of IS 813.
Note!
Vertical flues must not terminate within
600mm of an openable window, air vent or
any other ventilation opening.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
Terminal position mm
A Directly below an opening, above an opening or
horizontal to an opening, air brick, opening window,
etc.
B Below gutters, soil pipes or drain pipes 75
C B
elow eaves 200
D Below balconies 200
E F
rom vertical drain pipes and soil pipes 25
F F
rom internal or external corners 300
G Above ground, roof or balcony 300
H F
rom a surface facing a terminal 600
I From a terminal facing a terminal 1200
J F
rom an opening in the car port (e.g. door, window)
into the dwelling
K Vertically from a terminal on the same wall 1500
L Horiz
M Distance from adjacent wall for vertical Flue 500
ontally from a terminal on the same wall 300
300
1200
Fig. 3.7 Flue termination under balcony/eves
3.5.2 Internal flue installation
The flue can be installed from inside the building when
access to the outside wall face is not practicable.
3.6 Air supply
Detailed recommendations for air supply are given in
BS 5440: Part 2.
It is not necessary to have an air vent in the room or
internal space in which the boiler is installed.
3.7 Cupboard or compartment ventilation
The boilers are very high efficiency appliances.
As a consequence the heat loss from the appliance
casing during operation is very low. For cupboard or
compartment installations it is therefore not necessary
to provide any high or low level permanent air vents
for cooling purposes.
Table 3.1 Flue terminal position for a fan assisted
concentric flue
General requirements 3
3.8 Domestic hot water cylinder
Caution!
Single feed indirect cylinders are not suitable.
The domestic hot water cylinder must be of
the double feed fully indirect coil type. It must
be suitable for working at a gauge pressure of
0.35 bar above the safety valve setting.
.8.1 Unvented hot water cylinder
3
The ecoTEC plus can be connected to an unvented
hot water cylinder. Vaillant offer a range of cylinders
called uniSTOR with capacities from 125 litres to 310
litres. All unvented domestic hot water cylinders must
be installed by a competent person to the current
building regulations and water regulations at the time
of installation.
For building regulations refer to G3 and for water
regulations guidance G17 to G24 and recommendation
R17 to R24.
For Ireland: The current issue of BS5546 and BS6700.
If fitting to an existing system the local authority
should be informed.
3.9 Condensate drain
A plastic drain pipe must be fitted to allow discharge
of condensate to a drain.
Condensate should, if possible, be discharged into the
internal household draining system. If this is not
actical, discharge can be made externally into the
pr
household drainage system or a purpose designed soak
away, see Section 4.3.5 for more details.
3.10 Heating system controls
It is recommended that a programmer and room
thermostat control the boiler. Vaillant have a range of
optional easy fit controls available.
Thermostatic radiator valves must be installed,
however they must not be fitted in a room where the
room thermostat is located.
Note!
All systems must have at least one radiator
not fitted with a thermostatic valve.
Note!
For further information, see the current issue
of the Building Regulations, approved
document L1, and the following current
issues of:
1) Central heating system specification (CheSS)
and
2) Controls for domestic central heating
system and hot water. BRECSU.
3.11 Draining tap
A draining tap must be provided at all the lowest
points of the system, which will allow the entire system
and hot water system to be drained.
Draining taps shall be to the current issue of BS 2879.
3.12 Safety valve
A safety valve need not be fitted to an open-vented
system.
3.13 Bypass
A system bypass will be required fitted at least 1.5
metres away from the boiler, refer to the current issue
of central heating system specifications (CHeSS).
3.14 Pump specification
The pump should be fitted on the flow pipe from the
and have isolating valves each side.
boiler
A variable duty pump should be set to give a
emperature difference of no greater than 20°C
t
.15 Cleanser and inhibitor
3
In the case of an existing installation, it is ESSENTIAL
that prior to installing the new boiler the system
is thoroughly flushed. For optimum performance
after installation of a new system, the boiler and its
associated central heating system should also be
flushed. Flushing should be carried out in accordance
with BS7593: 1992 using a cleanser such as Sentinel
X300 or X400, or Fernox Superfloc.
For long-term corrosion protection, after flushing, an
inhibitor suitable for stainless steel heat exchangers
should be used, refer to the current issue of BS 5449
and BS 7593 on the use of inhibitors in central heating
systems. Examples are Sentinel X100 and Fernox.
Caution!
It is ESSENTIAL that the cleanser is fully
removed from the system after flushing and
before adding inhibitor. Take care to ensure
that all low points in the system are fully
drained.
For all systems follow the manufacture’s instructions,
but where new radiators are fitted do not leave the
cleanser in the system for longer than 24 hours.
For optimum performance the boiler and its
associated central heating system should be flushed in
accordance with BS7593: 1992 using a cleanser.
For optimum performance the boiler and its
associated central heating system should be flushed in
accordance with BS7593: 1992 using a cleanser.
For advice on the application of system cleansers and
inhibitors contact either;
Fernox, Alpha-Fry Technologies
Tandem House
Marlow Way
eddington Farm Road
B
Croydon CR0 4XS
Tel: 0870 601 5000
Fernox technical help line
01799 550811
or:
Sentinel, GE Betz
idnes
W
Cheshire, WA8 8UD
Tel: 0151 420 9595.
Installation and Servicing ecoTEC plus 13
Installation and Servicing ecoTEC plus14
3 General requirements
ecoTEC plus 415 pressure loss graph ecoTEC plus 428 pressure loss graph
ecoTEC plus 418 pressure loss graph ecoTEC plus 438 pressure loss graph
Fig. 3.8 Pressure loss
3.16 Open vented heating system
The boiler must be supplied from an unrestricted
water supply taken from a feed and expansion cistern
situated at a maximum height of 27 metres (90ft)
above the boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump,
cold feed and open vent are as shown in fig 3.9.
General requirements 3
Fig. 3.9 Open vented system
Installation and Servicing ecoTEC plus 15
Installation and Servicing ecoTEC plus16
3 General requirements
3.17 Sealed water systems
The installation must comply with the appropriate
equirements of the current issue of BS4814, BS5449,
r
BS6759, BS6798 and BS7074 Part 1 and 2. For IE your
attention is drawn to the current edition of IS 813.
See fig 3.10 for a suggested layout.
3.17.1 Safety valve
A safety valve must be fitted to a sealed system.
It shall be preset, non-adjustable with a lift pressure
of 3-bar, incorporating seating of a resilient material, a
test device and a connection for drain.
The safety valve discharge pipe must be routed to
side the building, must not discharge above an
out
trance or window or any type of public access area,
en
be clear of any electrical fittings and positioned so
that any discharge can be seen.
3.17.2 Expansion vessel
A diaphragm type expansion vessel, conforming to
the current issue of BS4814 (see also BS7074 Part
1 and 2). For IE the current edition of IS 813, must
be connected at a point close to the inlet side of the
circulating pump, see the Typical installation, Fig. 3.10.
unless laid down differently by the manufacturer.
The expansion vessel volume depends on the total
water system volume and the initial system design
pressure. For any system an accurate calculation of
vessel size is given in the current issue of BS5449 and
BS7074 Part 1.
Example: For an initial design pressure of 0.7 bar, the
minimum total vessel volume required is 0.063 x Total
System Volume.
Note!
A higher initial design pressure requires a
larger volume expansion vessel.
The charge pressure must not be less than the
tatic head of the system, that is, the height of the
s
st point of the system above the expansion
highe
vessel.
3.17.3 Pressure gauge
A pressure gauge with a set pointer and covering
at least 0 to 4 bar (0 to 60 lb/in2) shall be fitted
permanently to the system in a position where it can
be seen when filling the system.
3.17.4 Water make up
Provision should be made for replacing water loss
from the system using a make up bottle mounted in
a position higher than the top point of the system,
connected through a non-return valve to the return
side of either the heating circuit or the hot water
cylinder.
Alternatively, provision for make up water should be
made using a proprietary filling loop.
3.17.5 Filling a sealed water system
Provision for filling the system at low level must be
made. This can be achieved by the use of a proprietary
filling loop.
Fig. 3.10 Typical installation
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