Vaillant ecoTEC plus 612, ecoTEC plus 618, ecoTEC plus 637, ecoTEC plus 615, ecoTEC plus 824 Instructions For Installation And Servicing
...
For the installer
Instructions for installation and servicing
ecoTEC
Wall hung room sealed fan assisted condensing boiler
ecoTEC plus 612
ecoTEC plus 615
ecoTEC plus 618
ecoTEC plus 624
ecoTEC plus 630
ecoTEC plus 637
ecoTEC plus 824
ecoTEC plus 831
ecoTEC plus 837
ecoTEC pro 28
ecoTEC pro 24
GB, IE
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notes on the documentation . . . . . . . . . . . . . . . . 4
1.1.1 Applicable documents . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Retention of documents . . . . . . . . . . . . . . . . . . . . 4
1.1.3 Safety instructions and symbols . . . . . . . . . . . . . 4
1.2 Validity of the manual . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Gas council numbers . . . . . . . . . . . . . . . . . . . . . . . 5
2 Boiler specifications . . . . . . . . . . . . . . . . . . . . 6
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 General requirements . . . . . . . . . . . . . . . . . . . 10
3.1 Preliminary remarks for room sealed
appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Contents included with delivery . . . . . . . . . . . . . 10
3.4 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Flue pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6.1 Standard 100 mm flue system . . . . . . . . . . . . . . . 13
3.6.2 Optional 125 mm flue system . . . . . . . . . . . . . . . . 13
3.7 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.8 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 Guide to system requirements . . . . . . . . . . . . . . 15
3.10.1 Water circulation system . . . . . . . . . . . . . . . . . . . 15
3.10.2 Filling and preparing heating system . . . . . . . . . 15
3.10.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . 16
3.10.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.10.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11 Pump specifications . . . . . . . . . . . . . . . . . . . . . . . 17
3.11.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.11.2 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.11.3 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12 Condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Boiler installation sequence . . . . . . . . . . . . . . 18
4.1 Transporting the appliance . . . . . . . . . . . . . . . . . 18
4.2
Required minimum distances/assembly
clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1 Select position for boiler . . . . . . . . . . . . . . . . . . . 19
4.2.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.3 Using boiler template . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Fitting the boiler hanging bracket . . . . . . . . . . . 20
4.5 Installing the flue system . . . . . . . . . . . . . . . . . . . 21
4.6 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.7 Removing the front case . . . . . . . . . . . . . . . . . . . 21
4.8 General instructions for heating system . . . . . . 21
4.9 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.10 Cold water mains inlet and hot water outlet
(ecoTEC combination boilers only) . . . . . . . . . . . 22
4.11 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . . 23
4.12 Heating connection . . . . . . . . . . . . . . . . . . . . . . . 24
4.12.1 Heating flow and return connection . . . . . . . . . 24
4.12.2 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 25
4.13 Connecting the flue system to the boiler . . . . . 25
4.14 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 25
4.14.1 General requirements . . . . . . . . . . . . . . . . . . . . . . 25
4.14.2 Connection to the main supply . . . . . . . . . . . . . . 26
4.14.3 Electric board layout . . . . . . . . . . . . . . . . . . . . . . . 27
4.15 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.15.1 Vaillant controls and accessories . . . . . . . . . . . . 30
4.15.2 External electrical controls . . . . . . . . . . . . . . . . . 30
4.15.3 Connection details for external time
switches and boiler terminal strip . . . . . . . . . . . 30
4.15.4 Vaillant optional plug in timer accessories . . . . 30
4.15.5 Connection details using the VR 65 Control
Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.16 Thermostatic radiator valves . . . . . . . . . . . . . . . 31
4.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.19 Anticycling ‘economiser’ control . . . . . . . . . . . . 31
4.20 Automatic pump spin control (APS). . . . . . . . . . 31
5 Commissioning Part I . . . . . . . . . . . . . . . . . . . 32
5.1 Preliminary electrical checks . . . . . . . . . . . . . . . . 32
5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Cold water supply (ecoTEC combination
boilers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Filling and bleeding the heating system . . . . . . 32
5.4.1 Checking the filling pressure of the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4.2 ecoTEC plus combination boiler filling loop . . . 32
5.4.3 Filling the heating system in ecoTEC pro
combination boilers and ecoTEC plus system
boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.4.4 Filling the heating system for the first time . . . 33
5.5 Initial system flush (“cold”) . . . . . . . . . . . . . . . . . 33
5.6 Filling the condensate siphon . . . . . . . . . . . . . . . 34
5.7 Adjusting the pumping capacity . . . . . . . . . . . . . 34
5.8 Adjusting the by-pass . . . . . . . . . . . . . . . . . . . . . . 34
5.9 Checking the gas setting . . . . . . . . . . . . . . . . . . . 34
5.9.1 Checking for tightness of the flue gas
installation and flue gas recirculation . . . . . . . . 35
5.9.2
Checking the gas flow rate . . . . . . . . . . . . . . . . . 35
5.9.3 Checking the gas inlet working pressure . . . . . 36
5.10 Refitting the case . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.11 Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2
Instructions for installation and servicing ecoTEC 839592_12
6 Functional checks (commissioning part II). . 39
6.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.3 Water heating (combination boilers only) . . . . . 39
6.1.4 Final flush of the heating system (“hot”) . . . . . 39
6.2 Handing over to the user . . . . . . . . . . . . . . . . . . . 40
6.3 Factory guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 40
7 Inspection and maintenance . . . . . . . . . . . . . 41
7.1 Inspection and maintenance intervals . . . . . . . . 41
7.1.1 General inspection and maintenance
instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.3 Checking the CO
7.1.4 Adjusting the CO
concentration . . . . . . . . . . . . . 42
2
concentration
2
(or the air ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1.5 Inspection and maintenance work steps . . . . . . 44
7.2 Servicing the burner module . . . . . . . . . . . . . . . . 45
7.2.1 Removing the burner module . . . . . . . . . . . . . . . 45
7.2.2 Cleaning the integral condensation heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.4 Refitting the burner module . . . . . . . . . . . . . . . . 46
7.3 Cleaning the condensate siphon . . . . . . . . . . . . . 47
7.4 Checking the expansion vessel . . . . . . . . . . . . . . 48
7.5 Recommissioning the boiler. . . . . . . . . . . . . . . . . 48
7.6 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Contents
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Logical fault finding procedure . . . . . . . . . . . . . . 49
8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.3 Resetting parameter to factory settings . . . . . . 54
9 Parts replacement . . . . . . . . . . . . . . . . . . . . . 54
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 54
9.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.3 Replacing fan or gas valve . . . . . . . . . . . . . . . . . . 55
9.4 Replacing expansion vessel . . . . . . . . . . . . . . . . . 56
9.5 Replacing primary heat exchanger . . . . . . . . . . 56
9.6 Replacing electronics and display . . . . . . . . . . . 57
10 Recycling and disposal . . . . . . . . . . . . . . . . . . 58
11 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . . 58
Appendix
EG declaration of conformity . . . . . . . . . . . . . . . . . . . . . 59
Benchmark gas boiler commissioning checklist . . . . . 60
3Instructions for installation and servicing ecoTEC 839592_12
1 Introduction
1 Introduction
1.1 Notes on the documentation
The following information is intended to help you
throughout the entire documentation.
Further documents apply in combination with this
installation and maintenance manual.
We assume no liability for any damage caused by
non-observance of these manuals.
1.1.1 Applicable documents
• Always observe all installation instructions for struc-
tural parts and components of the system when
installing the ecoTEC plus 937. These installation
instructions are enclosed with the various system components as well as additional components.
• Also observe all the operating instructions included
with the system components.
1.1.2 Retention of documents
Pass on this installation manual to the owner of the system. The owner should retain the manuals so that they
are available when required.
Safety instructions and symbols
1.1.3
Observe the safety instructions in this manual for the
installation of the appliance!
Symbols used in the manual are explained below:
Danger!
Immediate danger to life and limb!
Danger!
Risk of death from electric shock!
Danger!
Risk of burns or scalding!
Caution!
Potentially dangerous situation for the product
and environment!
Note
Useful information and instructions.
• Symbol for a necessary task
1.2 Validity of the manual
This installation manual applies exclusively to units with
the following part numbers:
- 0010004108 - 308525
- 308511 - 308526
- 308520 - 308527
- 308521 - 308528
- 308522 - 308531
- 308523 - 308534
- 308524 - 308536
The part number of the unit can be obtained from the
identification plate.
1.3 Introduction
Note
This boiler must be installed and serviced by a
competent person approved at the time by the
Health and Safety executive and in accordance
with the Gas Safety (Installation and Use)
Regulations 1998.
ecoTEC combination boiler
The ecoTEC combination boiler is a fully automatic, wall
mounted, room sealed condensing (high efficiency)
boiler for central heating and domestic hot water.
Domestic hot water is supplied directly from the boiler,
without requiring a copper cylinder, cold water tank,
feed and expansion vessel and associated pipework.
Domestic hot water has priority over central heating.
The ecoTEC plus combination boiler consists of 3 models
with outputs of 23 kW, 31 kW and 37 kW for domestic hot
water and two pro versions with outputs of 24 kW and
28 kW for domestic hot water.
All versions are available in natural gas. The ecoTEC plus
831 is also available in LPG.
ecoTEC combination boilers incorporate a warm start
facility that keeps the domestic hot water heat
exchanger hot, providing an instantaneous delivery of
domestic hot water. The temperature in the domestic
hot water heat exchanger is limited by the boiler control
system and it is not necessary to install a scale reducer
on the cold mains to the boiler. However, in areas that
get exceptionally hard water, a scale reducer may be
fitted to prevent scale formation in the hot water
system pipes. The heating system on ecoTEC plus
combination boilers can be filled using the built–in filling
loop contained within the boiler.
4 Instructions for installation and servicing ecoTEC 839592_12
ecoTEC system boiler
The ecoTEC system boiler is a fully automatic, wall
mounted, room sealed condensing (high efficiency)
boiler for central heating and domestic hot water
(where a separate indirect hot water storage cylinder is
also incorporated in the system).
Introduction 1
The ecoTEC system boiler consists of models with
outputs of 12, 15, 18, 24, 30 and 37 kW.
All ecoTEC system boilers are available in Natural Gas.
The ecoTEC plus 618 and 630 are also available in LPG.
1.4 General Notes
The boilers have been designed for use with a sealed
central heating system, and come fully tested and
assembled with a built in circulating pump, expansion
vessel and diverter valve (ecoTEC combination boilers).
The boilers are easily mounted on any internal wall and
can be installed with either a horizontal or vertical RSF
(room sealed fan assisted) flue.
The boilers use 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.
All boilers have 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
underside of the boiler. See text of General
Requirements for installation requirements or notes.
1.5 Intended use
The Valliant ecoTEC are state-of-the-art appliances
which 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
impaired in the event of improper use.
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental
capabilities, or lack of experience and/or knowledge,
unless they have been given supervision or instruction
concerning use of the unit by a person responsible for
their safety.
Children must be watched to ensure that they do not
play with the unit.
The appliance is designed to generate heat for
connecting to hot water central heating systems and for
instantaneous hot water supply (ecoTEC combination
boilers only). Any other use or extended use is
considered to be improper. The manufacturer or
supplier is not liable for any resulting damage. The user
alone bears the risk.
Intended use includes the observance of the operating
and installation manual and the adherence to the
inspection and maintenance conditions.
Caution!
Any incorrect use is forbidden.
The appliances must be installed by a competent person
approved at the time by the Health and Safety executive, who is responsible for adhering to the existing regulations, rules and guidelines.
1.6 CE marking
The CE marking shows that the appliances
comply with the basic requirements of the
following directives:
- Gas appliances directive (90/396/EEC)
- Electromagnetic compatibility directive with threshold
class B (89/336/EEC)
- Low voltage directive (73/23/EEC)
The appliances satisfy the basic requirements of the
efficiency directive (92/42/EEC) as condensing
appliance.
- The Gas Applaince (Safety) Regulations 1992
- The boiler (Efficiency) Regulations 1993
Vaillant Ltd. supports the Benchmark initiative.
At the rear of this guide, 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.
1.7 Gas council numbers
Applaince Gas council numbers
ecoTEC pro 24 47-044-36
ecoTEC pro 28 47-044-30
ecoTEC plus 824 47-044-31
ecoTEC plus 831 47-044-32
ecoTEC plus 831 Propane 47-044-34
ecoTEC plus 837 47-044-33
ecoTEC plus 612 41-044-44
ecoTEC plus 615 41-044-45
ecoTEC plus 618 41-044-46
ecoTEC plus 618 Propane 41-044-51
ecoTEC plus 624 41-044-47
ecoTEC plus 630 41-044-48
ecoTEC plus 630 Propane 41-044-50
ecoTEC plus 637 41-044-49
Table 1.1 Gas council numbers
5Instructions for installation and servicing ecoTEC 839592_12
2 Boiler specifications
2 Boiler specifications
2.1 Technical data
Technical data
CH heat output range
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
Maximum DHW output 23.0 31.0 37 23.0 28.0 kW
Maximum output for heating 19 24 28 19 24 kW
Minimum output 6.7 8.7 12 6.7 9.0 kW
Category II
SEDBUK Band A A A A A Band
SAP Seasonal Efficiency 91.1 %
Inlet gas working pressure required (G20, natural gas) 20 mbar
Inlet gas working pressure required (G31, Propane) 37 mbar
Connected load (if needed, related to stored charge/
water heating) at 15 °C and 1013 mbar
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
Maximum CH system pressure 3.0 bar
Circulation water volume (
Approx. condensation volume
at 50 °C flow/30 °C return heating
Pump delivery height 250 mbar
Minimum DHW flow rate 1.5 l/min
DHW flow rate
Appr. DHW flow rate at factory set temp. rise ( T=42
K)
Permitted DHW overpressure 10 bar
Mains water pressure required for max. flow rate 0.5 0.75 0.75 0.5 0.5 bar
Mains water pressure required for min. flow rate 0.15 bar
Hot water discharge temperature range 35 – 65 °C
Exhaust flue 60/100 mm
Flue categories C13, C33, C43, C53, C83, B23, B33
10 l expansion vessel pre-charge pressure 0.75 bar
Connections heating flow/return 22 mm
Gas inlet 15 22 15 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
Dimensions (H x W x D)
Weight (boiler only) 35 38 44,5 34 37 kg
Primary water content 1.9 2.3 2.5 1.9 2.1 l
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input 110 125 140 110 115 W
Table 2.1 Technical data ecoTEC combination boiler
T=35 K rise 9.4 12.7 15.2 9.4 11.5 l/min
T=20 K) 817 1032 1204 817 1032 l/h
824 831 837 24 28
6.7 – 19.0
6.9 – 19.6
7.1 – 20.2
7.2 – 20.6
G20: 2.5
G31: 1.82
3.2
10.7
40
74
1.8 2.2 2.9 1.8 2.2 l/h
7.9 10.6 12.6 7.9 9.6 l/min
720 x 440 x
335
ecoTEC plus ecoTEC pro
8.7 – 24.0
9.0 – 24.7
9.2 – 25.5
9.4 – 26.0
G20: 3.3
G31: 2.46
4.2
14.4
40
83
30 – 85 40 – 85 30 – 85 °C
720 x 440 x
335
12.0 – 28.0
12.3 – 28.9
12.7 – 29.7
12.9 – 30.3
2H3P
G20: 4.0
G31: 2.94
5.7
17.1
40
70
720 x 440 x
403
6.7 – 19.0
6.9 – 19.6
7.1 – 20.2
7.2 – 20.6
G20: 2.5
G31: 1.82
3.2
10.7
40
74
720 x 440 x
335
9.0 – 24.0
9.3 – 24.7
9.6 – 25.5
9.8 – 26.0
G20: 3.0
G31: 2.22
4.4
13.0
40
74
720 x 440 x
335
Units
kW
kW
kW
kW
m
kg/h
g/s
g/s
°C
°C
mm
3
/h
6 Instructions for installation and servicing ecoTEC 839592_12
Boiler specifications 2
Technical data
CH heat output range
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
Category II
SEDBUK Band AAAAAABand
SAP Seasonal Efficiency 91.2 %
Inlet gas working pressure required (G20,
natural gas)
Inlet gas working pressure required (G31,
Propane)
Connected load (if needed, related to stored
charge/water heating) at 15 °C and 1013 mbar
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C
return
at maximum thermal load (80 °C flow/60 °C
return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C
return)
at maximum thermal load (80 °C flow/60 °C
return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
Maximum CH system pressure 3.0 bar
Circulating water volume ( T=20 K) 516 645 774 1032 1290 1591 l/h
Approx. condensation volume
at 50 °C flow/30 °C return heating
Pump delivery height 250 150 mbar
Adjustable storage target value (15 °C at left
stop, spare adjusting range 40 – 70 °C
Exhaust flue 60/100 mm
Flue categories C13, C33, C43, C53, C83, B23, B33
10 l expansion vessel pre-charge pressure 0.75 bar
Connections heating flow/return 22 mm
Gas inlet 15 22 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
Dimensions (H x W x D) 720 x 440 x 335
Weight (boiler only) 35 35 35 37 38 40 kg
Primary water content 1.9 1.9 1.9 2.1 2.3 2.5 l
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input 100 110 100 110 110 140 W
Table 2.2 Technical data ecoTEC system boiler
612 615 618 624 630 637
4.9 – 12.0
5.1 – 12.3
5.2 – 12.7
5.3 – 12.9
G20: 1.3
G31: 0.95
2.3
5.6
1.1 1.4 1.7 2.2 2.7 3.8 l/h
4.9 – 15.0
5.1 – 15.5
5.2 – 15.9
5.3 – 16.2
G20: 1.6
G31: 1.19
2.3
7.0
40
70
ecoTEC plus
6.7 – 18.0
6.9 – 18.6
7.1 – 19.1
7.2 – 19.5
G20: 1.9
G31: 1.43
3.2
8.3
8.7 – 24.0
9.0 – 24.7
9.2 – 25.5
9.4 – 26.0
2H3P
20 mbar
37 mbar
G20: 2.6
G31: 1.90
4.2
11.2
40
75
30 – 85 °C
15 – 70 °C
10.0 – 30.0
10.3 – 30.9
10.6 –31.8
10.8 – 32.4
G20: 3.2
G31: 2.38
4.8
13.9
40
83
720 x 440 x
369
12.0 – 37.0
12.3 – 38.2
12.7 – 39.3
12.9 – 40.1
G20: 4.0
G31: 2.94
5.7
17.1
40
70
720 x 440 x
403
Units
kW
kW
kW
kW
3
/h
m
kg/h
g/s
g/s
°C
°C
mm
7Instructions for installation and servicing ecoTEC 839592_12
2 Boiler specifications
2.2 Dimensions
440
9
190
8
7
65
241
883
720
642
20
Fig. 2.1 Dimensions in mm
175
35 35
6
10
125
11
12
5
75
45
180
12345
300
ecoTEC plus 630:
334
ecoTEC plus 637,
ecoTEC plus 837:
368
4
3
2
130
1
100100
Legend:
1 Heating return pipe Ø 22 mm
2 Cold water connection Ø 15 mm (combination boilers only)
3 Gas connection Ø 15 mm
4 Hot water connection Ø 15 mm (combination boilers only)
5 Heating flow pipe Ø 22 mm
6 Hanging bracket
7 Flue hole - flue system 60/100
8 Flue hole - flue system 80/125
9 Spacer frame accessory (Art. No.: 308 650)
10 Flue pipe connection
11 Condensate drain connection (Ø 19 mm)
12 Heating system expansion relief valve connection (Ø 15 mm)
Note
With the spacer frame (Art. No 308 650), the
pipes can be run behind the boiler. The distance
of the appliance from the wall thus increases
by 65 mm.
8 Instructions for installation and servicing ecoTEC 839592_12
2.3 Installation
Boiler specifications 2
14
13
12
10
14
1
13
2
3
4
5
12
11
6
7
8
9
11
1
2
3
4
5
7
9
Fig. 2.2 Function elements of combination boilers
Legend:
1 Expansion vessel
2 Air intake pipe
3 Burner module
4 Ignition electrode
5 Fan
6 Diverter valve with by-pass
7 Pump
8 Aqua-Sensor
9 Electronics box
10 Hot water heat exchanger
11 Gas valve
12 Pressure sensor
13 Heat exchanger
14 Flue pipe connection
2.4 Type plate
The type plate of the Valliant ecoTEC is attached to the
bottom of the appliance at the factory.
Fig. 2.3 Function elements of system boilers
Legend:
1 Expansion vessel
2 Air intake pipe
3 Burner module
4 Ignition electrode
5 Fan
7 Pump
9 Electronics box
11 Gas valve
12 Pressure sensor
13 Heat exchanger
14 Flue pipe connection
9Instructions for installation and servicing ecoTEC 839592_12
3 General requirements
3 General requirements
3.1 Preliminary remarks for room sealed
appliances
This appliance should only be installed in conjunction with
either a Vaillant flue system or an alternative approved
system (details of flue approval categories can be found
in the technical section of the installation manual).
Install the flue system as detailed in the separate flue
installation instructions supplied with this boiler.
3.2 Related documents
The installation of the appliance and any associated hot
water system must be in accordance with (but not
limited to) the following; COSHH regulations, Gas Safety
(Installation and Use) Regulations 1998, Health and
Safety Document No. 635 (The Electricity at Work
Regulations 1989), BS7671 (IEE Wiring Regulations) and
the Water Supply (Water Fitting) Regulations 1999, or
The Water Bylaws 2000 (Scotland). It should also be in
accordance with the relevant requirements of the Local
Authority, Building Regulations, The Building
Regulations (Scotland), The Building Regulations
(Northern Ireland) and the relevant recommendations of
the following British Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired
boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water
central heating systems.
Institute of Gas Engineers Publication IGE/UP/7/1998:
”Guide for gas installations in timber framed housing”
BS. 5482 Pt. 1 Domestic butane and propane gas
burning installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2 Gas installation pipework, boosters and
compressors on industrial and commercial premises.
IGE/UP10 Installation of gas appliances in industrial and
commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating
systems.
BS. 5440: Installation and maintenance of flues and
ventilation for gas appliances of rated input not
exceeding 70 kW net (1st, 2nd and 3rd family gases).
Part 1 Specification for installation of flues.
Part 2 Specification for installation and maintenance
of ventilation for gas appliances.
European installation directive
Caution!
The appliance must be installed and serviced by
a competent person approved at the time by
the Health and Safety Executive und in
accordance with 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 Contents included with delivery
The Vaillant ecoTEC is delivered pre-mounted in a
package unit. Check that all the parts have been
delivered intact (see Fig. 3.1 and Table 3.1, Fig. 3.2 and
Table 3.2 and Fig. 3.3 and Table 3.3).
10 Instructions for installation and servicing ecoTEC 839592_12
General requirements 3
8
7
6
5
1
2
3
4
8
7
6
5
1
2
3
4
Fig. 3.1 Contents included with delivery of ecoTEC plus
system boilers
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Boiler
3 1 Bottom cover
4 4 Connecting pipes (gas, heating, safety valve)
5 3 Isolating valves
6 1 Template
73
8 2 Installation and connection accessories
Table 3.1 Contents included with delivery of ecoTEC plus
system boilers
User, installation and service and flue installation manuals
For LPG appliances, extra: 1 sticker each for
2
tank and ventilation (above Fig.)
Fig. 3.2 Contents included with delivery of ecoTEC plus
combination boilers
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Boiler
3 1 Bottom cover
46
5 4 Isolating valves and filling loop
6 1 Template
73
8 2 Installation and connection accessories
Table 3.2 Contents included with delivery of ecoTEC plus
Connecting pipes (gas, heating, water, safety
valve)
User, installation and service and flue installation manuals
For LPG appliances, extra: 1 sticker each for
2
tank and ventilation (above Fig.)
combination boilers
11Instructions for installation and servicing ecoTEC 839592_12
3 General requirements
7
6
i F P
bar
5
4
Fig. 3.3 Contents included with delivery of ecoTEC pro combi-
nation boilers
1
2
3
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Boiler
32
4 4 Isolating valves
5 1 Template
61
7 2 Installation and connection accessories
Table 3.3 Contents included with delivery of ecoTEC pro combi-
Connecting pipes (hot water, heating safety
valve)
User, installation and service and flue installation manuals
nation boilers
3.4 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.
Note
If the boiler is to be installed in an airing cupboard it is not required to separate the boiler
with a non-combustible partition. However
installation and servicing clearances must be
maintained, and the appliance kept clear of any
clothing.
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 Edition
2 Gas installations in timber framed and ligh steel
framed buildings“. 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.
3.5 Gas supply
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
12 Instructions for installation and servicing ecoTEC 839592_12
General requirements 3
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. Pipework 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.
3.6 Flue pipe
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.
3.6.1 Standard 100 mm flue system
667
87
65
74
48
3.6.2 Optional 125 mm flue system
A concentric flue system of 125 mm outside diameter is
available and can be used to achieve flue lengths up to
25 m.
A vertical flue system is also available. Refer to flue
system installation instructions for full details.
1103
70
70
15
Fig. 3.6 Art. No. 303 209
650
1530
30
Fig. 3.4 Art. No. 303 933
A standard 100 mm flue system (Art. No. 303 933) is
available. Refer to flue system installation instructions
for full details.
Flue extensions are available to extend this length up to
8 m. Both 90° bends and 45° elbows are also available
to increase siting flexibility.
542
1456
84
901
Fig. 3.5 Art. No. 0020060570
880
Fig. 3.7 Art. No. 303 200
70
3.7 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).
13Instructions for installation and servicing ecoTEC 839592_12
3 General requirements
A
G
F
J
H, I
Fig. 3.8 Flue termination
E
BCD
A
A
A
G
Note
Vertical flues must not terminate within
600 mm 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.
B
F
M
G
L
F
F
K
K
L
In order to ensure that the condensate plume does
not affect adjacent surfaces the terminal should be
extended as shown in Fig. 3.9.
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.
Terminal position mm
Directly below an opening, above an opening or hori-
A
zontal to an opening, air brick, opening window, etc.
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
From an opening in the car port (e.g. door, window)
J
into the dwelling
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent for vertical Flue 500
Table 3.4 Terminal position for a fan assisted concentric flue
300
1200
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.
Fig. 3.9 Flue termination under balcony/eaves
3.8 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.
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.
3.9 Electrical supply
A 230 V, ~ 50 Hz single phase electricity supply fused to
3 Amp. must be provided in accordance with the latest
edition of BS 7671 (IEE Wiring Regulations) and any
other local regulations that may apply. In IE reference
should be made to the current edition of the ETCI rules.
The method of connection to the mains electricity
supply must provide a means of completely isolating the
boiler and its ancillary controls. Isolation is preferably
by the use of a fused three pin plug and unswitched
shuttered socket outlet, both complying with the
requirements of BS 1363. Alternatively, a 3 Amp. fused
double pole switch with a 3 mm contact separation on
both poles may be used.
Danger!
This appliance must be earthed.
14 Instructions for installation and servicing ecoTEC 839592_12
General requirements 3
3.10 Guide to system requirements
3.10.1 Water circulation system
Detailed recommendations for the water circulation
system are given in BS 6798 and BS 5449: Part 1 (for
small bore and micro bore central heating systems).
Pipework not forming part of the useful heating surface
should be insulated to help prevent heat loss and
possible freezing, particularly where pipes are run
through roof spaces and ventilated underfloor spaces.
Draining taps must be located in accessible positions
which permit the draining of the whole system including
the boiler and the hot water system. Draining taps
should be at least 1/2 in. BSP nominal size and be in
accordance with BS 2879.
The boiler is suitable for use with minibore or microbore
systems. Copper tubing to BS 2871: Part 1 should be
used for water carrying pipework. All capillary joints in
all DHW pipework must be made with lead free solder.
Particularly where a new boiler is to be fitted to an
existing system, it is good practice that the system is
thoroughly cleansed.
Caution!
To prevent the formation of deposits and prevent serious damage to the appliance and system, cleansers must be used carefully and must
be completely removed by thoroughly flushing
the system. Cleansers should only be left in
systems for a maximum of 24 hours.
This cleansing must take place prior to the fitting of the
new boiler and be in accordance with BS 7593. For
advice on the application of system cleansers contact
Sentinel, Betz Dearborn Ltd. Widnes, Cheshire, WA8
8UD. Tel: 0151 420 9595, or Fernox, Alpha Fry
Technologies, Tandem House, Marlow Way, Croydon,
CR0 4XS. Tel 0870 8700362.
3.10.2 Filling and preparing heating system
The system can be filled using the built in filling loop
(ecoTEC plus combination boilers only) or via a separate
filling point fitted at a convenient position on the
heating circuit. The connection must be removed when
filling is completed. Where local Water Authority
regulation does not allow temporary connection, a
sealed system filler pump with break tank must be used.
The heating system will not be filled automatically from
the domestic hot water side. (Alternative methods of
filling sealed systems are given in BS 5449).
Vaillant accepts no liability for the compatibility of any
additive or its effectiveness in the entire heating
system.
Additives for cleaning purposes
(subsequent flushing required)
- Fernox F3
- Jenaqua 200
- Jenaqua 300
- Jenaqua 400
- Sentinel X 300
- Sentinel X 400
Additives intended to remain permanently in the
system
- Fernox F1
- Fernox F2
- Jenaqua 100
- Jenaqua 110
- Sentinel X 100
- Sentinel X 200
Additives for frost protection intended to remain
permanently in the system
- Fernox Antifreeze Alphi 11
- Sentinel X 500
• Inform the operator of the necessary measures in
case you have used any of these additives.
• Inform the operator of the required procedures for
frost protection.
• Observe the applicable national regulations and
technical standards for the treatment of filling and
top-up water.
Provided the national regulations and technical
standards do not specify any higher requirements, the
following applies:
• You must treat the heating water
- if the total volume of filling and top-up water
exceeds thrice the nominal volume of the heating
system over the service life of the system
or
- if the limits given in the following tables are not
adhered to.
Mixing additives with the heating water can result in
material damage. However, up to now, no
incompatibility with Vaillant appliances has been
detected with proper use of the following products.
• When using additives, follow the additive
manufacturer‘s instructions without exception.
15Instructions for installation and servicing ecoTEC 839592_12
3 General requirements
Total heating
output
kW mol/m
< 50 No requirement or < 3
> 50 to ≤ 200
> 200 to ≤ 600
> 600
1) with systems equipped with wall-hung boiler and systems with electric heating elements
2) of the specific system volume (nominal capacity in litres/heating output; in case of multiple boiler systems the lowest individual
heating output should be used)
These data only apply up to 3x the system volume for filling and top-up water. Once this triple system volume is exceeded, the
water will have to be treated exactly the same as in case of exceeding the limit values given in Table 3.6 (softening, desalination,
hardness stabilisation and desludging).
Table 3.5 Guidelines for the heating water: Water hardness
Heating water
qualities
Electric conductivity
at 25 °C
Appearance Free of sedimentary substances
pH-value at 25 °C 8,2-10,0
Oxygen mg/L
1) With aluminium and aluminium alloys, the ph value range is
restricted from 6.5 to 8.5.
Table 3.6 Guidelines for heating water: Salinity
Total hardness at 20 l/kW
for the smallest boiler heating
2)
surface
3
1)
2 1,5 0,02
1,5 0,02 0,02
0,02 0,02 0,02
Total hardness at > 20 l/kW
< 50 l/kW for the smallest boiler
heating surface
mol/m3 mol/m
2 0,02
2)
3.10.3 Pressure relief valve
Unit Low-salt saline
A pressure relief valve is provided with the boiler. This
safety device is required on all sealed C.H. systems and
µS/cm < 100
100-1500
is preset at 3 bar and provided with a 15 mm
compression connection for a discharge pipe, which
1)
< 0,1 < 0,02
8,2-10,0
1)
must be of no less than 15 mm in diameter. The pressure
relief valve must not be used for draining purposes.
3.10.4 Pressure gauge
This is factory fitted to the boiler and indicates the
primary circuit pressure to facilitate filling and testing.
Total hardness at > 50 l/kW
for the smallest boiler heating
2)
surface
3
3.10.5 Expansion vessel
ecoTEC boilers incorporate a 10 litre expansion vessel
Caution!
Aluminium corrosion resulting in leakages
caused by unsuitable heating water!
Unlike materials such as steel, cast iron or copper, aluminium is reactive to alkalised heating
water (pH-value > 8,5) which results in significant corrosion.
With aluminium, ensure that the pH value of
the heating water ranges between 6.5 up to a
maximum of 8.5.
which is suitable for a sealed heating system with a
maximum water content of 100 litres.
If the nominal capacity of the built in expansion vessel is
not sufficient for the heating system (for instance in
case of modernisation of old open systems) an
additional expansion vessel can be installed external to
the boiler. It should be fitted in the return pipe as close
as possible to the boiler in accordance with BS 5449:
Part 1.
Guidance on the sizing of an additional expansion vessel
is given in Table 3.7.
Caution!
Risk of material damage if the heating water is
treated with unsuitable frost or corrosion protection agents!
Frost and corrosion protection agents may
cause changes in the seals, noises during heating and possibly subsequent damage.
Do not use any unsuitable frost or corrosion
protection agents.
16 Instructions for installation and servicing ecoTEC 839592_12
General requirements 3
Vessel Volume [L]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0
Total water content of system litres
25 2.7 3.9
50 5.4 7.8
100 10.9 15.6
125 13.6 19.5
150 16.3 23.4
175 19.1 27.3
200 21.8 31.2
225 24.5 35.1
250 27.2 39.0
275 30.0 42.9
300 32.7 46.8
325 35.7 50.7
350 38.1 54.6
375 40.9 58.5
400 43.6 62.4
425 46.3 66.3
450 49.0 70.2
475 51.8 74.1
500 54.5 78.0
For system volumes other than those given
above, multiply the system volume by the
factor across
Table 3.7 Sizing of additional expansion vessel
0.109 0.156
400
]
mbar
300
[
Lift
200
100
0
0 200 400 600 800 1000 1200 1600
Fig. 3.10.2 Pump specifications only ecoTEC 637 and 837
2. Step1. Step
18001400
2000
Volumeflow [l/h
]
only ecoTEC pro:
The circulating pump is included in the boiler. The
ecoTEC pro appliances are fitted with a single-stage
pump. The residual pump discharge height depending on
the by-pass valve is shown in Fig. 3.11.
]
400
mbar
[
300
Lift
200
100
3.11 Pump specifications
3.11.1 Circulating pump
only ecoTEC plus:
The circulating pump is included in the boiler. The residual
pump discharge height depending on the by-pass valve is
shown in Fig. 3.10.1 (ecoTEC plus) and 3.10.2 (ecoTEC plus
637 / 837).
The operating mode of the 2-step pump can be adjusted
below the diagnosis number “d.19”, see section 8.1.2.
]
400
mbar
[
300
Lift
200
100
0
0 200 400 600 800 1000 1200 1600
Fig. 3.10.1 Pump specifications ecoTEC plus
(except ecoTEC 637 and 837)
2. Step1. Step
1400
Volumeflow [l/h
1800
]
0
0 200 400 600 800 1000 1200 1600
Fig. 3.11 Pump specifications ecoTEC pro
1400
Volumeflow [l/h
1800
]
3.11.2 System by-pass
An automatic system by-pass is provided in the boiler.
The boiler is suitable for use in systems with
thermostatic radiator valves and no additional by-pass
is required. The by-pass valve is adjustable, see section
5.3.
3.11.3 Venting
The boiler is fitted with an automatic air vent. Additional
provision should be made to enable the heating system
to be vented during filling and commissioning either by
automatic air vents or manually.
3.12 Condensate trap
The boiler is fitted with a siphonic condensate discharge
(ecoTEC plus) or a condensate trap (ecoTEC pro)
incorporating a water trap of 140 mm.
17Instructions for installation and servicing ecoTEC 839592_12
4 Boiler installation sequence
4 Boiler installation sequence
4.1 Transporting the appliance
Caution!
With regards to the Manual Handling
Operations, 1992 Regulations, the following lift
operation exceeds the recommended weight for
a one man lift.
General recommendations when handling
Clear the route before attempting the lift. Ensure safe
lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. Do
not twist – reposition feet instead. If 2 persons
performing lift, ensure co-ordinated movements during
lift. Avoid upper body/top heavy bending - do not lean
forward/sideways. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp
edges and ensure good grip. Always use assistance if
required.
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack
truck. If 1 person is performing lift, straddle the load, tilt
and place carton into position on truck. Recommend
secure appliance onto truck with suitable straps. Ensure
safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible.
If 2 persons performing lift, ensure co-ordinated movements during lift. Always use assistance if required.
Carriage of carton from point of delivery to point of
installation – ground floor.
Recommend 2 person lift or 1 person with use of sack
truck. If 1 person is performing lift, straddle the load, tilt
and place carton into position on truck. Recommend
secure appliance onto truck with suitable straps. Ensure
safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible.
If 2 persons performing lift, ensure co-ordinated movements during lift. Clear the route before attempting the
lift. If removing boiler from truck straddle the load and
tilt forwards to facilitate secure grip. Ensure safe lifting
techniques are used – keep back straight – bend using
legs. Do not twist – reposition feet instead. Take care to
avoid trip hazards, slippery or wet surfaces and when
climbing steps and stairs. Always use assistance if
required.
Carriage of carton from point of delivery to point of
installation – first or higher floor, cellar.
Recommend 2-person lift or 1 person with use of sack
truck. If 1 person is performing lift, straddle the load, tilt
and place carton into position on truck. Recommend
secure appliance onto truck with suitable straps. Ensure
safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible.
If 2 persons performing lift, ensure co-ordinated
movements during lift. Avoid upper body/top heavy
bending - do not lean forward/sideways. Clear the route
before attempting the lift. If removing boiler from truck
straddle the load and tilt forwards to facilitate secure
grip. Ensure safe lifting techniques are used – keep back
straight – bend using legs. Do not twist – reposition feet
instead. Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs. Always use
assistance if required.
Carriage of carton from point of delivery to point of
installation – roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during lift. Avoid upper body/top heavy bending do not lean forward/sideways. Clear the route before
attempting the lift. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and
stairs. When transferring appliance into roofspace, recommend 1 person to be in roofspace to receive the
appliance and other person to be below to pass up and
support appliance. Ensure safe lifting techniques are
used – keep back straight – bend using legs. Keep load
as close to body as possible. Always use assistance if
required. It is assumed safe access, flooring and adequate lighting are provided in the roof space. It is recommended a risk assessment of the roof space area be
carried out before moving the appliance into the area to
take into account access, stability of flooring, lighting
and other factors, and appropriate measures taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton.
Always keep working area clear. Recommend cut base
end of carton and open carton flaps, then tilt boiler forwards from its side onto its base and remove carton by
sliding up over the boiler. Ensure safe lifting techniques
are used – keep back straight – bend using legs. Keep
load as close to body as possible. Always use assistance
if required. Dispose of packaging in a responsible manner. Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance outside packaging.
Positioning of Appliance for Final Installation –
no obstructions.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall
before lifting appliance into position. Obtain firm grip on
front and sides of appliance, lift upwards, ensure stable
balance achieved and lift upwards to position in place on
bracket. Ensure safe lifting techniques are used – keep
back straight – bend using legs - when lifting load from
floor level. Do not twist – reposition feet instead. Keep
boiler as close as possible to body throughout lift to
minimise strain on back. Ensure co-ordinated movements to ensure equal spread of weight of load. Always
use assistance if required. Recommend wear suitable
cut resistant gloves with good grip to protect against
sharp edges and ensure good grip when handling appliance.
18 Instructions for installation and servicing ecoTEC 839592_12
Boiler installation sequence 4
Positioning of Appliance for Final Installation – above
worktop, foreseeable obstructions etc.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall
before lifting appliance into position. Obtain firm grip on
front and sides of appliance, lift upwards, onto worktop
if practicable. Ensure stable balance achieved and lift
upwards to position in place on bracket. If 2 persons
positioning onto bracket obtain firm grip at front and
sides/base of boiler. Ensure coordinated movements
during 2 person lifts to ensure equal spread of weight of
load. Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from floor
level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise
strain on back. Avoid upper body/top heavy bending do not lean forward/sideways. Always use assistance if
required. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and
ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – within
compartment etc. restricting installation.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall
before lifting appliance into position. Obtain firm grip on
front and sides of appliance, lift upwards, onto worktop if
practicable. Ensure stable balance achieved and lift
upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain firm grip at front and sides/
base of boiler. Ensure coordinated movements during 2
person lifts to ensure equal spread of weight of load. If 1
person positioning onto bracket recommend obtain firm
grip supporting base of boiler. Ensure safe lifting techniques are used – keep back straight – bend using legs when lifting load from floor level. Do not twist – reposition
feet instead. Keep boiler as close as possible to body
throughout lift to minimise strain on back. Always use
assistance if required. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp
edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – in
roof space restricting installation.
This appliance is deemed to be a one person lift when
removed from the carton. Obtain firm grip on front and
sides of appliance, lift upwards, ensure stable balance
achieved and lift upwards to drop into place onto
bracket. If 2 persons positioning onto bracket obtain
firm grip at front and sides/base of boiler. Ensure coordinated movements during 2 person lifts to ensure
equal spread of weight of load. If 1 person positioning
onto bracket recommend obtain firm grip supporting
base of boiler. Ensure safe lifting techniques are used keep back straight – bend using legs - when lifting load
from floor level. Do not twist – reposition feet instead.
Keep boiler as close as possible to body throughout lift
to minimise strain on back. Always use assistance if
required. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and
ensure good grip when handling appliance. It is recommended a risk assessment of the roof space area be
carried out before moving the appliance into the area to
take into account access, stability of flooring, lighting
and other factors, and appropriate measures taken.
4.2
Required minimum distances/assembly clearances
min
165/246*
min 5
Fig. 4.1 Distances during installation (dimensions in mm)
min 5
min 180
min 500**
The boiler should be mounted on a flat and vertical area
of wall of sufficient area for the boiler plus the required
clearances for installation and servicing (Fig. 4.1). These
are shown on the installation template supplied with the
boiler and are:
– 5 mm either side of the boiler
– 180 mm below the boiler
– 165 mm* above the boiler when utilising the 100 mm
outside diameter flue
– 246 mm* above the boiler when utilising the 125 mm
outside diameter flue
– 500 mm in front of the boiler to enable easy access
for servicing (may be provided by an opening door)
Note
If the boiler is to be installed in a timber framed
building, it should be fitted in accordance with
„IGE/UP/7 Edition 2 Gas installations in timber
framed and ligh steel framed buildings“.
4.2.1 Select position for boiler
Refer to section 3.4 ‘Installation site’ for information
regarding the appliance location. In general the boiler
must be positioned such that:
• There is adequate space around the boiler for service
and maintenance
• The boiler can be correctly flued, i.e. the flue terminal
position is located in accordance with these instructions and the air/flue duct can be installed in accordance with the flue installation instructions supplied.
• All necessary pipework can be connected, including
the pressure relief valve and condensate drain.
19Instructions for installation and servicing ecoTEC 839592_12
4 Boiler installation sequence
4.2.2 Unpack the boiler
To unpack the boiler, cut both plastic carton straps,
open box and lift out the polystyrene top packing. Lift
the cardboard box upwards.
Note
Care should be taken not to scratch the white
surface of the boiler casing.
4.2.3 Using boiler template
20
165
5
60/100
25
A
95
175
5
A
• Fix the paper template to the wall ensure that the
template is vertical.
The template shows:
– The position of the fixing holes for the boiler
mounting bracket.
– The position of the connections.
– The position of the flue exit hole.
• Mark the position of the hanging bracket fixing holes.
• Drill 2 holes Ø 10 mm for the hanging bracket.
Note
Use alternative fixing holes where necessary.
4.3 Flue exit
• If using rear flue mark the position of the air/flue duct
and its circumference.
Other flue options
Flue instructions for other flue systems such as vertical
RSF flues, flues run to the side of the boiler and the use
of additional bends etc. are detailed in the flue
installation instructions provided with the boiler.
• Remove the template from the wall and plug the
drilled holes using the wallplugs supplied.
4.4 Fitting the boiler hanging bracket
1065
A
180
Fig. 4.2 Assembly template
A
1
2
3
Fig. 4.3 Appliance with hanging bracket
• Fix the hanging bracket to the wall using the plugs
A
and screws provided with the appliance.
Note
Use alternative fixing holes where necessary.
45
256723_01 01 2005
450
Note
If the boiler is to be fitted in a timber framed
building ensure that the bracket is secured to a
substantial part of the timber frame capable of
taking the weight of the boiler.
20 Instructions for installation and servicing ecoTEC 839592_12
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