Vaillant ecoTEC plus 612/615/618/624/630/824/831 | ecoTEC pro 28 INSTRUCTIONS FOR INSTALLATION AND SERVICING

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Page 1

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 824 ecoTEC plus 831

ecoTEC pro 28

Page 2

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 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.4 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5 Gas council numbers . . . . . . . . . . . . . . . . . . . . . . 5

2 Boiler specifications . . . . . . . . . . . . . . . . . . . 6

2.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 General requirements . . . . . . . . . . . . . . . . . . 10

3.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Contents included with delivery . . . . . . . . . . . . 10

3.4 Installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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. . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.8 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.9 Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . 15

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 . . . . . . . . . . . . . . . . . . . . . . 15

3.10.4 Pressure gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.10.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.11 Pump specifications . . . . . . . . . . . . . . . . . . . . . . 16

3.11.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.11.2 System by-pass. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.11.3 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.12 Condensate trap. . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Boiler installation sequence. . . . . . . . . . . . . 16

4.1 Required minimum distances/assembly

clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1.1 Select position for boiler . . . . . . . . . . . . . . . . . . 17

4.1.2 Unpack the boiler. . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1.3 Using boiler template . . . . . . . . . . . . . . . . . . . . . 17

4.2 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 Fitting the boiler hanging bracket . . . . . . . . . . 18

4.4 Installing the flue system . . . . . . . . . . . . . . . . . . 18

4.5 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.6 Removing the front case . . . . . . . . . . . . . . . . . . 18

4.7 General instructions for heating system . . . . . 18

4.8 Gas connection. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.9 Cold water mains inlet and hot water outlet

(ecoTEC combination boilers only) . . . . . . . . . . 19

4.10 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . 20

4.11 Heating connection . . . . . . . . . . . . . . . . . . . . . . 21

4.11.1 Heating flow and return connection. . . . . . . . . 21

4.11.2 Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . 22

4.12 Connecting the flue system to the boiler . . . . 22

4.13 Electrical connection. . . . . . . . . . . . . . . . . . . . . . 22

4.13.1 General requirements . . . . . . . . . . . . . . . . . . . . . 22

4.13.2 Connection to the main supply . . . . . . . . . . . . . 23

4.13.3 Electric board layout . . . . . . . . . . . . . . . . . . . . . . 24

4.14 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.14.1 Vaillant controls and accessories . . . . . . . . . . . 27

4.14.2 External electrical controls . . . . . . . . . . . . . . . . 27

4.14.3 Connection details for external time switches

and boiler terminal strip . . . . . . . . . . . . . . . . . . . 27

4.14.4 Vaillant optional plug in timer accessories . . . 27

4.14.5 Connection details using the VR 65 Control

Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.15 Thermostatic radiator valves. . . . . . . . . . . . . . . 27

4.16 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.17 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.18 Anticycling ‘economiser’ control. . . . . . . . . . . . 28

4.19 Automatic pump spin control (APS). . . . . . . . . 28

5 Commissioning Part I . . . . . . . . . . . . . . . . . . 28

5.1 Preliminary electrical checks. . . . . . . . . . . . . . . 28

5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.3 Cold water supply (ecoTEC combination

boilers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.4 Filling the heating system . . . . . . . . . . . . . . . . . 28

5.4.1 Checking the filling pressure of the heating

system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.4.2 ecoTEC plus combination boiler filling loop . . 29

5.4.3 Filling the heating system in ecoTEC pro combination boilers and ecoTEC plus system

boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.4.4 Filling the heating system for the first time . . 30

5.5 Initial system flush (“cold”) . . . . . . . . . . . . . . . . 30

5.6 Filling the condensate siphon . . . . . . . . . . . . . . 30

5.7 Adjusting the pumping capacity . . . . . . . . . . . . 31

5.8 Adjusting the by-pass . . . . . . . . . . . . . . . . . . . . . 31

5.9 Checking the gas supply. . . . . . . . . . . . . . . . . . . 31

5.9.1 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.9.2 Gas inlet working pressure. . . . . . . . . . . . . . . . . 31

5.9.3 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . 32

5.10 Refitting the case. . . . . . . . . . . . . . . . . . . . . . . . . 32

5.11 Adjusting the central heating output (range

rating). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6 Functional checks (commissioning part II). 33

6.1 Functional checks. . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1.2 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1.3 Water heating (combination boilers only) . . . . 33

6.1.4 Final flush of the heating system (“hot”) . . . . 34

6.2 Handing over to the user . . . . . . . . . . . . . . . . . . 34

7 Inspection and maintenance . . . . . . . . . . . . 34

7.1 Initial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.1.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 35

7.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Instructions for installation and servicing ecoTEC

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7.1.3 Overview of the maintenance tasks . . . . . . . . . 35

7.1.4 Functional check of boiler operation . . . . . . . . 36

7.2 Servicing the burner module . . . . . . . . . . . . . . . 36

7.2.1 Removing the burner module . . . . . . . . . . . . . . 36

7.2.2 Cleaning the integral condensation heat

exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . 37

7.2.4 Refitting the burner module . . . . . . . . . . . . . . . 37

7.3 Cleaning the condensate siphon. . . . . . . . . . . . 38

7.4 Checking the expansion vessel . . . . . . . . . . . . . 39

7.5 Recommissioning the boiler. . . . . . . . . . . . . . . . 39

7.6 Test operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 39

8.1 Logical fault finding procedure . . . . . . . . . . . . . 39

8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.4 Test programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.5 Resetting parameter to factory settings . . . . . 44

Contents

9 Parts replacement. . . . . . . . . . . . . . . . . . . . . 44

9.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 44

9.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.3 Replacing fan or gas valve . . . . . . . . . . . . . . . . . 45

9.4 Replacing expansion vessel . . . . . . . . . . . . . . . . 46

9.5 Replacing primary heat exchanger. . . . . . . . . . 46

9.6 Replacing electronics and display. . . . . . . . . . . 47

9.7 Check CO

(air-ratio adjustment) . . . . . . . . . . . . . . . . . . . . . 47

10 Recycling and disposal . . . . . . . . . . . . . . . . . 48

10.1 Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Appendix

EG declaration of conformity. . . . . . . . . . . . . . . 49

Benchmark gas boiler commissioning

checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

content and if necessary set

3Instructions for installation and servicing ecoTEC

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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

The following additional documents are provided with the appliance:

For the owner of the system:

Brief users instructions (only ecoTEC plus) no. 838404 Warranty card with return envelope no. 802922

For the qualified technician:

Instructions for installation and servicing no. 839592 Flue installation instructions no. 835296

The manuals for any accessories and controllers used also apply.

1.1.2 Retention of documents

Please pass on this installation manual to the owner of the system. The owner should retain the manuals so that they are available when required.

1.1.3 Safety instructions and symbols

Please 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!

Caution!

Potentially dangerous situation for the product and environment!

Note

Useful information and instructions.

• Symbol for a necessary task

- List for function descriptions or general list

1.2 Introduction

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.

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 2 models with outputs of 23 kW and 31 kW for domestic hot water and a pro version with an output of 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.

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). The ecoTEC system boiler consists of models with outputs of 12, 15, 18, 24 and 30 kW. All ecoTEC system boilers are available in Natural Gas. The ecoTEC plus 618 and 630 are also available in LPG.

1.3 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.

4 Instructions for installation and servicing ecoTEC

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Introduction 1

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 damaged in the event of improper use. 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 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.

Danger!

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.

1.4 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

1.5 Gas council numbers

Applaince Gas council numbers

ecoTEC pro 28 47-044-30 ecoTEC plus 824 47-044-31 ecoTEC plus 831 47-044-32 ecoTEC plus 612 41-044-44 ecoTEC plus 615 41-044-45 ecoTEC plus 618 41-044-46 ecoTEC plus 624 41-044-47 ecoTEC plus 630 41-044-48

Table 1.1 Gas council numbers

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.

5Instructions for installation and servicing ecoTEC

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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 28.0 kW Maximum output for heating 19 24 24 kW Minimum output 6.7 8.7 9.0 kW Category II SEDBUK Band 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 (∆T=20 K) 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 ∆T=35 K rise Appr. DHW flow rate at factory set temp. rise (∆T=42 K) Permitted DHW overpressure 10 bar Required DHW connecting pressure 0.35 bar Hot water discharge temperature range 35 – 65 °C Exhaust flue 60/100 mm 10 l expansion vessel pre-charge pressure 0.75 bar Connections heating flow/return 22 mm Gas inlet 15 mm Pressure relief discharge pipework (min.) 15 mm Condensate drain (min. internal drain) 19 mm Weight (boiler only) 35 38 37 kg Primary water content 1.9 2.3 2.1 l Electrical supply voltage 230/50 V ~/Hz Internal fuse (slow) main voltage 2 A Power input 110 125 115 W

Table 2.1 Technical data ecoTEC combination boiler

6.7 – 19.0

6.9 – 19.6

7.1 – 20.2

7.2 – 20.6

G20: 2.5 G31: 1.82

ecoTEC plus

824 831

8.7 – 24.0

9.0 – 24.7

9.2 – 25.5

9.4 – 26.0

2H3P

G20: 3.3

G31: 2.46

3.2

10.7

817 1032 1032 l/h

1.8 2.2 2.2 l/h

9.4 12.7 11.5 l/min

7.9 10.6 9.6 l/min

4.2

14.4

30 – 85 °C

ecoTEC pro

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

Units

kW kW kW kW

m kg/h

g/s g/s

°C °C

6 Instructions for installation and servicing ecoTEC

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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 AAAAABand SAP Seasonal Efficiency 91.2 % 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

Circulating water volume (∆T=20 K) Approx. condensation volume

at 50 °C flow/30 °C return heating Pump delivery height 250 mbar Adjustable storage target value (15 °C at left stop,

spare adjusting range 40 – 70 °C Exhaust flue 60/100 mm 10 l expansion vessel pre-charge pressure 0.75 bar Connections heating flow/return 22 mm Gas inlet 15 mm Pressure relief discharge pipework (min.) 15 mm Condensate drain (min. internal drain) 19 mm Weight (boiler only) 35 35 35 37 38 kg Primary water content 1.9 1.9 1.9 2.1 2.3 l Electrical supply voltage 230/50 V ~/Hz Internal fuse (slow) main voltage 2 A Power input 100 110 100 110 110 W

Table 2.2 Technical data ecoTEC system boiler

612 615 618 624 630

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

516 645 774 1032 1290 l/h

1.1 1.4 1.7 2.2 2.7 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

ecoTEC plus

6.7 – 18.0

6.9 – 18.6

7.1 – 19.1

7.2 – 19.5

2H3P

G20: 1.9

G31: 1.43

3.2

8.3

30 – 85 °C

15 – 70 °C

8.7 – 24.0

9.0 – 24.7

9.2 – 25.5

9.4 – 26.0

G20: 2.6 G31: 1.90

4.2

11.2

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 80

Units

kW kW kW kW

m kg/h

g/s g/s

°C °C

7Instructions for installation and servicing ecoTEC

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2 Boiler specifications

2.2 Dimensions

440

190

241

883

720

642

Fig. 2.1 Dimensions in mm

175

35 35

125

5 4 3 2

130

100100

180

300

12345

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 Flue pipe connection 10 Spacer frame accessory (Art. No.: 308 650)

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

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2.4 Installation

Boiler specifications 2

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 Pressure sensor 11 Hot water heat exchanger 12 Gas valve 13 Heat exchanger 14 Flue pipe connection

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 10 Pressure sensor 12 Gas valve 13 Heat exchanger 14 Flue pipe connection

2.5 Type plate

The type plate of the Valliant ecoTEC is attached to the bottom of the appliance at the factory.

9Instructions for installation and servicing ecoTEC

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3 General requirements

3.1 Preliminary remarks

This appliance shall only be installed in conjunction 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

ecoTEC appliances satisfy the Gas Appliance (Safety) Regulations 1992 and the Boiler (Efficiency) Regulations

1993.

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), BS 7671 (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, including amendments to the Approved Documents Part L and J 2002, The Building Regulations (Scotland). The Building Regulations (Northern Ireland) and the relevant recommendations of the following British Standards and regulations: BS 5440: Flues and ventilation of gas fired boilers not

exceeding 70 kW net: – Part 1: Flues – Part 2: Ventilation

BS 5449: Specification for forced circulation hot water

for domestic premises.

BS 5546: Specification for gas hot water supplies for

domestic premises.

BS 6700: Services supplying water for domestic use

within buildings and their curtilages.

BS 6798: Specification for installation of gas fired boil-

ers 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 cen-

tral heating systems.

Institute of Gas Engineers Publication IGE/UP/7/1998:

“Guide for gas installations in timber framed housing”

European installation directive

Important:

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).

Important:

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.

10 Instructions for installation and servicing ecoTEC

Page 11

General requirements 3

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

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

tank and ventilation (above Fig.)

Fig. 3.2 Contents included with delivery of ecoTEC plus combi-

nation 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 com-

bination boilers

Connecting pipes (gas, heating, water, safety valve)

User, installation and service and flue installation manuals

For LPG appliances, extra: 1 sticker each for

tank and ventilation (above Fig.)

11Instructions for installation and servicing ecoTEC

Page 12

3 General requirements

r a b

Fig. 3.3 Contents included with delivery of ecoTEC pro combi-

nation boilers

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 71

8 2 Installation and connection accessories

Table 3.3 Contents included with delivery of ecoTEC pro combi-

nation boilers

Connecting pipes (hot water, heating safety valve)

User, installation and service and flue installation manuals

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.

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.

12 Instructions for installation and servicing ecoTEC

Page 13

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 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.

General requirements 3

550

1435

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

754

880

Fig. 3.5 Art. No. 303 900

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

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.

Fig. 3.6 Art. No. 303 209

650

1530

880

Fig. 3.7 Art. No. 303 200

13Instructions for installation and servicing ecoTEC

Page 14

3 General requirements

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).

A G

H, I

Fig. 3.8 Flue termination

BCD

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. 3.9.

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.

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.

Terminal position mm

Directly below an opening, above an opening or hori-

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)

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

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.

14 Instructions for installation and servicing ecoTEC

Page 15

General requirements 3

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.

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.

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).

3.10.3 Pressure relief valve

A pressure relief valve is provided with the boiler. This safety device is required on all sealed C.H. systems and is preset at 3 bar and provided with a 15 mm compression connection for a discharge pipe, which 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.

3.10.5 Expansion vessel

ecoTEC boilers incorporate a 10 litre expansion vessel 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 3.5.

Important:

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.

15Instructions for installation and servicing ecoTEC

Page 16

3 General requirements 4 Boiler installation sequence

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 3.5 Sizing of additional expansion vessel

0.109 0.156

3.11 Pump specifications

]

400

mbar

[

300

Lift

200

100

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 5.8.

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.

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. 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

0 200 400 600 800 1000 1200 1600

Fig. 3.10 Pump specifications ecoTEC plus

2. Step1. Step

1400

Volumeflow [l/h

1800

]

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.

4 Boiler installation sequence

4.1 Required minimum distances/assembly clearances

min

165/246*

min 5

Fig. 4.1 Distances during installation (dimensions in mm)

min 5

min 180

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:

min 500**

16 Instructions for installation and servicing ecoTEC

Page 17

– 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 fitted in a timber framed building, it should be fitted in accordance with British Gas publication DM2 ‘Guide for gas installations in timber framed housing’.

4.1.1 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.

Boiler installation sequence 4

165

60/100

1065

175

4.1.2 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

4.1.3 Using boiler template

• 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 8 mm for the hanging bracket.

Note

Use alternative fixing holes where necessary.

180

Fig. 4.2 Assembly template

45°

256723_01 01 2005

450

17Instructions for installation and servicing ecoTEC

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4 Boiler installation sequence

4.2 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.

4.3 Fitting the boiler hanging bracket

Note

Lift the boiler from either side at the bottom edge

• Lower the boiler slowly onto the hanging bracket so that the cross member at the rear of the boiler fully engages onto the hanging bracket.

4.6 Removing the front case

Fig. 4.3 Appliance with hanging bracket

• Fix the hanging bracket to the wall using the plugs and screws provided with the appliance.

Note

Use alternative fixing holes where necessary.

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.

4.4 Installing the flue system

• Install the flue system (refer to the seperate air/flue duct installation instructions).

Fig. 4.4 Removing/fixing the front case

To remove the front section of the case, proceed as follows:

• Loosen the screw (1) on the bottom of the unit.

• Push in the two retaining clips (2) on the bottom of

the appliance until the case is released.

• Grasp the front case by its bottom edge, pull it towards the front and remove it by lifting it off the unit.

4.7 General instructions for heating system

Caution!

Thoroughly cleanse the heating system before connecting the appliance! By doing that, residue such as welds, cinder, hemp, putty, rust, rough dust and similar substances are removed from the pipes. Otherwise such substances can be deposited in the appliance and cause damage.

4.5 Fitting the boiler

• Lift the boiler (3) up to the wall so that it is slightly above the hanging bracket (1).

- The appliance is fitted with an expansion vessel (10 l/

0.75 bar). Before assembling the appliance check if this volume is adequate. If not, an extra expansion vessel must be installed, see Section 3.10.5.

18 Instructions for installation and servicing ecoTEC

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Boiler installation sequence 4

4.8 Gas connection

Note

With the spacer frame (Art. No 308 650), the pipes can be fitted vertically upwards behind the appliance. The distance of the appliance from the wall thus increases by 65 mm.

Danger!

The gas connection may only be made by a competent person. The legal directives and the local regulations for gas supply companies must be observed.

Caution!

Ensure a stress-relief assembly of the gas pipes to avoid leakages!

Caution!

The gas regulating block may be tested for leakage only with a maximum pressure of 150 mbar! Higher testing pressures can damage the gas fitting.

Caution!

When making final connection to the boiler, if using soldered fittings, extra care should be taken to avoid damage to isolation valves through heat transfer.

• Fit the union nut (6) and the compression olive (5) to

the pre-formed tail provided with ecoTEC plus appliances (7).

• Fully insert the service valve (4) onto the gas connec-

tion pipe and the pre-formed tail into the service valve. Tighten both union nuts of the service valve.

• The diameter of the pipework (7) is 15 mm. Connect a

gas supply pipe of not less than 15 mm diameter to the copper tail.

Note

Ensure the gas supply pipework is adequately sized so that a 20 mbar gas pressure is available at the boiler inlet at full flow rate.

• Tighten all connections.

• Check the gas connection with leak indicator spray for leakage.

4.9 Cold water mains inlet and hot water outlet

(ecoTEC combination boilers only)

Caution!

When making final connection to the boiler, if using soldered fittings, extra care should be taken to avoid damage to isolation valves through heat transfer.

Fig. 4.5 Fitting the gas connection (example ecoTEC plus com-

bination boiler)

• Fit the union nut (2) and the compression olive (3) to the gas connection pipe (1) of the boiler.

Fig. 4.6 Installing the hot and cold water connection (ecoTEC

plus combination boiler)

19Instructions for installation and servicing ecoTEC

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4 Boiler installation sequence

4.10 Condensate drain pipe

Fig. 4.7 Installing the hot and cold water connection (ecoTEC

pro combination boiler)

Note

Flush all foreign matter from the mains supply before connecting to the boiler.

• Insert the seal (1) and connect the service valve (2) to the appliance cold water connection.

• Fit the union nut (4) and the compression olive (3) to the pre-formed tail provided with ecoTEC plus appliances (5). The diameter of the pipe is 15 mm.

• Fully insert the pre-formed tail into the service valve. Tighten the union nuts.

• Insert the seal (7) and connect in the pipe (6) to the appliance hot water connection. The diameter of the pipe is 15 mm.

• Mount the handle for the filling loop with a countersunk screw to the service valve (2).

Internal stackpipe

Fig. 4.8 Installing the condensate drain pipe (picture shows

ecoTEC plus combination boiler)

Internal discharge system

Gulley

Soakaway

The ecoTEC plus appliances are fitted with a siphonic trap. The siphon collects the accumulated condensate in a container of approx. 200 ml capacity and directs the entire content into the drain pipe. The risk of the condensate drain pipe freezing is thus minimised. The ecoTEC pro appliances are equipped with a normal condensing water trap where the condensate is constantly emptied into the drain pipe.

• Connect the boiler condensate drain (1) to a condensate discharge pipe (2) which should be minimum of 19 mm internal diameter (22 mm external diameter for any pipework installed external to the property) and be made of an acid resistant material (e.g. plastic overflow pipe).

Note

The discharge pipe from the boiler condensate drain must have a continuous fall (45 mm per meter) and preferably be installed and terminated within the building to prevent possible freezing.

The condensate discharge pipe must terminate in a suitable position, e.g.: a) preferably the discharge pipe should run and termi-

nate internally to the house soil and vent stack (at least 450 mm above the invert of the stack). A trap giving a water seal of at least 75 mm (3) should be incorporated into the pipe run, and there must be an air break (4) in the discharge pipe upstream of the trap. This should be designed so that the condensate cannot be discharged into the house if the condensate pipe becomes blocked.

b) connecting into the internal discharge branch (e.g. sink

waste or washing machine) with an external termination, the condensate discharge pipe should have a

20 Instructions for installation and servicing ecoTEC

Page 21

Boiler installation sequence 4

minimum diameter of 22 mm with no length restriction and should incorporate a trap with a 75 mm (3) seal. The connection should preferably be made down stream of the sink waste trap. If the connection is only possible upstream, then an air break is needed between the two traps. This is normally provided by the sink waste.

c) terminating in a gully (5) below grid level (6) and

above the water level. The external pipe length should be kept as short as possible to minimise the risk of freezing and should not be more than 3 m.

d)at a condensate absorption point (soakaway) (7). The

external pipe length should not be more than 3 m.

Refer to ‘BS 6798 Specification for installation of gas– fired boilers of rated input not exceeding 70 kW net’ for further information. Before operating the boiler the condensate trap (1) must be filled with water as described in relevant section.

4.11 Heating connection

Caution!

When making final connection to the boiler, if using soldered fittings, extra care should be taken to avoid damage to isolation valves through heat transfer.

• Insert the seal (1) and fit the service valve (2) to the return connection of the appliance.

• Insert the seal (10) and fit the service valve (9) to the flow connection of the appliance.

• Install the O-ring seal (12) on the return valve (11).

Note

Lay the filling loop hose (13) above the pipework elbows.

• Fit the union nuts (4) and (7) as well as the compression olives (3) and (8) to the pipe elbows (5) and (6). The diameter of the pipes is 22 mm.

• Fully insert the pipe elbows into the service valves. Tighten the union nuts in this position.

• Mount the handle for the filling loop with a countersunk screw to the service valve (9).

ecoTEC pro combination boiler

4.11.1 Heating flow and return connection

Note

Before connecting the heating circuit to the boiler, all pipework and radiators must be thoroughly flushed to remove any installation debris.

ecoTEC plus combination boiler

12 11

Fig. 4.10 Heating flow and return connection for ecoTEC pro

combination boiler

• Insert a seal (1) and fit the service valves (2) to the flow and return connection of the appliance.

• Fit a union nut (4) and a compression olive (3) to the two pipe elbows (5) with a diameter of 22 mm.

• Fully insert the pipe elbows into the service valves. Tighten the union nuts in this position.

Fig. 4.9 Installing the heating flow and return connection for

ecoTEC plus combination boiler

21Instructions for installation and servicing ecoTEC

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4 Boiler installation sequence

ecoTEC plus system boiler

Fig. 4.11 Heating-side flow and return connection for ecoTEC

plus system boiler

• Insert a seal (1) and fit the service valves (2) to the

flow and return connection of the appliance.

• Fit a union nut (4) and a compression olive (3) to both pipe elbows (5). The diameter of the pipes is 22 mm.

• Fully insert the pipe elbows into the service valves. Tighten the union nuts in this position.

4.11.2 Pressure Relief Valve

Caution!

To ensure fumes do not escape through the syphon of the boiler the trap must be filled with water before the boiler is turned on. Therefore the discharge pipework should be installed so as not to interfere with the removal and refitting of the condensate trap, we recommend the outlet pressure release valve pipe supplied is not shortened. You must leave a bottom clearance of at least 180 mm below the condensate trap for removal and refitting.

The pressure release valve for the heating system is integrated in the appliance.

• Position the seal (1) and screw the drain pipe (2) on to

the pressure release valve.

The discharge pipework should be as short as possible and installed with a continuous fall away from the boiler. The pipe should terminate in a position which ensures that any discharge of water or steam from the valve cannot create a hazard to persons in or around the premises, or cause damage to any electrical components or external wiring, and the point of discharge should be clearly visible.

4.12 Connecting the flue system to the boiler

• Refer to separate air/flue duct installation instructions included with the boiler.

4.13 Electrical connection

min.

180

Fig. 4.12 Installing the drain pipe on the pressure release valve

of the heating system (picture shows ecoTEC plus combination boiler)

1 2

4.13.1 General requirements

Danger!

Electrocution caused by touching live parts can be fatal. Before working on the appliance, turn off the power supply and secure against restart.

All electrical work shall be carried out by a competent person and shall comply with BS 7671 (IEE Regulations). In IE, reference should be made to the current edition of the ETCI rules. The boiler is supplied for connection to 230 V, ~ 50 Hz supply fused at 3 A rating. Connection to the mains supply shall be made via a fused 3 pin plug to an unswitched shuttered socket, both complying with the requirements of BS 1363. (Alternatively, connection may be made via a 3 A fused double pole isolator having a contact separation of at least 3 mm in all poles and supplying the boiler and controls only). The point of connection to the mains supply must allow complete electrical isolation of the boiler and its ancillary controls. It should be readily accessible and adjacent to the boiler. A 3 core flexible cord according to BS 6500 tables 6, 8 or 16 (3 x 0.75 to 3 x 1.5 mm

)

should be used.

22 Instructions for installation and servicing ecoTEC

Page 23

-+789 LN 345

Boiler installation sequence 4

Danger!

This appliance must be earthed.

Danger!

Mains connection terminals L and N remain live even when the boiler on/off control is switched off.

Note

Do not connect any power voltage to the connections 7-8-9 or BUS (+,-).

Note

Ensure that all cords pass through the cable clamps in the rear of the control box and are securely fixed. Ensure that the power supply is connected such that the current carrying conductors become taut before the earth conductor should the supply cord slip from the cable clamp.

4.13.2 Connection to the main supply

• Remove the front case and lower the control panel.

• Feed the power supply flex into the appliance and the control panel through the cable clamps provided and tighten.

-+789 LN 345

Fig. 4.14 Wiring system

• Connect the flex to the L, N and earth plug to the terminal block.

Green/yellow (earth) wire – boiler terminal Earth sign Blue (neutral) wire – boiler terminal N Brown (live) wire – boiler terminal L

Note

Do not connect any power voltage to the connections 7-8-9 or BUS (+,-).

Note

Ensure that the wires are securely fixed in the terminal block.

• Refit the terminal box cover by pushing into place until it clips back into position.

• Raise the control panel.

Fig. 4.13 Opening the electronics box

• Unclip the bottom of the terminal box cover and hinge back to reveal the connection plugs.

23Instructions for installation and servicing ecoTEC

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4 Boiler installation sequence

4.13.3 Electric board layout

eBUS accessory connection

Burner cable harness

Accessory module connection

Diagnosis via eBUS, vrnetDIALOG

outer probe ext. flow or return probe

Hydraulic cable harness Connection for external

eBUS controller

Room thermostat 24 V: Connection 7, 8 and 9 No bi-directional interface (analogue only)

Mains supply: 23o V/50 Hz

Room thermostat 230 V/50 Hz (remove bridge on connection)

Heating pump With ecoTEC pro: 1-step pump (plug with 3-pin) With ecoTEC plus: 2-step pump (plug with 5-pin)

2A fuse, slow

Caution: Do not connect supply voltage! Risk of damage to electronics!

Igniter

Connection: 230 V Supply for accessory module

Fig. 4.15 Connection wiring ecoTEC

24 Instructions for installation and servicing ecoTEC

Page 25

Boiler installation sequence 4

NTC flow

X 20/5 red

X 20/7 black

X 20/8 blue

X 20/7 black

Gas valve assembly

X 2/9 black

X 2/11 red

X 2/12 green

NTC return

Ignition electrode

Thermal fuse

X 20/18 red (24 VDC)

X 20/9 blue (earth)

Water pressure sensor

Aqua sensor

X 20/13 black X 20/12 black

Fan unit

Plug in coupling

X 20/16 blue (earth)

X 20/4 grey (PWM)

X 20/3 black (Hall signal)

X 20/17 red (24 VDC)

X 2/16 black A

X 2/7 blue B

X 2/15 brown C

X 2/8 pink D

Diverter valve

Pump

X 2/3 red (+ 5V)

X 2/2 black (earth)

X 2/6 green (signal)

X40

X 20

X31

Electronic control box

X 2

X41

— +

BUS

X 2/4 orange

X 2/10 black

X 2/5 violet (signal)

X 2/1 black

7 8 9

24V

L N 3 4 5

230V

NTC Plate heat exchanger

NTC Hot water outlet

X12

Fig. 4.16 Connection wiring ecoTEC combination boiler

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4 Boiler installation sequence

NTC flow

X 20/5 red

X 20/7 black

X 20/8 blue

X 20/7 black

Gas valve assembly

X 2/10 black

X 2/14 brown

NTC return

Hot water contact C1/C2

Ignition electrode

Thermal fuse

X 20/18 red (24 VDC)

X 20/9 blue (earth)

X 20/13 black X 20/12 black

Fan unit

Plug in coupling

X 20/16 blue (earth)

X 20/4 grey (PWM)

X 20/3 black (Hall signal)

X 20/17 red (24 VDC)

X 2/9 black

X 2/11 red

X 2/12 green

X 20

X31

Water pressure sensor

X40

X 2

X41

7 8 9— +

BUS 24V

X 2/4 orange

X 2/10 black

L N 3 4 5

230V

Pump

tank NTC connection

X12

Electronic control box

Fig. 4.17 Connection wiring ecoTEC system boiler

26 Instructions for installation and servicing ecoTEC

Page 27

Boiler installation sequence 4

4.14 Controls

4.14.1 Vaillant controls and accessories

Controller Item no. Connection

VRC 400 (1-circuit controller, weather-controlled) 00 2001 0843 Installation in electronics box (plug-and-play) VRT 360 (room temperature controller) 00 2001 0842 Wall-mounted, 2-wire bus VRT 230 (room temperature controller) 00 2001 0841 Wall-mounted, 3-wire connection to terminals 7-8-9 timeSWITCH 140 (timer) 306 760 Installation in electronics box (plug-and-play) timeSWITCH 130 (timer) 306 759 Installation in electronics box (plug-and-play) VRT 30 (room thermostat) 300 637 Wall-mounted, 3-wire connection to terminals 3-4-5

Telecommunication Item no. Connection

vrnetDIALOG 830 (Int) 00 2000 3988 GSM/GPRS, installation in electronics box (plug-and-play) vrnetDIALOG 860/2 (Int) 00 2000 3984 Wall-mounted, GSM/GPRS, up to 16 appliances

Accessories Item no. Connection

VR 65 control centre for UK cylinder installation (eBUS) 307 215 System solution for UK cylinder connection vrDIALOG 810 306 743 Diagnostic software

Table 4.1 Vaillant controls and accessories

4.14.2 External electrical controls

The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. Terminals 3 and 4 are linked together when the boiler is supplied. If external controls are used, this link must be removed, and the controls connected across terminals 3 and 4. Terminal 5 is an additional neutral connection for external neutrals such as from the anticipator of a room thermostat.

4.14.3 Connection details for external time switches

and boiler terminal strip

20 VDC (DO NOT USE 7, 8, 9 IN UK!)

987

N L

3 A FUSE

MAINS SUPPLY 230 V

50 Hz

SWITCH CONTACTS

CLOCK

ROOM THERMOSTAT

4.14.4 Vaillant optional plug in timer accessories

Refer to the instructions supplied with the optional accessories for connection details. Upon completion of all electrical connections refit the terminal box cover by pushing into place. The cover is secured by two locking clips.

4.14.5 Connection details using the VR 65 Control Center

The Control Center VR 65 is an eBUS system component. In a storage unit installation, it is responsible for the communication between the storage unit, the ecoTEC plus system boilers and external 2- or 3-way-valves. Connect the VR 65 Controll Center as described in the enclosed manual.

4.15 Thermostatic radiator valves

The boiler has a built in automatic by-pass valve making it ideal for use in systems with thermostatic radiator valves (no separate system by-pass is required). For optimum fuel economy where TRV’s are used they must be used in conjunction with a boiler control interlock. A programmable room thermostat or separate timer and room thermostat will ensure complete boiler shut down when the heating demand is satisfied. (The radiator in the room containing the room thermostat should not be fitted with a TRV).

Fig. 4.18 Connection details for time switches

If a room thermostat is to be connected in addition to a time switch the wire between the time switch “ON” terminal and boiler terminal 4 should be broken by the contacts of the room thermostat (see schematic layout, Fig.

4.18).

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4 Boiler installation sequence 5 Commissioning Part I

4.16 Frost protection

The boiler has an integral frost thermostat which is designed for protection of the boiler. To protect remote or exposed parts of the heating system or property additional frost protection measures must be taken such as the installation of an external frost thermostat. This frost thermostat should be connected across the boiler terminals 3 and 4, in parallel with any external heating controls.

Note

External frost protection cannot be used when plug in timers are utilised.

4.17 Circulating pump

The boiler incorporates a built in circulating pump that is fully prewired (no additional wiring is necessary). The pump incorporates an automatic overrun period after the boiler switches off.

4.18 Anticycling ‘economiser’ control

The boiler incorporates a built in anticycling control to ensure that energy wasteful short cycling of the boiler cannot occur. This control prevents the boiler from reigniting for a preset period after central heating operation (the hot water operation is unaffected by this control and hot water can be drawn at any time).

Note

To temporarily override the anticycling control turn the main boiler on/off switch to the off position “0” and then back to the on position “I” after a few seconds.

4.19 Automatic pump spin control (APS)

The boiler incorporates a built in control which will spin the built in circulating pump and operate the diverter valve (ecoTEC combination boilers only) once in a 23 hour period. This control helps to prevent seizure when the boiler is not operated for a period of time. This control is not active when the power supply to the appliance is turned off.

5 Commissioning Part I

5.1 Preliminary electrical checks

Check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity.

5.2 Gas supply

The complete gas installation including the gas meter must be inspected, checked for leaks and purged in accordance with BS 6891. In IE the current edition of IS

813. The gas supply to the boiler can be purged by slack-

ening the gas service valve beneath the boiler. Ensure that there is adequate ventilation, extinguish all naked flames and do not smoke whilst purging. After purging, the gas service valve connection must be retightened and checked for leaks. (The boiler itself does not require purging as this will be done by the automatic burner sequence control).

5.3 Cold water supply (ecoTEC combination boilers only)

Open all domestic hot water taps supplied by the boiler, turn on the mains water supply to the boiler and open the mains water isolating valve below the boiler. Water will now flow through the boiler to the hot taps. Starting with the lowest tap supplied, turn the hot taps off one at a time until the hot water pipework is purged of air. Check all hot and cold water pipework for leaks.

5.4 Filling the heating system

Note

The P.6 test program is for filling the heating system: The diverter valve (combination boilers only) moves to the centre position, the pump does not run and the appliance does not go into heating mode. Use the test program as described in Section 8.4. The P.0 test program is for bleeding the hot water circuit (as well as the DHW circuit on combination boilers): The appliance does not go into heating mode; the pump runs inttermittently and bleeds the two circuits in succession. Use the test program as described in Section

8.4.

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5.4.1 Checking the filling pressure of the heating system

plus pro

iFP

Commissioning Part I 5

bar

Fig. 5.1 Checking the filling pressure of the heating system

Note

The ecoTEC appliances come with a manometer and a digital pressure indicator. The manometer allows you to quickly check whether the filling pressure is in target range or not even when the appliance is turned off. If the appliance is in operation, you can display the exact pressure by pressing the “-” (2).

For the heating system to operate properly, the indicator on the manometer (1) must be in the dark grey area when the system is cold. This corresponds to a filling pressure between 1.0 and 2.0 bar. If the pointer is in the light grey area, please refill water.

If the heating system extends over several storeys, the system may require a higher filling pressure.

Fig. 5.2 Filling device ecoTEC plus combination boiler

• Insert the double check valve (1) of the filling pipe at

the cold water shutoff valve and secure the double check valve with the spring clip (2).

• To fill, first open the stop valve (3).

• Open the stop valve (4), so that water flows into the

heating system. Fill the heating system as described in Section 5.4.4.

• Close both stop valves after filling and detach the filling device by pulling the double check valve from the cold water stop valve.

Note

Both stop valves must be closed while operating the heating system and the filling pipe must be again detached at the double check valve.

5.4.2 ecoTEC plus combination boiler filling loop

The ecoTEC plus combination boiler will be delivered with a filling loop.

Fig. 5.3 Double check valve detached while heating

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5 Commissioning Part I

5.4.3 Filling the heating system in ecoTEC pro combination boilers and ecoTEC plus system boilers

The ecoTEC pro combination boilers and the ecoTEC plus system boilers do not come with a filling device. In these appliances, water is filled in the heating system through a filling pipe provided onsite.

• Join a hose between a cold water dispensing valve and

the filling pipe of the heating system.

• To fill, first open the cold water dispensing valve.

• Open the stop valve on the filling pipe, so that water

flows into the heating system. Fill the heating system as described in Section 5.4.4.

• After filling, close the stop valve on the filling pipe and

the cold water dispensing valve and remove the filling hose.

5.4.4 Filling the heating system for the first time

Note

As long as there is insufficient water pressure in the heating system, the display indicator changes between the error message F.22 and the actual pressure indicator when the appliance is on.

• Connect a hose to the drain valve located at the lowest position of the heating system.

• Open the 1/2” BSP drain taps and all vent valves on the heating elements and allow the water to flow out of the heating system and the boiler quickly and completely to remove all installation residue from the heating system before commissioning the boiler.

• Close the 1/2” BSP drain taps.

• Fill the heating system again with water as described in Section 5.4.4.

• Check that the pressure relief valve of the heating system is working by turning the handle on the valve.

• Check the pressure in the heating system and fill water if needed.

• Close the filling valve and the cold water dispensing valve.

5.6 Filling the condensate siphon

Fill the heating system as follows:

• Open all heating element thermostat valves.

• Check if both stop valves on the heater are open.

• Only in ecoTEC plus combination boilers: Connect the filling pipe as described in Section 5.4.2.

• Only in ecoTEC plus system boilers and in ecoTEC pro combination boilers: As described in Section 5.4.3 join a hose between the cold water dispensing valve and the filling pipe of the heating system.

• Open the cold water dispensing valve.

• Slowly open the filling valve and let the water flow into the heating system. Bleed the lowest radiator until the water flows out at the bleed valve without bubbles.

• Bleed all other radiators until the heating system is completely filled with water, all bleed valves have been shut and the manometer pointer is in the centre of the dark grey area. Bleed the heating pump by loosening the central screw. Close the filling valve and the cold water dispensing valve.

• Loosen the cap of the pump A.A.V. (automatic air vent) (the appliance is ventilated independently by the pump A.A.V. during continuous operation).

• Check all connections and the entire system for leaks.

5.5 Initial system flush (“cold”)

Note

The complete heating system must be flushed out at least twice: once cold, and once hot as instructed below.

Fig. 5.4 Filling the condensate siphon

Danger!

Note that if the boiler is run with an empty condensate trap there is a danger that fumes might escape into the room and cause poisoning. For this reason, it is important to ensure that the trap is topped up each time the unit is cleaned.

• Remove the lower part (1) of the condensate siphon by

turning the bayonet catch in anticlockwise direction.

• Fill the lower part with water until about 10 mm below the upper edge.

• Refit the lower part of the condensate siphon.

• Check if all radiator thermostatic valves and both service valves on the boiler are open.

30 Instructions for installation and servicing ecoTEC

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Commissioning Part I 5

5.7 Adjusting the pumping capacity

Only in ecoTEC plus boilers:

The capacity of the two-stage pump can be adjusted to the requirements of the heating system. If needed, change the setting of the operating mode dependent pump speed under the diagnostic number “d.19” (see Section 8.1.2).

5.8 Adjusting the by-pass

The appliances have an adjustable by-pass valve. The pressure can be adjusted between 170 and 350 mbar. Approx. 250 mbar is preset (mid-position). The pressure changes by approx. 10 mbar each time the adjusting screw is rotated. By turning right, the pressure increases and turning left decreases it.

5.9 Checking the gas supply

5.9.1 Factory settings

Caution!

Before operating the boiler check the data badge and ensure that the correct gas type appliance has been installed.

The boiler is supplied ready adjusted and no further gas adjustments are necessary, however both the gas inlet working pressures and maximum gas rates should be checked as detailed in 5.9.2 and 5.9.3.

5.9.2 Gas inlet working pressure

Check the inlet pressure as described below:

• Remove the front case from the boiler.

• Close the gas shutoff valve fitted to the boiler.

Fig. 5.11 Adjusting the by-pass valve (in combination boilers)

Fig. 5.12 Adjusting the by-pass valve (in system boilers)

• Regulating the by-pass on the adjusting screw (1).

Fig. 5.13 Checking the gas supply pressure

• Loosen the sealing screw marked “in” (1) on the gas

valve assembly.

• Connect a digital or a U gauge (2).

• Open the gas shutoff valve fitted to the boiler.

• Put the boiler into operation (refer to the Instructions for Use supplied with the boiler).

• Check the U gauge reading and ensure the inlet gas pressure is between the pressures detailed below.

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5 Commissioning Part I

Natural gas:

DO NOT proceed with adjustment or attempt to put the unit into service if the inlet working pressure lies outside the 17–25 mbar range.

LPG:

DO NOT proceed with adjustment or attempt to put the unit into service if the inlet working pressure is lower than 37 mbar.

• Turn off the appliance, remove U gauge.

• Tighten the test point screw and check for leaks.

• Record appliance working gas inlet pressure (mbar) in the Benchmark gas boiler commissioning checklist.

5.9.3 Checking the gas rate

The boiler is fitted with a fully modulating automatic gas valve which ensures that the precise air/gas ratio is provided under all operating conditions. The gas rate has been set during production and does not require adjustment. The gas rate of the boiler should be checked with the front case fitted as follows:

• Activate full gas rate mode by simultaneously pressing the “+” and “–” buttons on the display system (for ecoTEC combination boilers fully open the hot water tap to maximum water flow rate).

• Wait at least 5 minutes, or until the boiler has reached its operating temperature.

• With all other gas appliances turned off measure the gas rate at the gas meter. Check that the gas rate is as stated in Table 5.1.

Appliance

ecoTEC plus 612 12.2 1.3 0.95 ecoTEC plus 615 15.3 1.6 1.19 ecoTEC plus 618 18.4 1.9 1.43 ecoTEC plus 624 24.5 2.6 1.90 ecoTEC plus 630 30.6 3.2 2.38 ecoTEC plus 824 23.5 2.5 1.82 ecoTEC plus 831 31.6 3.3 2.46 ecoTEC pro 28 28.6 3.0 2.22

Table 5.1 Nominal gas rates

Maximum

net heat

input in kW

Nominal gas rate (Tolerance ±5 %)

Natural gas

in m3/h

Propane

in kg/h

Caution!

If the measured gas flow volume lies outside the tolerance limits specified in Table 5.1, do not operate the appliance and inform the Vaillant Customer Service.

5.10 Refitting the case

Fig. 5.14 Refitting the case

• Hook the top of the front casing over the lip on the top of the boiler chassis and push the bottom of the front casing into place.

• Ensure the spring retaining clips (2) engage correctly.

• Tighten case securing screw (1).

5.11 Adjusting the central heating output (range

rating)

The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the boiler, as follows:

• Press the “i” and “+” buttons simultaneously.

• Keep the “+” button pressed until “d.0” is displayed.

Note

The display runs from “d.0” to “d.99” before restarting at “d.0”.

• Press the “i” button. The “=” symbol is displayed. The part load setting is now displayed in kW.

• Use the “+” and “–” buttons to increase or decrease the value in steps of 1 kW. The displayed value will flash while the adjustment procedure is being carried out. The available ranges of settings are given in Table

5.2.

• Push the “i” button for about five seconds, or until the display stops flashing. The value is now saved to memory. The display will now return to its normal state (current heating system flow temperature, e.g. 45 °C).

32 Instructions for installation and servicing ecoTEC

Page 33

• Press the “i” and “+” buttons simultaneously to cancel

adjustment mode. Adjustment mode is also cancelled if no button is operated for a period of 4 minutes.

Appliance Heating output in kW

ecoTEC plus 612 5 – 12 ecoTEC plus 615 5 – 15 ecoTEC plus 618 7 – 18 ecoTEC plus 624 9 – 24 ecoTEC plus 630 10 – 30 ecoTEC plus 824 7 – 19 ecoTEC plus 831 9 – 24 ecoTEC pro 28 9 – 24

Table 5.2 Heating system part load adjustment ranges

5.12 Gas changeover

Note

To reset the appliance from natural gas to LPG mode, you need the Vaillant conversion kit Art. No. 00 2001 0641. To reset the appliance from LPG to natural gas mode, you need the Vaillant conversion kit Art. No. 00 2001 0642. Convert the appliance as described in the conversion kit.

6 Functional checks (commissioning

part II)

Commissioning Part I 5

Commissioning Part II 6

Fig. 6.1 Function check

6.1.2 Heating

• Switch on the appliance.

• Make sure that there is a heating demand.

• Press “i” to activate the status indicator.

As soon as a heat demand is received, the appliance runs through the status indicators “S. 1” to “S. 3”, until the appliance is running correctly in normal mode and the display shows “S. 4”.

6.1 Functional checks

6.1.1 Procedure

After installing and checking the gas supply pressure, perform a function check before commissioning the appliance and handing over to the user.

• Commission the appliance according to the relevant operating manual.

• Check the gas supply pipe, exhaust system, heating system and the hot water lines (combination boilers only) for leaks.

• Check that the flue system has been installed properly according to the flue system assembly manual.

• Check for ignition and an even flame on the burner.

• Perform a function check on the heating system (see Section 6.1.2) and the water heating (combination boilers only, see Section 6.1.3).

• Hand over the appliance to the user (see Section 6.2).

plus pro

Fig. 6.2 Display indicator during heating mode

6.1.3 Water heating (combination boilers only)

• Switch on the appliance.

• Fully open the hot water tap.

• Press “i” to activate the status indicator. If the water heating is working correctly, the display shows the following: “S.14”.

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6 Commissioning Part II 7 Inspection and maintenance

plus pro

Fig. 6.3 Display indicator during water heating

6.1.4 Final flush of the heating system (“hot”)

• Operate the appliance until the appliance and the heating system are up to temperature.

• Check the heating system for leaks.

• Connect a hose to the drain valve located at the lowest position of the heating system.

• Shut off the appliance, open the drain valve and all bleed valves on the radiators and allow the water to flow out of the heating system and the boiler quickly and fully.

• Close the drain valve.

• Fill the heating system again with water as described in Section 5.4.4.

• Release water from the system until the system design pressure of 1.0 bar is attained. (The actual reading on the digital pressure gauge should ideally be 0.5 bar plus an additional pressure corresponding to the highest point of the system above the base of the boiler – 10 m head equals an additional 1 bar reading on the pressure gauge. The minimum pressure should not be less than 1 bar in any installation.) If the system is to be treated with an inhibitor it should be applied at this stage in accordance with the manufacturer’s instructions. Further information can be obtained from Sentinel, Betz Dearborn Ltd., Tel: 0151 420 9595, or Fernox, Alpha–Fry technologies. Tel: 0870 8700362.

• Refit the boiler casing (see Section 5.10).

• Only in ecoTEC plus appliances: Attach the bottom cover to the boiler by sliding the front edge of the cover into the lip at the bottom front edge of the appliance chassis.

• Carefully push the rear of the bottom cover upwards until the spring retaining clips engage at the side of the appliance. It may be necessary to adapt the bottom cover by removing the easy break sections.

6.2 Handing over to the user

Note

When you have finished the installation, attach the sticker supplied (835593) to the appliance in the user’s language.

• Set the maximum radiator temperature control to the desired setting.

• Set the maximum hot water temperature control to the desired setting.

• Instruct the user in the safe and efficient operation of the boiler, in particular the function of – the boiler on/off control – the maximum radiator temperature control – the maximum hot water temperature control (combi-

nation boilers only)

– the pressure gauge

• Show the user how to operate any external controls.

• Explain to the user the importance of having the boiler regularly serviced by a competent servicing company. To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details.

• Record central heating operating pressure in the Benchmark gas boiler commissioning checklist along with the heat input (kW) and temperature difference between flow and return. Failure to install and commission this appliance in compliance with the manufacturers instructions may invalidate the warranty (Note: This does not affect your statutory rights).

• Leave the user instructions and the installation instructions with the user.

7 Inspection and maintenance

7.1 Initial inspection

To ensure the continued safe and efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate.

Danger!

It is law that all servicing work is carried out by a competent person (CORGI registered). Inspections/Maintenance work not carried out by a competent person can result in damage to property and personal injury.

Only genuine Vaillant spare parts may be used for inspections, maintenance and repair work to ensure the long-term working order of all functions of your Vaillant appliance.

34 Instructions for installation and servicing ecoTEC

Page 35

Inspection and maintenance 7

Any spare parts which might be required are contained in the current spare parts catalogues. Information can be obtained from Vaillant Customer Service Centres.

7.1.1 Safety instructions

Important: Before starting any maintenance work:

• Isolate the mains electricity supply by disconnecting the plug at the socket outlet (if there is only an isolating switch remove the fuse from the switch).

• Turn OFF the gas supply at the gas service valve fitted to the boiler.

• When removing any water carrying components ensure that water is kept away from all electrical components.

• Always use new seals and O–rings when parts are replaced.

• Always test for gas soundness and always carry out functional checks after any service work and after replacing any gas carrying component.

• Always check earth continuity, polarity and resistance to earth with a multimeter after any service work and after replacing any electrical component.

Danger!

Electrocution by touching live parts can be fatal! The supply terminals in the appliance switch box are live even if the main ON/OFF switch is turned off. Protect the switch box from spray water. Before working on the appliance, turn off the power supply and secure against restart!

Always perform the following steps after completing any inspection tasks:

• Open the service valves in the heating flow and return and in the cold water inlet (combination boilers only).

• If necessary, refill the device with cold water up to a pressure of approx 1.5 bar and bleed air from the entire heating system.

• Open the service valve of the gas supply pipe.

• Turn on the power supply and the main switch.

• Check the appliance for gas and water leaks.

• Fill and bleed air from the heating system again, if necessary.

Note

If it is necessary to keep the main switch on for certain inspection and maintenance, this is indicated in the description of the maintenance task.

Note

The boiler is fitted with a combustion analysis test point. A suitable combustion analyser can be connected to this point to establish the combustion performance of the boiler. It is not necessary to check the CO

content or adjust the

air ratio of the boiler during the annual service. Checking/adjustment of this value is only required in the following instances; replacement of gas valve, conversion to or from Natural Gas/ LPG or if incorrect combustion is suspected (see Section 9.7).

7.1.2 Maintenance

Before commencing any servicing or maintenance work, carry out an initial inspection of the system as follows:

• Inspect the flue, pipework and electrical connections for indications of damage or deterioration.

• Inspect the air supply and ventilation arrangements of the installation.

• Check the heating and water system, in particular the condition of radiator valves, evidence of leakage from the heating system and dripping hot water taps.

7.1.3 Overview of the maintenance tasks

No. Activity

Disconnect the device from the mains supply, close

the gas supply and service valves, depressurise the device (observe the manometer)

2 Remove the burner module X 3 Clean primary heat exchanger X 4 Check whether the burner is dirty X

Refit burner module, replace burner seal. (Spare

part number 981 046) Check whether the electrical plug connections

and other connections are fitted tightly and make adjustments, if necessary.

7 Check/re-pressurise expansion vessel as necessary. X

Open the service valves, fill up the appliance/

system up to approx. 1.0 - 2.0 bar (depending on the static height of the system)

Check appliance generally, check for dust on the

appliance and remove in the low-pressure chamber Check and clean condensate trap and connection

pipes

11 Clean the condensation waterways in the device X

12 Open the gas supply and switch on the device X

Table 7.1 Maintenance steps

carry

out for

service

35Instructions for installation and servicing ecoTEC

Page 36

7 Inspection and maintenance

No. Activity

Perform a test operation of the appliance and

heating system, including water heating and bleed

system, if necessary 14 Check ignition and burner flame picture X 15 Check boiler for any leaks X 16 Check the air/gas flue system X

Check appliance gas setting, reset and record if 17

necessary.

Complete Benchmark gas boiler commissioning 18

checklist

Table 7.1 Maintenance steps (continued)

carry out for service

7.1.4 Functional check of boiler operation

• Carry out a functional check of the boiler operation as previously detailed.

• Remove the appliance casing as detailed and operate the boiler.

• Inspect the burner operation through the viewing window.

• Check that the flames are evenly covering the surface of the burner.

• Inspect for signs of excessive flame lift or sooting.

7.2 Servicing the burner module

7.2.1 Removing the burner module

The burner module consists of the burner, fan, gas valve und the gas supply (mixer tube). These four components make up the complete assembly, the burner module.

Danger!

Danger of explosion through gas leak! The mixer tube between the gas valve and burner must not be split. It can only be guaranteed that this component is sealed after it has been checked at the factory.

Danger!

There is danger of being injured or burnt by the burner module and at all components carrying water. Only carry out work on these components once they have cooled down.

• Loosen screw, release the front case spring retaining clips located beneath the front edge of the appliance.

• Remove the front casing by easing forward the bottom edge and gently lifting.

• Lower electronic control box.

Fig. 7.1 Dismantling air intake pipe

• Remove screw (2) and remove the air intake pipe (1).

• Disconnect the gas supply (3) on the gas valve. Ensure the corrugated gas pipe does not twist by holding the flattened section of the pipe, with an open ended spanner, whilst loosening the union nut.

Caution!

Damage to corrugated gas pipe! Under no circumstances must the burner module be suspended from the flexible corrugated gas pipe.

Proceed as follows to remove it:

• Turn off the boiler

• Isolate the electrical supply to the boiler.

• Remove boiler bottom cover by releasing the two spring retaining lugs and lowering the rear of the bottom cover.

• Gently pull the bottom cover backwards to remove from the appliance.

• Turn off the gas service valve.

• Turn off the boiler CH service valves.

Fig. 7.2 Dismantling burner module

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Inspection and maintenance 7

• Disconnect HT lead (5) and earth lead (6) from spark electrode.

• Remove four nuts (4) from burner manifold.

• Disconnect two electrical connections (7 and 8) from fan and gas valve.

• Pull forward and remove burner, gas valve and fan assembly (9) from integral condensation heat exchanger (10).

Note

You can suspend the burner module on the hook (11) while carrying out maintenance tasks.

• After removing the thermal compact module, clean the components as described below.

7.2.2 Cleaning the integral condensation heat

exchanger

Caution!

Protect the electronics box against sprayed water.

water used to clean the main heat exchanger will drain through the condensate trap). Avoid pointing the water jet directly at the insulating surface (2) on the

back of the heat exchanger. If required the heat exchanger can be cleaned using regular vinegar.

7.2.3 Checking the burner

Fig. 7.4 Checking burner

The burner (1) is maintenance-free and needs no cleaning.

• Check the burner surface for damage, replace the

burner if necessary.

• After checking/replacing the burner, re-assemble the

burner module in the boiler as described in Section

7.2.4.

Fig. 7.3 Cleaning the integral condensation heat exchanger

• Dismantle the burner module as described under 7.2.1.

Caution!

Risk of damaging the primary heat exchanger! Do not attempt to loosen nor retighten the four screws (1).

With the burner and fan assembly removed it is now possible to inspect the main heat exchanger (4).

• Remove any loose deposits from the heating spirals

(3) using a soft brush and jet of water (ensure that water is kept away from all electrical components. Any

7.2.4 Refitting the burner module

Fig. 7.5 Replacing the silicone seal

• Insert a new silicone seal (1) in the burner door.

Caution!

The silicone seal (1) on the burner module (Art. No.: 981 046) must be replaced each time the module is removed (for example during maintenance or at least once a year). If the burner flange insulation on the burner module (Art. No.: 210 734) shows any signs of damage other small cracks it must also be replaced.

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7 Inspection and maintenance

Fig. 7.6 Refitting the burner module

• Insert the burner module (9) in the integral condensation heat exchanger (10).

• Tighten the four nuts (4) on the alternate left and right sides until the burner door fits closely and uniformly to the stop surfaces.

• Reconnect the HT lead (5) and earth lead (6) to the spark electrode.

• Insert the cables (8) on the fan motor and the cable (7) on the gas fitting.

Fig. 7.8 Testing the gas supply for soundness

• Turn on the gas supply and test for soundness. Check

especially the screwed connections (3) and (11).

• Refit the air inlet pipe, ensuring that the blue seal in the air intake pipe is correctly located.

7.3 Cleaning the condensate siphon

Fig. 7.7 Refitting the gas supply

• Reconnect the gas supply (3) to the gas valve, ensur-

ing that a new sealing washer is used and correctly located. Use the spanner flat at the flexible gas line to hold the gas fittings.

Fig. 7.9 Cleaning the condensate siphon

Danger!

• Remove the lower part (1) of the condensate siphon by turning the bayonet catch in anticlockwise direction.

• Clean the siphon part section by rinsing it out with water.

• Fill the lower part with water until about 10 mm below the upper edge.

• Fasten the lower part again on the condensate siphon.

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Inspection and maintenance 7

Troubleshooting 8

7.4 Checking the expansion vessel

Fig. 7.10 Checking expansion vessel admission pressure

Note

It is not necessary to perform this check every year – a check every three years is sufficient.

• Fill out the Benchmark gas boiler commissioning checklist at the rear of this guide.

Fig. 7.11 Function check

8 Troubleshooting

• Ensure the boiler CH service valves are closed.

• Release the pressure from the boiler.

• Remove valve cap from expansion vessel charge point.

• Check that the internal charge pressure of the expansion vessel is between 0.75 and 0.9 bar.

If the pressure is lower than this the vessel should be

repressurised using an air pump.

• Refit the valve cap.

• Repressurise boiler and heating system.

7.5 Recommissioning the boiler

• Carry out electrical safety checks.

• Turn on the electrical supply.

• Open the boiler CH service valves.

• Carry out function checks of boiler operation as previously detailed.

• Check gas rate as previously detailed.

• Check for water leaks.

• Refit case, ensuring that a good seal is obtained.

7.6 Test operation

Always perform the following checks after completing any maintenance task:

• Commission the appliance according to the relevant operating manual.

• Check the appliance for gas and water leaks.

• Check the air/flue gas system for leaks, check its fastening

• Check for ignition and an even flame on the burner.

• Check that the heating system and the water heating is working (combination boilers only).

8.1 Logical fault finding procedure

These checks must be carried out before attempting to use the fault finding guide.

1. Carry out electrical safety checks (see section ‘Preliminary Electrical Checks’).

2. Check that the external electricity supply to the boiler is on, and a supply of 230 V~ is present between boiler terminals ‘L’ and ‘N’.

3. Check that the gas supply to the boiler is on, that it has been correctly purged and that an inlet pressure of 20 mbar is available at the gas valve. (See section ‘Gas Supply’).

4. Ensure the heating system is full of water and charged to between 1 and 1.5 bar. If not, refill and vent the system. (See section ‘Filling the heating system’). Ensure boiler flow and return service valves are open.

5. Check that the main on/off control is set to the ‘on’ position.

6. Set the central heating temperature to maximum.

7. Set the domestic hot water temperature to maximum (combination boilers only).

8. Check that all external controls are on and calling for heat (if no external controls are fitted, boiler terminals 3 and 4 must be linked). Check that the boiler anti– cycling economiser is not engaged.

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8 Troubleshooting

8.1.1 Status codes

The status codes that you can see on the display provides information about the current operating condition of the appliance.

The display of the status codes can be called as follows:

plus pro

Fig. 8.1 Display of status codes

• Press the “i” key. The display shows the status code, e.g. S.04 for “Burner mode - Heating”.

The display of the status codes can be cancelled as follows:

• Press the “i” key or

• Do not press any key for about 4 minutes.

The current heating flow temperature appears in the

display again.

Display Meaning All models (heating mode):

S.00 No heat demand S.01 Fan running S.02 Water pump running S.03 Ignition sequence S.04 Burner ignited S.05 Fan and pump running S.06 Fan over run S.07 Pump over run S.08 Anti cycling mode

ecoTEC combination boilers only (Domestic hot water mode):

S.10 Hot water demand S.11 Fan running S.13 Ignition sequence S.14 Burner ignited S.15 Fan and pump running S.16 Fan over run S.17 Pump over run

Table 8.1 Status codes

Display Meaning ecoTEC combination boilers only (warm start):

S.20 Warmstart demand S.21 Fan running S.22 Pump running S.23 Ignition sequence S.24 Burner ignited S.25 Fan and water pump running S.26 Fan over run S.27 Pump over run S.28 Anti cycling mode

All boilers:

S.30 No heating demand from external controls (clamp 3-4

open)

S.31 Central heating thermostat knob turned off or no heat

demand by the eBUS control unit

S.32 Heat exchanger antifreeze active, as fan speed varia-

tion is too high. Appliance is within the waiting time of the operation block function

S.34 Antifrost mode active S.36 No heating demand from low voltage controls (clamp

7-8-9)

S.42 Response from accessory modul or defective conden-

sate pump is blocking burner operation

S.53 Appliance is within the waiting period of the operation

block function due to water shortage (VL-RL spread too big)

S.54 Appliance is within the waiting period of the operation

block function due to water shortage (temperature gradient)

S.76 Appliance is within the waiting period of the operation

block function due to water shortage (water pressure sensor)

S.96 Return-sensor check is running, demand (DHW or heat-

ing) is blocked

S.97 Waterpressure sensor check is running, demand (DHW

or heating) is blocked

S.98 Flow-/Return-sensor check is running, demand (DHW or

heating) is blocked

Table 8.1 Status codes (continued)

8.1.2 Diagnostic codes

In the diagnostic mode, you can change certain parameters or display more information. The diagnostic information is divided into two diagnostic levels. The second diagnostic level can be reached only after entering a password.

Caution!

Access to the second diagnostic level must be used exclusively by a qualified technician.

First Diagnostic level

• Press the “i” and “+” keys simultaneously. The display shows “d.00”.

• Use the “+” or “–” keys to scroll through the desired

diagnostic numbers of the first diagnostic level (see Table 8.2).

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Troubleshooting 8

• Press the “i” key.

You are now in the second diagnostic level where all information from the first diagnostic level (see Table 8.2)

The display shows the relevant diagnostic information.

and the second diagnostic level (see Table 8.3) is displayed.

• If necessary, use the “+” or “–” keys to change the value (display flashes).

Scrolling and changing values and exiting the diagnostic mode is done as described in the first diagnostic level.

• Save the new value by holding down the “i” key for approx. 5 seconds until the display no longer flashes.

You can end the diagnostic mode as follows:

• Press the “i” and “+” keys simultaneously. or

• Do not press any key for approx. 4 minutes.

Note

After exiting the second diagnostic level, if you press “i” and “+” within 4 minutes, you will directly reach the second diagnostic level without having to enter the password again.

The current heating flow temperature appears in the display again.

Second diagnostic level

• As described above in the first diagnostic level, scroll through the diagnostic number d.97.

• Change the displayed value to 17 (password) and press the “i” button.

Display Meaning Display value/adjustable value

d.00 Heating part load Adjustable heating part load in kW (factory setting: max. output)

d.01 Water pump over run time for heating mode 1 - 60 min (factory setting: 5 min)

d.02 Max. burner anti cycling period at 20 °C Flow tempera-

ture

d.03 Hot water flow temperature reading (combination boiler

only)

d.04 Current temperature for warm start sensor

(combination boilers only) Current storage tank sensor (system boilers only)

d.05 Flow temperature target value or return target value

when return regulation is set.

d.06 Hot water temperature target value in °C, 35 to 65 °C d.07 Warm start temperature target value

(ecoTEC plus combination boiler only) Storage temperature target value (system boiler only)

d.08 External controls heat demand (Clamp 3-4) 0 = no heat request (open)

d.09 Flow target temperature from external analogue regula-

tor to terminal 7-8-9/eBUS

d.10 Status internal heating pump 1, 2 = on, 0 = off

d.11 Status external heating pump 1 to 100 = on, 0 = off

d.13 Hot water circulation pump (via accessory module) 1 to 100 = on, 0 = off d.22 Hot water demand 1 = on, 0 = off d.23 Summer/Winter function 1 = Winter, 0 = Summer d.25 Hot water activation via eBUS Control 1 = yes, 0 = no d.40 Flow temperature Actual value in °C

d.41 Return temperature Actual value in °C d.47 Outside temperature

(see the instructions for the controller)

d.67 Remaining burner anti cycling time in min

d.76 Appliance variant (device specific number) 00 to 99

d.90 Digital regulator status 1 = identified, 0 = unidentified (eBUS Address <=10)

d.91 DCF status with connected external probe with DCF77

receiver

d.97 Activation of the second diagnostic level Password: 17

2 - 60 min (factory setting: 20 min)

in °C

1 to 100 = on, 0 = off

In °C, min. 30 °C and max. the value set in d.71 Limited by the eBUS controller (if an eBUS controller is connected)

in °C, 40 to 65 °C

in °C, 15 °C for left stop, then 40 to 70 °C

1 = heat request (closed) in °C, minimum from ext. eBUS target value and target value terminal 7

Actual value in °C (uncorrected value)

0 = no reception, 1 = reception, 2 = synchronised, 3 = valid

Table 8.2 Diagnostic codes of the first diagnostic level

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8 Troubleshooting

Display Meaning Display value/adjustable value

d.17 Heating flow/return regulation changeover 0 = flow, 1 = return (factory setting: 0)

d.18 Pump mode 0 = return, 1 = nonstop, 2 = winter d.19 Only in ecoTEC plus:

Operating modes of the two-stage heating pump

d.27 Switching accessory relay 1 in the accessory module 1 = Circulation pump (default)

d.28 Switching accessory relay 2 in the accessory module 1 = Circulation pump

d.30 Control signal for both gas valves 1 = on, 0 = off d.33 Fan speed target value in rpm/10 d.34 Fan speed actual value in rpm/10 d.35 Position of diverter valve (combination boilers only) 0 = Heating; 1 = Hot water; 2 = Centre position d.36 Hot water flow sensor in l/min d.44 Ionisation current Actual value [10nA] d.50 Offset for minimum speed in rpm/10, adjustment range: 0 to 250

d.51 Offset for maximum speed in rpm/10, adjustment range: -99 to -0

d.60 Number of safety temperature limiter cut offs Quantity

d.61 Number of lock outs Number of unsuccessful ignitions in the last attempt d.64 Average ignition time in seconds d.65 Maximum ignition time in seconds d.68 Unsuccessful ignitions in the first attempt Quantity d.69 Unsuccessful ignitions in the second attempt Quantity d.70 Set diverter valve position 0 = Normal mode (factory setting)

d.71 Maximum setting of heater control knob

d.72 Pump overrun time after charging an electronically

controlled hot water storage (also warm start and charging through C1-C2)

d.73 Offset for warm start target value (combination boilers

only)

d.75 Maximum charging time for a storage without own

controller

d.77 Storage partial load (storage charging capacity limit) Adjustment range in kW: appliance-specific

d.78 Storage charging temperature limit (target flow tem-

perature in storage mode)

d.80 Heating operating hours in h

d.81 Water heating operating hours (combination boilers

only)

d.82 Cycles in heating mode Quantity d.83 Cycles in hot water operation Quantity d.84 Maintenance indicator: Number of hours until the next

maintenance

d.93 DSN appliance variant setting Adjustment range: 0 to 99 d.96 Factory setting 1 = Resetting adjustable parameters to factory setting

Table 8.3 Diagnostics codes of the second diagnostic level

0 = Burner mode = 2, flow/return = 1 1 = Heating + flow =1, service water = 2 2 = Like 1, but speed in heating mode dependent on heating partial

load (default setting)

3 = Always stage 2

2 = Ext. pump 3 = Storage charging pump 4 = Flue gas flap/extractor hood 5 = External gas valve 6 = External error message

2 = Ext. pump (default) 3 = Storage charging pump 4 = Flue gas flap/extractor hood 5 = External gas valve 6 = External error message

1 = Centre position 2 = permanent heating position

Adjustment range in °C: 40 to 85 (Factory setting: 75) Adjustment range in sec: 0, 10, 20 to 600

Factory setting for 800 series: 80 Factory setting for 600 series: 300

Adjustment range: -15 K to +5 K (Factory setting: 0 K)

Adjustment range in min: 20, 21, 22 to 90 (Factory setting: 45)

Factory setting: max. output Adjustment range in °C 55 to 90 (Factory setting: 80)

in h

Adjustment range: 0 to 3000 h and “-” Factory setting: “-” (300 corresponds to 3000 h)

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Troubleshooting 8

8.1.3 Fault codes

Fault codes take priority over all other display functions in the event of a system fault occurring. If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each.

To cancel fault error memory display mode, proceed as follows:

• Press the ”i” button below the display or

• Do not touch any key for about four minutes. The display will now revert back to showing the current flow temperature.

8.1.4 Fault memory

The fault memory stores details of the ten most recent faults.

• Press the ”i” and ”–” buttons simultaneously.

• Use the ”+” button to scroll back through the list of

memorised errors.

Code Meaning Cause

F.00 Flow–NTC open circuit NTC broken, NTC cable broken, Defective connection at NTC,

F.01 Return–NTC open circuit NTC broken, NTC cable broken, Defective connection at NTC,

F.02 Domestic hot water outlet NTC open circuit

(combination boiler only) F.10 Flow NTC short circuit NTC defective,cable/casing shortcut F.11 Return NTC short circuit NTC defective, cable/casing shortcut

F.13 Tank NTC short circuit NTC defective,short circuit in cable harness, cable/casing shortcut F.20 Safety temperature limiter by NTC activated Flow-NTC not correctly thermal-connected or defective; appliance

F.22 Dry fire Too little water in the appliance, water pressure sensor defective,

F.23 Water shortage, temperature difference between flow

and return NTC too large F.24 Water shortage, temperature rise too quick Pump blocked, insufficient pump output, air in appliance, water

F.27 Incorrect sensing of flame Flame detector defective F.28 Appliance does not start: Attempts to ignite during start

failed

F.29 Flame goes off during operation and subsequent ignition

attempts failed F.32 Fan speed variation Fan blocked, plug not inserted correctly on fan, hall sensor defec-

F.49 eBUS undervoltage Short circuit on eBUS, overload on eBUS or two power sources on

F.61 Gas–valve control defective Short circuit/earth (ground) leak in cable harness to gas valves, gas

F.62 Gas valve shutoff delay Gas valve leaking, electronics defective F.63 EEPROM error Electronics defective F.64 Electronics/NTC fault Short-circuit in flow or return NTC or electronics defective F.65 Electronics temperature too high Electronics too hot due to external effect, electronics defective F.70 No valid DSN in display and/or mainboard Spare part failure display and maiboard interchanged at same time

F.71 Flow NTC reports constant value (stuck at) Flow NTC is defective F.72 Flow and/or return NTC fault Flow and/or return NTC is defective (tolerances too big) F.73 Water pressure sensor signal out of range (too low) Cable to water pressure sensor is broken or has a short-circuit at

Table 8.4 Error codes

Defective connection at electronics

Defective connection at electronics NTC-connector not plugged in or loose, NTC defective connector on

the electronics not plugged in correctly, cable defective

does not shut down

cable to pump or water sensor defective, pump blocked or defective, pump output too low

Pump blocked or defective, pump output too low, flow and return NTC interchanged

pressure too low

Faults in the gas supply such as:

- Gas meter or gas pressure detector defective

- Air in gas

- Gas flow pressure too low

- Fire protection tap has disengaged Faults in the gas valve, wrong gas setting, igniter (ignition transformer, ignition cable, ignition plug) defective, ionisation current stopped (cable, electrode), faulty earthing in appliance, electronics defective

Gas supply temporarily stopped, faulty earthing of appliance

tive, fault in cable harness, electronics defective

eBUS with different polarity

valve assembly defective (earth/ground leak from coils), electronic control system defective

and device specific number not adjusted

0 V or water pressure sensor defective

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8 Troubleshooting 9 Parts replacement

Code Meaning Cause

F.74 Water pressure sensor signal out of range (too high) Cable to water pressure sensor has a short-circuit at 5 V / 24 V or

F.75 No pressure rise was detected on turning on the pump Water pressure sensor or/and pump defective

F.76 Overheating protection on primary heat exchanger trig-

gered F.77 condensate pump or feedback of accessorie blocks heat-

ing F.78 wrong configuration with accessory link box VR65 connected to combination boiler

con no communication to mainboard connection error display mainboard

Table 8.4 Error codes (continued)

internal fault in water pressure sensor

Too little water in appliance; check adjustable by-pass; connect external expension vessel to return

Cable or cable connection of fuse in the primary heat exchanger defective, or primary heat exchanger defective

condensate pump defective or flume flap feedback triggered

8.4 Test programs

Special functions can be triggered on the appliances by activating various test programs. These programs are given in detail in the Table 8.5.

• The test programs P.0 to P.6 will be started when “Power ON” is turned on and the “+” key is pressed for 5 s. The display shows “P.0”.

• Press the “+” key to start counting the test number upwards.

• Press the “i” to operate the appliance now and to start the test program.

• Press “i” and “+” simultaneously to exit the test programs. You can also exit the test programs by not pressing any key for 15 minutes.

Display Meaning

P.0 Bleeding test program. The heating circuit and hot

water circuit (combination boiler only) is bled via the automatic air vent (the cap on the automatic air vent must be loosened).

P.1 Test program where the appliance is operated in full

load after successful ignition

P.2 Test program where the appliance is operated with

minimum gas volume (ignition gas volume) after successful ignition

P.3 not available P.4 not available P.5 Test program for the safety temperature limit check;

appliance heats up by by-passing a regulating shutdown through the flow regulator until the shutoff temperature of 97 °C is achieved.

P.6 Filling test program. The diverter valve moves to the

centre position

Table 8.5 Test programs

8.5 Resetting parameter to factory settings

Besides the option to reset individual parameters manually to the factory settings specified in Tables 8.2 and

8.3, you can also reset all parameters simultaneously.

• In the second diagnostic level, under the diagnostic number “d.96” change the value to 1 (see Section

8.1.2).

The parameters of all adjustable diagnostic numbers now correspond to the factory settings.

9 Parts replacement

The tasks listed below in this section may be carried out only by a qualified engineer.

• Only use genuine spare parts for repairs.

• Make sure the parts are correctly fitted and that their original position and alignment are retained.

9.1 Safety instructions

Danger!

Each time the components are replaced, comply with the safety instructions below for your own safety and to avoid damage to the appliance!

• Put the appliance out of operation.

Important:

Before starting any maintenance work: Isolate the mains electricity supply by disconnecting the plug at the socket outlet (if there is only an isolating switch remove the fuse from the switch).

• Close the service valve in the gas supply as well as the service valves in the heating flow and return pipe.

• Close the service valve in the cold water supply line (combination boilers only)!

• Empty the appliance if you want to replace water-bearing components of the appliance!

• Make sure that no water drops on live components (e.g. switch box etc.)!

• Use only new seals and O-rings!

• After completing the work, check for gas leaks and perform a function check (see Section 7.6)!

• Always check earth continuity, polarity and resistance to earth with a multimeter after any service work and after exchanging any electrical component.

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9.2 Replacing burner

Danger!

Before replacing the component, comply with the safety instructions in Section 9.1.

Parts replacement 9

• Dismantle the burner module as described in Section

7. 2 .1 .

Fig. 9.1 Replacing burner

• Loosen the 4 screws (1) on burner, and remove the

burner.

• Mount the new burner with a new seal. Ensuring that the notch in the burner aligns with the burner viewing window.

• Install the burner module as described in Section 7.2.4.

• After completing the work, check for gas leaks and perform a function check (see Section 7.6)!

9.3 Replacing fan or gas valve

Fig. 9.2 Dismantling fan with gas fitting

• Pull out the plug (4) from the gas valve.

• Pull out the plug (3) from the fan.

• Remove the three screws (2) on the burner module (1).

• Remove the complete “gas valve/fan” unit.

Danger!

Before replacing the component, comply with the safety instructions in Section 9.1.

• Turn off the boiler.

• Isolate the electrical supply to the boiler

• Remove the air intake pipe (Fig. 7.1, Pos. 2).

• Loosen the gas supply pipe on the gas fitting (Fig. 7.2,

Pos. 3).

Fig. 9.3 Gas fitting/fan screwed joint

• Remove both fixing screws (5) on the gas valve and remove the fan from the gas valve.

• Replace the defective component.

Caution!

Mount the gas valve and the fan in the same position as before.

• Screw on the fan with the gas valve. Please use new seals.

• Install the complete “gas valve/fan” unit in reverse sequence.

• After completing the work, check for gas leaks and perform a function check (see Section 7.6)!

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9 Parts replacement

9.4 Replacing expansion vessel

Danger!

Before replacing the component, comply with the safety instructions in Section 9.1.

• Disconnect the appliance from the mains as described in Section 9.1, and close the service valve in the gas supply pipe.

• Close the flow and return service valves and drain the water from the boiler.

• After completing the work, check for water leaks and perform a function check (see Section 7.6)!

9.5 Replacing primary heat exchanger

Danger!

Before replacing the component, comply with the safety instructions in Section 9.1.

• Disconnect the appliance from the mains as described in Section 9.1, and close the service valve in the gas supply pipe.

• Close the flow and return service valves and drain the appliance.

• Remove the burner module as described under 7.2.1.

• Remove the expansion vessel as described under 9.4.

• Pull out the condensate pipe to the siphon from the primary heat exchanger.

Fig. 9.4 Replacing expansion vessel

• Undo the nut (4) on the water pipe on the lower side

of the expansion vessel.

• Remove both screws (1) retaining plate (2) and remove

the retaining plate.

• Pull out the expansion vessel (3) forwards.

• Guide the new expansion vessel back into the appliance.

• Re-connect the new expansion vessel using a new seal.

• Refix the retaining plate.

• Check the pressure of the expansion vessel (minimum pressure 0.75 bar). If necessary, adjust the pressure to the static height of the heating system.

• Fill and vent the boiler.

Fig. 9.5 Replacing primary heat exchanger

• Pull out the clamps (1) and (2) and free the return pipe

as well as the flow pipe on the primary heat exchanger.

• Remove the four screws (3) on the primary heat

exchanger holder.

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Parts replacement 9

Replacing display or electronics

If you are replacing only one of the two components, the parameter adjustment functions automatically. On turning on the appliance, the new component takes over the previously set parameters from the components that are not replaced.

Replacing display and electronics

When replacing both components, after being turned on, the appliance goes to fault and displays the error message “F70”.

Fig. 9.6 Primary heat exchanger holder

• Disconnect the plug-in connection (2) of the thermal fuse in the primary heat exchanger.

• Remove the three screws (3) on the primary heat exchanger holder.

• Turn the holder to the side around the rivet (1), pull the primary heat exchanger downwards to the right and remove it from the appliance.

• Mount the new primary heat exchanger in reverse order and replace the seals.

Caution!

Risk of damaging the primary heat exchanger! Neither loosen nor retighten the four screws (Fig. 9.5, Pos. 4).

Caution!

Insert the seal rings for the flow and return pipe on the primary heat exchanger with a suitable lubricant. Make sure the clamps are fitted correctly on the flow and return pipe (see Fig. 9.5).

• Fill and vent the boiler as required.

• After completing the work, check for gas and water leaks and perform a function check (see Section 7.6)!

• In the second diagnostic level, under the diagnostic

number “d.93” enter the number of appliance variant according to Table 9.1 (see Section 8.1.2).

The electronics is now set to the appliance type and the parameters of all adjustable diagnostics numbers correspond to the factory settings.

Appliance Device specific number

ecoTEC plus 612 0 ecoTEC plus 615 1 ecoTEC plus 618 2 ecoTEC plus 624 3 ecoTEC plus 630 4 ecoTEC plus 824 6 ecoTEC plus 831 7 ecoTEC pro 28 0

Table 9.1 Device specific numbers

9.7 Check CO2 content and if necessary set (airratio adjustment)

Note

Checking/adjustment of this value is required in the following instances: replacement of gas valve, conversion to or from Natural Gas/LPG or if incorrect combustion is suspected!

• Remove the front cover.

• Press the “+” and “-” keys simultaneously.

The “Full load mode” is activated.

• Wait at least 5 minutes until the appliance reaches its

operating temperature.

9.6 Replacing electronics and display

Danger!

Before replacing the component, comply with the safety instructions in Section 9.1.

• Comply with the assembly and installation manuals provided with the spare parts.

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9 Parts replacement 10 Recycling and disposal

Fig. 9.7 Carrying out measurement of CO2 levels, preparing for

air-ratio adjustment

• Measure the CO2 content on the flue gas measuring nozzles (1).

• If necessary, loosen the screw and fold the suction pipe extension forwards by 90° (don‘t remove!).

• If necessary, set the corresponding flue gas value (value with removed appliance front, see Table 9.2) by turning the screw (2).

-> Turn to the left: higher CO

-> Turn to the right: lower CO

content,

Note

Only for natural gas: Adjust only in increments of 1/8 turn and wait approx. 1 minute after each adjustment until the value stabilises.

Only for liquid gas: Adjust only in very small increments (approx. 1/16 turn), and wait approx. 1 minute after each adjustment until the value stabilises.

Settings Natural gas (H)

after 5 min.

full load mode with appliance front closed CO

after 5 min.

full load mode with appliance front removed Set for Wobbe-Index W

Table 9.2 Factory gas settings

Tolerance

9.2 ± 1,0 10.2 ± 0,5

9.0 ± 1,0 10.0 ± 0,5

15 22.5 kWh/m

Propane Tolerance

Unit

Vol.–%

10 Recycling and disposal

The design of all Vaillant products takes into account the subsequent recycling and/or eventual safe scrapping of each component used. Vaillant’s in–house rules set strict standards in this respect. The selection process used for choosing raw materials includes full consideration of their recycling characteristics, and of the breakdown and separation properties of subassemblies. We also take fully into account the environmental and health hazards involved in recycling and in the disposal of non–reusable waste items.

10.1 Appliance

The Vaillant ecoTEC consists largely (92 %) of metal components designed for eventual recycling by incorporation into the smelting process of a steelworks. This gives these parts virtually unlimited scope for subsequent re–use. All plastic materials are duly identified to facilitate sorting and separation when the time comes to recycle the unit.

10.2 Packaging

Vaillant endeavours to keep the amount of transport packaging used for its equipment to the bare minimum necessary. Subsequent re–use is taken into account when selecting packaging materials. High–quality cardboard has long been a valuable secondary raw material for the card and paper industry. The sections of EPS (Styropor in transit. EPS is 100 % recyclable and CFC–free. The foil–wrapping and securing straps are likewise made of recyclable plastic.

) are required in order to protect equipment

• Fold back the suction pipe extension upwards.

• Check the CO

content again.

• If necessary, repeat setting.

• Press the “+” and “-” keys simultaneously. The “Full load mode” is turned off. The full load mode is also turned of if no key is pressed for 15 minutes.

• Fasten the suction pipe extension.

• Attach the front cover again.

48 Instructions for installation and servicing ecoTEC

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Appendix

49Instructions for installation and servicing ecoTEC

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