Vaillant ecoTEC plus 618, ecoTEC plus 824, ecoTEC plus 624, ecoTEC plus 637, ecoTEC plus 831 Instructions For Installation And Servicing
...
Supplied By www.heating spares.co Tel. 0161 620 6677
For the installer
Instructions for installation and servicing
ecoTEC
Wall hung room sealed fan assisted condensing boiler
ecoTEC plus 612
ecoTEC plus 615
ecoTEC plus 618
ecoTEC plus 624
ecoTEC plus 630
ecoTEC plus 637
ecoTEC plus 824
ecoTEC plus 831
ecoTEC plus 837
ecoTEC pro 28
ecoTEC pro 24
GB
Supplied By www.heating spares.co Tel. 0161 620 6677
Contents
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 for room sealed
appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Contents included with delivery . . . . . . . . . . . . . 10
3.4 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Transporting the appliance . . . . . . . . . . . . . . . . . 16
4.2 Required minimum distances/assembly
clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.1 Select position for boiler . . . . . . . . . . . . . . . . . . . 18
4.2.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.3 Using boiler template . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Fitting the boiler hanging bracket . . . . . . . . . . . 20
4.5 Installing the flue system . . . . . . . . . . . . . . . . . . . 20
4.6 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.7 Removing the front case . . . . . . . . . . . . . . . . . . . 20
4.8 General instructions for heating system . . . . . . 20
4.9 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.10 Cold water mains inlet and hot water outlet
(ecoTEC combination boilers only) . . . . . . . . . . . 21
4.11 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . . 22
4.12 Heating connection . . . . . . . . . . . . . . . . . . . . . . . 23
4.12.1 Heating flow and return connection . . . . . . . . . . 23
4.12.2 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 24
4.13 Connecting the flue system to the boiler . . . . . 24
4.14 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 24
4.14.1 General requirements . . . . . . . . . . . . . . . . . . . . . . 24
4.14.2 Connection to the main supply . . . . . . . . . . . . . . 25
4.14.3 Electric board layout . . . . . . . . . . . . . . . . . . . . . . . 26
4.15 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.15.1 Vaillant controls and accessories . . . . . . . . . . . . 29
4.15.2 External electrical controls . . . . . . . . . . . . . . . . . 29
4.15.3 Connection details for external time switches
and boiler terminal strip . . . . . . . . . . . . . . . . . . . . 29
4.15.4 Vaillant optional plug in timer accessories . . . . 29
4.15.5 Connection details using the VR 65 Control
Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.16 Thermostatic radiator valves . . . . . . . . . . . . . . . . 29
4.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.19 Anticycling ‘economiser’ control . . . . . . . . . . . . . 30
4.20 Automatic pump spin control (APS) . . . . . . . . . . 30
5 Commissioning Part I . . . . . . . . . . . . . . . . . . 30
5.1 Preliminary electrical checks . . . . . . . . . . . . . . . . 30
5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Cold water supply (ecoTEC combination
boilers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Filling and bleeding the heating system . . . . . . 30
5.4.1 Checking the filling pressure of the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4.2 ecoTEC plus combination boiler filling loop . . . 31
5.4.3 Filling the heating system in ecoTEC pro
combination boilers and ecoTEC plus system
boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4.4 Filling the heating system for the first time . . . 32
5.5 Initial system flush (“cold”) . . . . . . . . . . . . . . . . . 32
5.6 Filling the condensate siphon . . . . . . . . . . . . . . . 32
5.7 Adjusting the pumping capacity . . . . . . . . . . . . . 33
5.8 Adjusting the by-pass . . . . . . . . . . . . . . . . . . . . . . 33
5.9 Checking the gas supply . . . . . . . . . . . . . . . . . . . . 33
5.9.1 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.9.2 Gas inlet working pressure . . . . . . . . . . . . . . . . . . 33
5.9.3 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . 34
5.10 Refitting the case . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.11 Adjusting the central heating output (range
rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Functional checks (commissioning part II) . 35
6.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.1.3 Water heating (combination boilers only) . . . . . 36
6.1.4 Final flush of the heating system (“hot”) . . . . . 36
6.2 Handing over to the user . . . . . . . . . . . . . . . . . . . 36
6.3 Vaillant warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2
Instructions for installation and servicing ecoTEC
Supplied By www.heating spares.co Tel. 0161 620 6677
7 Inspection and maintenance . . . . . . . . . . . . 37
7.1 Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.3 Overview of the inspection and maintenance
tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.4 Functional check of boiler operation . . . . . . . . . 38
7.2 Servicing the burner module . . . . . . . . . . . . . . . . 39
7.2.1 Removing the burner module . . . . . . . . . . . . . . . 39
7.2.2 Cleaning the integral condensation heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.4 Refitting the burner module . . . . . . . . . . . . . . . . 40
7.3 Cleaning the condensate siphon . . . . . . . . . . . . . 41
7.4 Checking the expansion vessel . . . . . . . . . . . . . . 42
7.5 Recommissioning the boiler . . . . . . . . . . . . . . . . . 42
7.6 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 42
8.1 Logical fault finding procedure . . . . . . . . . . . . . . 42
8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5 Resetting parameter to factory settings . . . . . . 48
Contents
9 Parts replacement . . . . . . . . . . . . . . . . . . . . . 48
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.3 Replacing fan or gas valve . . . . . . . . . . . . . . . . . . 49
9.4 Replacing expansion vessel . . . . . . . . . . . . . . . . . 49
9.5 Replacing primary heat exchanger . . . . . . . . . . . 50
9.6 Replacing electronics and display . . . . . . . . . . . . 51
9.7 Check CO
(air-ratio adjustment) . . . . . . . . . . . . . . . . . . . . . . 51
10 Recycling and disposal . . . . . . . . . . . . . . . . . 52
11 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . 52
Appendix
EG declaration of conformity . . . . . . . . . . . . . . . . 53
Benchmark gas boiler commissioning
checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
content and if necessary set
2
3Instructions for installation and servicing ecoTEC
Supplied By www.heating spares.co Tel. 0161 620 6677
1 Introduction
1 Introduction
1.1 Notes on the documentation
The following information is intended to help you
throughout the entire documentation.
Further documents apply in combination with this installation and maintenance manual.
We assume no liability for any damage caused by
non-observance of these manuals.
1.1.1 Applicable documents
The following additional documents are provided with
the appliance:
For the owner of the system:
Instructions for use Nr. 838402
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. 834449
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:
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 3 models
with outputs of 23 kW, 31 kW and 37 kW for domestic hot
water and two pro versions with outputs of 24 kW and
28 kW for domestic hot water.
All versions are available in natural gas. The ecoTEC plus
831 is also available in LPG.
ecoTEC combination boilers incorporate a warm start
facility that keeps the domestic hot water heat exchanger hot, providing an instantaneous delivery of domestic
hot water. The temperature in the domestic hot water
heat exchanger is limited by the boiler control system
and it is not necessary to install a scale reducer on the
cold mains to the boiler. However, in areas that get
exceptionally hard water, a scale reducer may be fitted
to prevent scale formation in the hot water system
pipes. The heating system on ecoTEC plus combination
boilers can be filled using the built–in filling loop contained within the boiler.
Danger!
Immediate danger to life and limb!
Danger!
Risk of death from electric shock!
Danger!
Risk of burns or scalding!
Caution!
Potentially dangerous situation for the product
and environment!
Note
Useful information and instructions.
• Symbol for a necessary task
4 Instructions for installation and servicing ecoTEC
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, 30 and
37 kW. All ecoTEC system boilers are available in Natural
Gas. The ecoTEC plus 618 and 630 are also available in
LPG.
1.3 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
Supplied By www.heating spares.co Tel. 0161 620 6677
Introduction 1
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.
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.
1.5 Gas council numbers
Applaince Gas council numbers
ecoTEC pro 24 47-044-36
ecoTEC pro 28 47-044-30
ecoTEC plus 824 47-044-31
ecoTEC plus 831 47-044-32
ecoTEC plus 831 Propane 47-044-34
ecoTEC plus 837 47-044-33
ecoTEC plus 612 41-044-44
ecoTEC plus 615 41-044-45
ecoTEC plus 618 41-044-46
ecoTEC plus 618 Propane 41-044-51
ecoTEC plus 624 41-044-47
ecoTEC plus 630 41-044-48
ecoTEC plus 630 Propane 41-044-50
ecoTEC plus 637 41-044-49
Table 1.1 Gas council numbers
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
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
Supplied By www.heating spares.co Tel. 0161 620 6677
2 Boiler specifications
2 Boiler specifications
2.1 Technical data
Technical data
CH heat output range
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
Maximum DHW output 23.0 31.0 37 23.0 28.0 kW
Maximum output for heating 19 24 28 19 24 kW
Minimum output 6.7 8.7 12 6.7 9.0 kW
Category II
SEDBUK Band A A A A A Band
SAP Seasonal Efficiency 91.1 %
Inlet gas working pressure required (G20, natural gas) 20 mbar
Inlet gas working pressure required (G31, Propane) 37 mbar
Connected load (if needed, related to stored charge/
water heating) at 15 °C and 1013 mbar
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
Maximum CH system pressure 3.0 bar
Circulation water volume (∆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
Mains water pressure required for max. flow rate 0.5 0.75 0.75 0.5 0.5 bar
Mains water pressure required for min. flow rate 0.15 bar
Hot water discharge temperature range 35 – 65 °C
Exhaust flue 60/100 mm
Flue categories C13, C33, C43, C53, C83, B23, B33
10 l expansion vessel pre-charge pressure 0.75 bar
Connections heating flow/return 22 mm
Gas inlet 15 22 15 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
Dimensions (H x W x D)
Weight (boiler only) 35 38 43 34 37 kg
Primary water content 1.9 2.3 2.5 1.9 2.1 l
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input 110 125 140 110 115 W
Table 2.1 Technical data ecoTEC combination boiler
824 831 837 24 28
6.7 – 19.0
6.9 – 19.6
7.1 – 20.2
7.2 – 20.6
G20: 2.5
G31: 1.82
3.2
10.7
40
74
817 1032 1204 817 1032 l/h
1.8 2.2 2.9 1.8 2.2 l/h
9.4 12.7 15.2 9.4 11.5 l/min
7.9 10.6 12.6 7.9 9.6 l/min
720 x 440 x
335
ecoTEC plus ecoTEC pro
8.7 – 24.0
9.0 – 24.7
9.2 – 25.5
9.4 – 26.0
G20: 3.3
G31: 2.46
4.2
14.4
40
83
30 – 85 40 – 85 30 – 85 °C
720 x 440 x
335
12.0 – 28.0
12.3 – 28.9
12.7 – 29.7
12.9 – 30.3
2H3P
G20: 4.0
G31: 2.94
5.7
17.1
40
70
720 x 440 x
403
6.7 – 19.0
6.9 – 19.6
7.1 – 20.2
7.2 – 20.6
G20: 2.5
G31: 1.82
3.2
10.7
40
74
720 x 440 x
335
9.0 – 24.0
9.3 – 24.7
9.6 – 25.5
9.8 – 26.0
G20: 3.0
G31: 2.22
4.4
13.0
40
74
720 x 440 x
335
Units
kW
kW
kW
kW
m
kg/h
g/s
g/s
°C
°C
mm
3
/h
6 Instructions for installation and servicing ecoTEC
Supplied By www.heating spares.co Tel. 0161 620 6677
Boiler specifications 2
Technical data
CH heat output range
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
Category II
SEDBUK Band AAAAAABand
SAP Seasonal Efficiency 91.2 %
Inlet gas working pressure required (G20,
natural gas)
Inlet gas working pressure required (G31,
Propane)
Connected load (if needed, related to stored
charge/water heating) at 15 °C and 1013 mbar
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C
return
at maximum thermal load (80 °C flow/60 °C
return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C
return)
at maximum thermal load (80 °C flow/60 °C
return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
Maximum CH system pressure 3.0 bar
Circulating water volume (∆T=20 K)
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
Flue categories C13, C33, C43, C53, C83, B23, B33
10 l expansion vessel pre-charge pressure 0.75 bar
Connections heating flow/return 22 mm
Gas inlet 15 22 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
Dimensions (H x W x D) 720 x 440 x 335
Weight (boiler only) 35 35 35 37 38 40 kg
Primary water content 1.9 1.9 1.9 2.1 2.3 2.5 l
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input 100 110 100 110 110 140 W
Table 2.2 Technical data ecoTEC system boiler
612 615 618 624 630 637
4.9 – 12.0
5.1 – 12.3
5.2 – 12.7
5.3 – 12.9
G20: 1.3
G31: 0.95
2.3
5.6
516 645 774 1032 1290 1591 l/h
1.1 1.4 1.7 2.2 2.7 3.8 l/h
4.9 – 15.0
5.1 – 15.5
5.2 – 15.9
5.3 – 16.2
G20: 1.6
G31: 1.19
2.3
7. 0
40
70
ecoTEC plus
6.7 – 18.0
6.9 – 18.6
7.1 – 19.1
7.2 – 19.5
G20: 1.9
G31: 1.43
3.2
8.3
8.7 – 24.0
9.0 – 24.7
9.2 – 25.5
9.4 – 26.0
2H3P
20 mbar
37 mbar
G20: 2.6
G31: 1.90
4.2
11.2
40
75
30 – 85 °C
15 – 70 °C
10.0 – 30.0
10.3 – 30.9
10.6 –31.8
10.8 – 32.4
G20: 3.2
G31: 2.38
4.8
13.9
40
83
720 x 440 x
369
12.0 – 37.0
12.3 – 38.2
12.7 – 39.3
12.9 – 40.1
G20: 4.0
G31: 2.94
5.7
17.1
40
70
720 x 440 x
403
Units
kW
kW
kW
kW
3
/h
m
kg/h
g/s
g/s
°C
°C
mm
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2 Boiler specifications
2.2 Dimensions
440
9
8
7
190
65
241
883
720
642
20
Fig. 2.1 Dimensions in mm
175
35 35
6
10
125
11
12
5
75
45
180
12345
300
ecoTEC plus 630:
334
ecoTEC plus 637,
ecoTEC plus 837:
368
4
3
2
130
1
100100
Legend:
1 Heating return pipe Ø 22 mm
2 Cold water connection Ø 15 mm (combination boilers only)
3 Gas connection Ø 15 mm
4 Hot water connection Ø 15 mm (combination boilers only)
5 Heating flow pipe Ø 22 mm
6 Hanging bracket
7 Flue hole - flue system 60/100
8 Flue hole - flue system 80/125
9 Spacer frame accessory (Art. No.: 308 650)
10 Flue pipe connection
11 Condensate drain connection (Ø 19 mm)
12 Heating system expansion relief valve connection (Ø 15 mm)
Note
With the spacer frame (Art. No 308 650), the
pipes can be run behind the boiler. The distance
of the appliance from the wall thus increases by
65 mm.
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2.4 Installation
14
13
12
Boiler specifications 2
14
1
13
1
2
3
4
5
12
6
2
3
4
5
11
10
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
10
7
8
9
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
7
9
2.5 Type plate
The type plate of the Valliant ecoTEC is attached to the
bottom of the appliance at the factory.
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3 General requirements
3 General requirements
3.1 Preliminary remarks for room sealed appliances
This appliance should only be installed in conjunction
with either a Vaillant flue system or an alternative
approved system (details of flue approval categories can
be found in the technical section of the installation manual).
Install the flue system as detailed in the separate flue
installation instructions supplied with this boiler.
3.2 Related documents
The installation of the boiler must be in accordance with
the relevant requirements of Gas Safety (Installation and
Use) Regulations 1998, Health and Safety Document No.
635 (The Electricity at Work Regulations 1989), BS7671
(IEE Wiring Regulations) and the Water Supply (Water
Fitting) Regulations 1999, or The Water Bylaws 2000
(Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building
Regulations, The Building Regulations (Scotland), The
Building Regulations (Northern Ireland) and the relevant
recommendations of the following British Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water central heating systems. Institute of Gas Engineers Publication IGE/UP/7/1998: ”Guide for gas installations in timber framed housing”
BS. 5482: Pt. 1 Domestic butane and propane gas burning installations.
IGE/UP1: Soundness testing and purging of industrial and
commercial gas installation.
IGE/UP2: Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP10. Installation of gas appliances in industrial and
commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating systems.
BS. 5440: Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding
70 kW net (1st, 2nd and 3rd family gases).
Part 1 Specification for installation of flues.
Part 2 Specification for installation and maintenance
of ventilation for gas appliances.
European installation directive
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.
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).
10 Instructions for installation and servicing ecoTEC
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General requirements 3
8
7
6
5
1
2
3
4
8
7
6
5
1
2
3
4
Fig. 3.1 Contents included with delivery of ecoTEC plus system
boilers
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Boiler
3 1 Bottom cover
4 4 Connecting pipes (gas, heating, safety valve)
5 3 Isolating valves
6 1 Template
73
8 2 Installation and connection accessories
Table 3.1 Contents included with delivery of ecoTEC plus system
boilers
User, installation and service and flue installation manuals
For LPG appliances, extra: 1 sticker each for
2
tank and ventilation (above Fig.)
Fig. 3.2 Contents included with delivery of ecoTEC plus 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
2
tank and ventilation (above Fig.)
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3 General requirements
7
6
i F P
r
a
b
5
4
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
1
2
3
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.
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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
10
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
667
87
65
74
30
880
40
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
48
70
70
15
Fig. 3.4 Art. No. 303 933
Fig. 3.6 Art. No. 303 209
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. 3.7 Art. No. 303 200
650
1530
880
70
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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
F
J
H, I
Fig. 3.8 Flue termination
BCD
A
A
A
E
G
B
F
M
G
L
F
F
K
K
L
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-
A
zontal to an opening, air brick, opening window, etc.
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
J From an opening (e.g. door, window) into the dwelling 1200
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
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.
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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.
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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
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
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 Transporting the appliance
Important:
With regards to the Manual Handling
Operations, 1992 Regulations, the following lift
operation exceeds the recommended weight for
a one man lift.
General recommendations when handling
Clear the route before attempting the lift.
Ensure safe lifting techniques are used – keep back
straight – bend using legs. Keep load as close to body as
possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements
during lift. Avoid upper body/top heavy bending - do not
lean forward/sideways. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp
edges and ensure good grip. Always use assistance if
required.
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack
truck. If 1 person is performing lift, straddle the load, tilt
and place carton into position on truck. Recommend
secure appliance onto truck with suitable straps. Ensure
16 Instructions for installation and servicing ecoTEC
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Boiler installation sequence 4
safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible.
If 2 persons performing lift, ensure co-ordinated movements during lift. Always use assistance if required.
Carriage of carton from point of delivery to point of
installation – ground floor.
Recommend 2 person lift or 1 person with use of sack
truck. If 1 person is performing lift, straddle the load, tilt
and place carton into position on truck. Recommend
secure appliance onto truck with suitable straps. Ensure
safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible.
If 2 persons performing lift, ensure co-ordinated movements during lift. Clear the route before attempting the
lift. If removing boiler from truck straddle the load and
tilt forwards to facilitate secure grip. Ensure safe lifting
techniques are used – keep back straight – bend using
legs. Do not twist – reposition feet instead. Take care to
avoid trip hazards, slippery or wet surfaces and when
climbing steps and stairs. Always use assistance if
required.
Carriage of carton from point of delivery to point of
installation – first or higher floor, cellar.
Recommend 2-person lift or 1 person with use of sack
truck. If 1 person is performing lift, straddle the load, tilt
and place carton into position on truck. Recommend
secure appliance onto truck with suitable straps. Ensure
safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible.
If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top heavy bending do not lean forward/sideways. Clear the route before
attempting the lift. If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip.
Ensure safe lifting techniques are used – keep back
straight – bend using legs. Do not twist – reposition feet
instead. Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs. Always use
assistance if required.
Carriage of carton from point of delivery to point of
installation – roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during lift. Avoid upper body/top heavy bending do not lean forward/sideways. Clear the route before
attempting the lift. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs.
When transferring appliance into roofspace, recommend
1 person to be in roofspace to receive the appliance and
other person to be below to pass up and support appliance. Ensure safe lifting techniques are used – keep back
straight – bend using legs. Keep load as close to body as
possible. Always use assistance if required. It is assumed
safe access, flooring and adequate lighting are provided
in the roof space. It is recommended a risk assessment
of the roof space area be carried out before moving the
appliance into the area to take into account access, sta-
bility of flooring, lighting and other factors, and appropriate measures taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton.
Always keep working area clear. Recommend cut base
end of carton and open carton flaps, then tilt boiler forwards from its side onto its base and remove carton by
sliding up over the boiler. Ensure safe lifting techniques
are used – keep back straight – bend using legs. Keep
load as close to body as possible. Always use assistance
if required. Dispose of packaging in a responsible manner. Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure
good grip when handling appliance outside packaging.
Positioning of Appliance for Final Installation – no
obstructions.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall
before lifting appliance into position. Obtain firm grip on
front and sides of appliance, lift upwards, ensure stable
balance achieved and lift upwards to position in place on
bracket. Ensure safe lifting techniques are used – keep
back straight – bend using legs - when lifting load from
floor level. Do not twist – reposition feet instead. Keep
boiler as close as possible to body throughout lift to
minimise strain on back. Ensure co-ordinated movements to ensure equal spread of weight of load. Always
use assistance if required. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp
edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – above
worktop, foreseeable obstructions etc.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall
before lifting appliance into position. Obtain firm grip on
front and sides of appliance, lift upwards, onto worktop if
practicable. Ensure stable balance achieved and lift
upwards to position in place on bracket. If 2 persons
positioning onto bracket obtain firm grip at front and
sides/base of boiler. Ensure coordinated movements during 2 person lifts to ensure equal spread of weight of
load. Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from floor
level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise
strain on back. Avoid upper body/top heavy bending - do
not lean forward/sideways. Always use assistance if
required. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and
ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – within
compartment etc. restricting installation.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall
before lifting appliance into position. Obtain firm grip on
17Instructions for installation and servicing ecoTEC
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4 Boiler installation sequence
front and sides of appliance, lift upwards, onto worktop if
practicable. Ensure stable balance achieved and lift
upwards to drop into place onto bracket. If 2 persons
positioning onto bracket obtain firm grip at front and
sides/base of boiler. Ensure coordinated movements during 2 person lifts to ensure equal spread of weight of
load. If 1 person positioning onto bracket recommend
obtain firm grip supporting base of boiler. Ensure safe
lifting techniques are used – keep back straight – bend
using legs - when lifting load from floor level. Do not
twist – reposition feet instead. Keep boiler as close as
possible to body throughout lift to minimise strain on
back. Always use assistance if required. Recommend
wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when
handling appliance.
Positioning of Appliance for Final Installation – in
roof space restricting installation.
This appliance is deemed to be a one person lift when
removed from the carton. Obtain firm grip on front and
sides of appliance, lift upwards, ensure stable balance
achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain firm grip
at front and sides/base of boiler. Ensure co-ordinated
movements during 2 person lifts to ensure equal spread
of weight of load. If 1 person positioning onto bracket
recommend obtain firm grip supporting base of boiler.
Ensure safe lifting techniques are used - keep back
straight – bend using legs - when lifting load from floor
level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise
strain on back. Always use assistance if required.
Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good
grip when handling appliance. It is recommended a risk
assessment of the roof space area be carried out before
moving the appliance into the area to take into account
access, stability of flooring, lighting and other factors,
and appropriate measures taken.
4.2 Required minimum distances/assembly clearances
min
165/246*
min 5
Fig. 4.1 Distances during installation (dimensions in mm)
min 5
min 180
min 500**
The boiler should be mounted on a flat and vertical area
of wall of sufficient area for the boiler plus the required
clearances for installation and servicing (fig. 4.1). These
are shown on the installation template supplied with the
boiler and are:
– 5 mm either side of the boiler
– 180 mm below the boiler
– 165 mm* above the boiler when utilising the 100 mm
outside diameter flue
– 246 mm* above the boiler when utilising the 125 mm
outside diameter flue
– 500 mm in front of the boiler to enable easy access
for servicing (may be provided by an opening door)
Note
If the boiler is to be 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’.
4.2.1 Select position for boiler
Refer to section 3.4 ‘Installation site’ for information
regarding the appliance location. In general the boiler
must be positioned such that:
• There is adequate space around the boiler for service
and maintenance
• The boiler can be correctly flued, i.e. the flue terminal
position is located in accordance with these instructions and the air/flue duct can be installed in accordance with the flue installation instructions supplied.
• All necessary pipework can be connected, including
the pressure relief valve and condensate drain.
4.2.2 Unpack the boiler
To unpack the boiler, cut both plastic carton straps, open
box and lift out the polystyrene top packing. Lift the
cardboard box upwards.
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Note
Care should be taken not to scratch the white
surface of the boiler casing.
4.2.3 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 10 mm for the hanging bracket.
Note
Use alternative fixing holes where necessary.
Boiler installation sequence 4
20
165
5
60/100
25
A
95
175
A
5
A
1065
A
180
A
Fig. 4.2 Assembly template
45°
256723_01 01 2005
450
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4 Boiler installation sequence
4.3 Flue exit
• If using rear flue mark the position of the air/flue duct
and its circumference.
Other flue options
Flue instructions for other flue systems such as vertical
RSF flues, flues run to the side of the boiler and the use
of additional bends etc. are detailed in the flue installation instructions provided with the boiler.
• Remove the template from the wall and plug the
drilled holes using the wallplugs supplied.
4.4 Fitting the boiler hanging bracket
1
2
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.
4.7 Removing the front case
2
1
3
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.
4.5 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.
4.8 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.
4.6 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.
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Boiler installation sequence 4
4.9 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 connection 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 (22 mm for
37kW models). 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.
4.10 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.
1
2
3
4
5
6
7
Fig. 4.6 Installing the hot and cold water connection (ecoTEC
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.
7
6
1
2
3
4
5
plus combination boiler)
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4 Boiler installation sequence
bar
4.11 Condensate drain pipe
1
2
7
6
1
2
3
4
5
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).
4
a
3
Internal
stackpipe
Fig. 4.8 Installing the condensate drain pipe (picture shows
ecoTEC plus combination boiler)
b
3
Internal
discharge system
5
c
Gulley
d
6
7
Soakaway
The ecoTEC plus appliances are fitted with a siphonic
trap (The filling height is 145 mm). 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) (built into the
boiler) should be incorporated into the pipe run, and
there must be an air break (4) in the discharge pipe
upstream of the trap. The connection to the stack
should not be made in a way that could cause cross
flow into any other branch pipe, or from that branch
pipe into the condensate drainpipe. This can be
achieved by maintaining an offset between branch
pipes of at least 110 mm on a 100 mm diameter stack
and 250 mm on a 150 mm diameter stack.
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Boiler installation sequence 4
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
minimum diameter of 22 mm with no length restriction
and should incorporate a trap with a 75 mm (3) (built
into the boiler) 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.
4.12 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.
4.12.1 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
13
6
12
11
10
9
8
7
1
2
3
4
5
• 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 pre-bended 22 mm copper tails (5) and (6).
• Fully insert pipes (5) and (6) into the service valves.
Tighten the union nuts in this position.
• Fit the handle for the filling loop with a countersunk
screw to the service valve (9).
ecoTEC pro combination boiler
bar
1
2
3
4
5
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
22 mm pre-bended copper tail (5) .
• Fully insert pipe (5) into the service valve. Tighten the
union nuts in this position.
Fig. 4.9 Installing the heating flow and return connection for
ecoTEC plus combination boiler
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4 Boiler installation sequence
ecoTEC plus system boiler
1
2
3
4
5
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 the
22 mm pre-bended copper tail (5) .
• Fully insert pipe (5) into the service valve. Tighten the
union nuts in this position.
4.12.2 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.
4.13 Connecting the flue system to the boiler
• Refer to separate air/flue duct installation instructions
included with the boiler.
4.14 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
3
4.14.1 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 the Republic of Ireland, reference should be made to
the current edition of the ETCI (Electro-Technical Council
for Ireland) 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
2
)
should be used.
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-+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.
4.14.2 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.
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4 Boiler installation sequence
4.14.3 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: 230 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!
Fig. 4.15 Connection wiring ecoTEC
26 Instructions for installation and servicing ecoTEC
Igniter
Connection: 230 V
Supply for accessory module
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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 pink B
X 2/15 brown C
X 2/8 blue 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
ecoTEC plus only:
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
Pump
tank NTC
connection
230V
X12
Electronic control box
Fig. 4.17 Connection wiring ecoTEC system boiler
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Boiler installation sequence 4
4.15 Controls
4.15.1 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
Available from 10-01-2006
VRT 360f (room temperature controller) 00 2001 8258 Wireless controller, receiver wall-mounted
VRT 230 (room temperature controller) 00 2001 0841 Wall-mounted, 3-wire connection to terminals 3-4-5
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
VRT 50 (room thermostat) 00 2001 8265 Wall-mounted, 2-wire bus
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 810/2 00 2002 3370 Diagnostic software
Table 4.1 Vaillant controls and accessories
4.15.2 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.
4.15.3 Connection details for external time switches
and boiler terminal strip
20 VDC (DO NOT USE 7, 8, 9 IN UK!)
987
LN
N
L
3 A FUSE
MAINS
SUPPLY
230 V
50 Hz
Fig. 4.18 Connection details for time switches
SWITCH
CONTACTS
L
CLOCK
N
5
4
3
ROOM
THERMOSTAT
N
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).
4.15.4 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.
4.15.5 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.
4.16 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
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4 Boiler installation sequence
5 Commissioning Part I
the room containing the room thermostat should not be
fitted with a TRV).
4.17 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.
4.18 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.
4.19 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).
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 and bleeding the heating system
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.
4.20 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.
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.
30 Instructions for installation and servicing ecoTEC
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