Vaillant ecoTEC plus 624, ecoTEC plus 630, ecoTEC plus 824, ecoTEC plus 831, ecoTEC pro 828 Installation And Maintenance Manual
...
For the installer
ecoTEC plus 612
ecoTEC plus 615
ecoTEC plus 618
ecoTEC plus 624
ecoTEC plus 630
ecoTEC plus 824
ecoTEC plus 831
ecoTEC pro 828
Installation and maintenance manual
ecoTEC
Wall hung room sealed fan assisted condensing boiler
GB
2
Contents
Installation and maintenance manual ecoTEC
Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notes on the documentation . . . . . . . . . . . . . . . 4
1.1.1 Applicable documents. . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Preservation of documents . . . . . . . . . . . . . . . . 4
1.1.3 Safety instructions and symbols. . . . . . . . . . . . 4
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Declaration of conformity. . . . . . . . . . . . . . . . . . 5
2 Boiler specifications . . . . . . . . . . . . . . . . . . . 6
2.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 General requirements . . . . . . . . . . . . . . . . . . 10
3.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Scope of delivery and accessories . . . . . . . . . . 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 bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 of boiler . . . . . . . . . . . . . . . . . . . 17
4.1.2 Unpack the boiler. . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.3 Using assembly templates . . . . . . . . . . . . . . . . . 17
4.2 Cutting through the wall. . . . . . . . . . . . . . . . . . . 18
4.3 Installing appliance holder . . . . . . . . . . . . . . . . . 18
4.4 Installing flue system. . . . . . . . . . . . . . . . . . . . . . 18
4.5 Fitting the appliance . . . . . . . . . . . . . . . . . . . . . . 18
4.6 Removing the housing . . . . . . . . . . . . . . . . . . . . 18
4.7 General instructions for heating system . . . . . 18
4.8 Gas connection. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.9 Cold water mains inlet and hot water outlet
(only 800 series) . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.10 Heating connection . . . . . . . . . . . . . . . . . . . . . . 20
4.10.1 Heating flow and return connection. . . . . . . . . 20
4.10.2 Drain pipe on the pressure control valve
of the heating system . . . . . . . . . . . . . . . . . . . . . 21
4.11 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . 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
4.13.4 Connection of programmable thermostats . . . 27
4.14 Controls (800 series) . . . . . . . . . . . . . . . . . . . . . 27
4.14.1 External electrical controls . . . . . . . . . . . . . . . . 27
4.14.2 Connection of external controls . . . . . . . . . . . . 27
4.14.3 Connection details for programmable
room thermostats . . . . . . . . . . . . . . . . . . . . . . . . 27
4.14.4 Connection of time switches . . . . . . . . . . . . . . . 28
4.14.5 Connection details for external time switches
and boiler terminal strip . . . . . . . . . . . . . . . . . . . 29
4.14.6 Vaillant optional plug in timer accessories . . . 29
4.15 Controls (600 series) . . . . . . . . . . . . . . . . . . . . . 29
4.15.1 External electrical controls . . . . . . . . . . . . . . . . 29
4.15.2 Connection of external electrical controls . . . 29
4.15.3 Connection details using an external
wiring centre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.16 Thermostatic radiator valves. . . . . . . . . . . . . . . 29
4.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.19 Anticycling ‘economiser’ control. . . . . . . . . . . . 29
4.20 Automatic pump spin control (APS). . . . . . . . . 29
5 Commissioning Part I . . . . . . . . . . . . . . . . . . 32
5.1 Preliminary electrical checks. . . . . . . . . . . . . . . 32
5.2 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Cold water supply (only 800 series). . . . . . . . . 32
5.4 Filling the heating system . . . . . . . . . . . . . . . . . 32
5.4.1 Checking the filling pressure
of the heating system . . . . . . . . . . . . . . . . . . . . . 32
5.4.2 ecoTEC plus filling device (800 series) . . . . . . 33
5.4.3 Filling the heating system in ecoTEC pro
and ecoTEC plus (600 series) . . . . . . . . . . . . . . 33
5.4.4 Filling the heating system for the first time . . 33
5.5 Rinsing the heating system for the first time
(“cold”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.6 Filling the condensation water siphon . . . . . . . 34
5.7 Adjusting the pumping capacity . . . . . . . . . . . . 35
5.8 Adjusting the discharge valve . . . . . . . . . . . . . . 35
5.9 Checking the gas setting . . . . . . . . . . . . . . . . . . 35
5.9.1 Factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9.2 Gas inlet working pressure. . . . . . . . . . . . . . . . . 35
5.9.3 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . 36
5.10 Refitting the case. . . . . . . . . . . . . . . . . . . . . . . . . 36
5.11 Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Functional checks (commissioning part II). 37
6.1 Functional checks. . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1.2 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1.3 Water heating (only 800 series) . . . . . . . . . . . . 38
3Installation and maintenance manual ecoTEC
Contents
6.1.4 Final rinsing of the heating system (“hot”). . . 38
6.2 Handing over to the user . . . . . . . . . . . . . . . . . . 38
7 Inspection and maintenance . . . . . . . . . . . . 38
7.1 Initial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.4 Overview of the maintenance tasks . . . . . . . . . 40
7.1.5 Functional check of boiler operation . . . . . . . . 40
7.2 Servicing the compact thermal module. . . . . . 40
7.2.1 Dismantling the compact thermal module . . . 40
7.2.2 Cleaning the integral condensation heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . 42
7.2.4 Installing the compact thermal module . . . . . . 42
7.3 Cleaning the condensation water siphon . . . . 43
7.4 Checking the expansion vessel . . . . . . . . . . . . . 43
7.5 Recommissioning the boiler. . . . . . . . . . . . . . . . 44
7.6 Test operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 44
8.1 Logical fault finding procedure . . . . . . . . . . . . . 44
8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.2 Diagnosis codes . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1.3 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1.4 Error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4 Test programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5 Resetting parameter to factory settings . . . . . 49
9 Replacing components . . . . . . . . . . . . . . . . . 49
9.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Replacing fan or gas fittings . . . . . . . . . . . . . . . 50
9.4 Replacing expansion tank. . . . . . . . . . . . . . . . . . 50
9.5 Replacing primary heat exchanger. . . . . . . . . . 51
9.6 Replacing electronics and display. . . . . . . . . . . 52
9.7 Check CO
2
content and if necessary set
(air-ratio adjustment) . . . . . . . . . . . . . . . . . . . . . 53
10 Recycling and disposal . . . . . . . . . . . . . . . . . 54
10.1 Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Installation and maintenance manual ecoTEC
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:
Brief operating instructions
(only ecoTEC plus) no. 838404
Benchmark logbook no. 800371
Warranty card with return envelope no. 802922
For the qualified technician:
Installation and maintenance manual no. 839592
Assembly manual for flue accessories no. 835296
The manuals for any accessories and controllers used
also apply.
1.1.2 Preservation of documents
Please pass on this installation manual to the owner of
the system. The owner shall preserve 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 800 range
The ecoTEC 800 range is a fully automatic, wall mounted, room sealed condensing (high efficiency) combination 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 tank and associated pipework.
Domestic hot water has priority over central heating.
The ecoTEC 800 range consists of models with outputs
of 23 kW, 28 kW and 31 kW for domestic hot water. All
versions are available in natural gas. The 31 kW version
version 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 can be filled using the built–in
filling loop contained within the boiler.
ecoTEC 600 range
The ecoTEC 600 range is a fully automatic, wall mounted, room sealed condensing (high efficiency) system
boiler for central heating and domestic hot water (where
a separate indirect hot water storage cylinder is also
incorporated in the system). The ecoTEC 600 range consists of models with outputs of 12, 15, 18, 24 and 30 kW.
All ecoTEC 600 range boilers are available in Natural
Gas. The 18 kW and the 30 kW version 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 800). 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.
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
5Installation and maintenance manual ecoTEC
the appliance or other material assets be impaired in the
event of improper use.
The appliance is designed to generate heat for connected hot water central heating systems and for central hot
water supply (only 800 series). Any other use or extended use is considered to be use other than intended. The
manufacturer/supplier is not liable for any resulting
damage. The user alone bears the risk.
Intended use includes the observance of the operating
and installation manual and the adherence to the inspection and maintenance conditions.
Danger!
Any improper use is forbidden.
The appliances must be installed by a qualified engineer,
who is responsible for adhering to the existing regulations, rules and guidelines.
1.4 CE mark
The CE mark 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.
Vaillant Ltd. supports the Benchmark initiative.
In the information pack, you will find a
Benchmark Logbook. It is very important that
this is completed correctly at the time of
installation, commissioning and hand over to
the user.
1.5 Declaration of conformity
Fig. 1.1 Declaration of conformity
Introduction 1
6 Installation and maintenance manual ecoTEC
2 Boiler specifications
2.1 Technical data
Technical data
ecoTEC plus
Units
612 615 618 624 630
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
4.0 – 12.0
4.1 – 12.3
4.3 – 12.7
4.4 – 12.9
4.0 – 15.0
4.1 – 15.5
4.3 – 15.9
4.4 – 16.2
6.0 – 18.0
6.1 – 18.6
6.3 – 19.1
6.5 – 19.5
8.7 – 24.0
9.0 – 24.7
9.3 – 25.5
9.4 – 26.0
10.0 – 30.0
10.3 – 30.9
10.6 –31.8
10.8 – 32.4
kW
kW
kW
kW
Memory charging capacity 12.0 15.0 18.0 24.0 30.0 kW
Maximum thermal load during memory charging 12.2 15.3 18.4 24.5 30.6 kW
Maximum thermal load for heating 12.2 15.3 18.4 24.5 30.6 kW
Minimum thermal load 4.1 4.1 6.1 8.9 10.2 kW
Category II
2H3P
SEDBUK AAAAABand
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
G20: 1.3
G31: 0.95
G20: 1.6
G31: 1.19
G20: 1.9
G31: 1.43
G20: 4.1
G31: 1.90
G20: 3.2
G31: 2.38
m
3
/h
kg/h
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return
at maximum thermal load (80 °C flow/60 °C return)
1.9
5.5
1.9
6.9
2.8
8.3
4.1
11.1
4.7
13.8
g/s
g/s
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
40
70
°C
°C
Standard efficiency factor in compliance with DIN
4702, T.8 (related to rated thermal output setting)
75 °C flow/60 °C return
40 °C flow/30 °C return
107
109
%
%
30 % efficiency 108
%
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
40 – 85 °C
Permitted total overpressure 3.0 bar
Circulating water volume (∆T=20 K)
516 645 774 1032 1290 l/h
Approx. condensation volume
at 40 °C flow/30 °C return heating
1.1 1.4 1.7 2.2 2.7 l/h
Pump delivery height 250 mbar
Adjustable storage target value (15 °C at left stop,
spare adjusting range 40 – 70 °C
15 – 70 °C
Exhaust nozzles 60/100 mm
10 l expansion vessel pre-charge pressure 0.75 0.75 0.75 0.75 0.75 bar
Maximum CH system pressure 2.5 2.5 2.5 2.5 2.5 bar
Connections heating flow/return 3/4“ 3/4“ 3/4“ 3/4“ 3/4“
Gas inlet 15 15 15 15 15 mm
Pressure relief discharge pipework (min.) 15 15 15 15 15 mm
Condensate drain (min. internal drain) 19 19 19 19 19 mm
Weight 38 38 40 39 40 kg
Primary water content 1.9 1.9 1.9 2.1 2.3 l
Electrical supply voltage 230/50 230/50 230/50 230/50 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input min.
max.
at 30 % efficiency
70
130
65
W
W
W
Table 2.1 Technical data 600 series
2 Boiler specifications
7Installation and maintenance manual ecoTEC
Technical data
ecoTEC plus
ecoTEC pro
828
Units
823 831
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
6.0 – 18.0
6.1 – 18.6
6.3 – 19.1
6.5 – 19.5
8.7 – 24.0
9.0 – 24.7
9.3 – 25.5
9.4 – 26.0
8.7 – 24.0
9.0 – 24.7
9.3 – 25.5
9.4 – 26.0
kW
kW
kW
kW
Drinking water capacity 23.0 31.0 28.0 kW
Maximum thermal load during drinking water heating 23.5 31.6 28.6 kW
Maximum thermal load for heating 18.4 24.5 24.5 kW
Minimum thermal load 6.1 8.9 8.9 kW
Category II
2H3P
SEDBUK A A A Band
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
G20: 1.9
G31: 1.43
G20: 3.3
G31: 2.45
G20: 3.0
G31: 2.22
m
3
/h
kg/h
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
2.8
8.3
4.1
14.2
4.1
12.9
g/s
g/s
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
40
70
°C
°C
Standard efficiency factor in compliance with DIN 4702,
T.8 (related to rated thermal output setting)
75 °C flow/60 °C return
40 °C flow/30 °C return
107
109
%
%
Rated efficiency (stationary)
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
98
101
104
106
%
%
%
%
30 % efficiency 108
%
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
40 – 85 °C
Permitted total overpressure 3.0 bar
Circulation water volume (∆T=20 K)
774 1032 1032 l/h
Approx. condensation volume
at 40 °C flow/30 °C return heating
1.7 2.2 2.2 l/h
Pump delivery height 250 mbar
Minimum drinking water volume 1.5 1.5 1.5 l/min
Hot water volume (∆T=30 K)
11.0 14.8 13.4 l/min
Permitted overpressure 10 bar
Required connecting pressure 0.35 bar
Hot water discharge temperature range 35 – 65 °C
Exhaust nozzles 60/100 mm
10 l expansion vessel pre-charge pressure 0.75 0.75 0.75 bar
Maximum CH system pressure 2.5 2.5 2.5 bar
Connections heating flow/return 3/4“ 3/4“ 3/4“
Gas inlet 15 15 15 mm
Pressure relief discharge pipework (min.) 15 15 15 mm
Condensate drain (min. internal drain) 19 19 19 mm
Weight 41 kg
Primary water content 1.9 2.3 2.1 l
Electrical supply voltage 230/50 230/50 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input min.
max.
at 30 % efficiency
70
130
65
W
W
W
Table 2.2 Technical data 800 series
Boiler specifications 2
8 Installation and maintenance manual ecoTEC
2.2 Dimensions
241
20
642
720
883
125
100100
440
35 35
130
180
300
175
190
65
8
6
4
3
2
1
5
7
9
10
12345
Fig. 2.1 Dimensions in mm
Legend:
1 Heating return pipe Ø 22 mm
2 Cold water connection Ø 15 mm (only 800 series)
3 Gas connection Ø 15 mm
4 Hot water connection Ø 15 mm (only 800 series)
5 Heating flow pipe Ø 22 mm
6 Appliance holder
7 Wall lead-in - flue system 60/100
8 Wall lead-in - flue system 80/125
9 Connection for the flue pipe
10 Balancing frame (Accessories, Art. No.: 308 650)
Note
With the balancing frame (Art. No 308 650),
the pipes can be laid in front of the wall
upwards behind the appliance. The distance of
the appliance from the wall thus increases by
65 mm.
2 Boiler specifications
9Installation and maintenance manual ecoTEC
2.4 Installation
1
2
3
4
6
5
7
8
9
14
13
12
10
11
Fig. 2.2 Function elements of 800 series
Legend:
1 Diaphragm expansion tank
2 Air intake pipe
3 Compact thermal module
4 Ignition electrode
5 Rapid-action fan
6 Priority reversing valve with bypass
7 Pump
8 Aqua-Sensor
9 Electronics box
10 Pressure sensor
11 Hot water heat exchanger
12 Gas fitting
13 Heat exchanger
14 Connection for the flue pipe
1
2
3
4
5
7
9
14
13
12
10
Fig. 2.3 Function elements of 600 series
Legend:
1 Diaphragm expansion tank
2 Air intake pipe
3 Compact thermal module
4 Ignition electrode
5 Rapid-action fan
7 Pump
9 Electronics box
10 Pressure sensor
12 Gas fitting
13 Heat exchanger
14 Connection for the flue pipe
Boiler specifications 2
10 Installation and maintenance manual ecoTEC
2.5 Type plate
The type plate of the Valliant ecoTEC is attached to the
bottom of the appliance at the factory.
Fig. 2.4 Type plate
3 General requirements
3.1 Preliminary remarks
This appliance shall only be installed in conjunction with
a Vaillant air flue duct. 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), 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, 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:
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 Scope of delivery and accessories
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).
2 Boiler specifications
3 General requirements
11Installation and maintenance manual ecoTEC
1
2
3
4
8
9
7
6
5
Fig. 3.1 Scope of delivery for ecoTEC plus 600 series
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Appliance holder
2 1 Appliance
3 1 Lower appliance cover
4 4 Connecting pipes (gas, heating, safety valve)
53
Maintenance taps (gas, heating flow and
return)
1 Bag with literature (Item 6 - 8)
6 1 Assembly template
7 1 Benchmark logbook
83
Operating, installation, maintenance manual
andassembly manual for flue pipe
92
Bag with small items: 4 wooden screws,
4 plugs 10x60 mm, 4 plain washers, 2 gaskets
R3/4, 1 gasket R1/2, 1 union nut
2
For liquid gas appliances, extra: 1 sticker each
for tank and ventilation (above Fig.)
Table 3.1 Scope of delivery for ecoTEC plus 600 series
1
2
3
4
6
5
8
9
7
Fig. 3.2 Scope of delivery for ecoTEC plus 800 series
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Appliance holder
2 1 Appliance
3 1 Lower appliance cover
46
Connecting pipes (gas, heating, water, safety
valve)
54
Maintenance taps (gas, heating flow and return,
cold water with filling pipe)
1 Bag with literature (Item 6 - 8)
6 1 Assembly template
7 1 Benchmark logbook
83
Flue system operating, installation, maintenance and assembly manual
92
Bag with small items: 4 wooden screws, 4 plugs
10x60 mm, 4 plain washers, 42 gaskets R3/4,
1 gasket R1/2, 1 union nut, 1 O-ring seal, 2 grips
with countersunk screws, 1 clamp
2
For liquid gas appliances, extra: 1 sticker each
for tank and ventilation (above Fig.)
Table 3.2 Scope of delivery for ecoTEC plus 800 series
General requirements 3
12 Installation and maintenance manual ecoTEC
b
a
r
i
F
P
1
2
3
8
7
6
5
4
Fig. 3.3 Scope of delivery for ecoTEC pro
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Appliance holder
2 1 Appliance
32
Connecting pipes (hot water, heating safety
valve)
44
Maintenance taps (gas, heating flow and return,
cold water)
1 Bag with literature (Item 5 - 7)
5 1 Assembly template
6 1 Benchmark logbook
71
Flue system operating, installation, maintenance and assembly manual
82
Bag with small items: 4 wooden screws, 4 plugs
10x60 mm, 4 plain washers, 4 gaskets R3/4,
1 gasket R1/2, 2 union nuts
Table 3.3 Scope of delivery for ecoTEC pro
3.4 Installation site
Please note the safety instructions below before choosing where to install the heater:
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 combustion air
is technically free of chemical substances containing fluorine, chlorine, sulphur etc. Sprays, solvents and cleaning agents, paints, adhesives etc. contain this 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 combustion air supply is technical free of the above mentioned substances.
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 BS7671 (IEE Regulations), the electrical
provisions of the Building Standards (Scotland)
Regulations, and in IE the current edition of IS813 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
3 General requirements
13Installation and maintenance manual ecoTEC
of Gas Engineers Publication IGE/UP/7/1998 “Guide for
Gas Installation in Timber Framed Housing”.
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.
3.6 Flue pipe
Danger!
Vaillant appliances are certified only 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
600
65.5
30
74
48
Fig. 3.4 Art. No. 303 933
The standard 100 mm flue system (Art. No. 303 933) is
suitable for installations up to 666 mm measured from
the centre of the boiler flue outlet to the outside face of
the wall.
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.
70
1435
10
550
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
20 m.
A vertical flue system is also available. Refer to flue system installation instructions for full details.
70
1103
70
15
Fig. 3.6 Art. No. 303 209
1530
880
70
Fig. 3.7 Art. No. 303 200
General requirements 3
14 Installation and maintenance manual ecoTEC
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).
A
BCD
A
G
H, I
F
J
B
F
M
L
L
K
K
G
G
F
F
E
A
A
Fig. 3.8 Flue termination
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
A
Directly below an opening, above an opening or horizontal to an opening, air brick, opening window, etc.
300
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 in the car port (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
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 combustible substances are not directly
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.
Fig. 3.9 Flue termination under balcony/eaves
3.8 Air supply
Detailed recommendations for air supply are given in
BS 5440: Part 2.
It is not necessary to have an air vent in the room or
internal space in which the boiler is installed.
Cupboard or compartment ventilation
The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during
operation is very low. For cupboard or compartment
installations it is therefore not necessary to provide any
high or low level permanent air vents for cooling purposes.
3 General requirements
15Installation and maintenance manual ecoTEC
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. This cleansing should 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 495 1861, or Fernox, Alpha
Fry Technologies, Tandem House, Marlow Way, Croydon,
CR0 4XS. Tel 0870 6015000.
3.10.2 Filling and preparing heating system
The system can be filled using the built in filling loop
(ecoTEC plus 800 series) 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.
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
0.109 0.156
Table 3.5 Sizing of additional expansion vessel
General requirements 3
16 Installation and maintenance manual ecoTEC
3.11 Pump specifications
3.11.1 Circulating pump
only ecoTEC plus:
The circulating pump is included in the boiler. The residual pump discharge height depending on the overflow
valve is shown in Fig. 3.10.
The operating mode of the 2-step pump can be adjusted
below the diagnosis point d.12, see Section 8.1.2.
400
300
200
100
0
0 200 400 600 800 1000 1200 1600
Lift
[
mbar
]
Volumeflow [l/h
]
1800
1400
2. Step1. Step
Fig. 3.10 Pump specifications ecoTEC plus
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
overflow valve is shown in Fig. 3.11.
400
300
200
100
0
0 200 400 600 800 1000 1200 1600
Lift
[
mbar
]
Volumeflow [l/h
]
1800
1400
Fig. 3.11 Pump specifications ecoTEC pro
3.11.2 System bypass
An automatic system bypass is provided in the boiler.
The boiler is suitable for use in systems with thermostatic radiator valves and no additional bypass is required.
The overflow 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 siphon condensate discharge
(ecoTEC plus) or a condensate trap (ecoTEC pro) incorporating a water trap of 140 mm.
4 Boiler installation sequence
4.1 Required minimum distances/assembly clearances
min
min 5
min 5
min 500**
min 180
167/246*
Fig. 4.1 Distances during installation (dimensions in mm)
Both for the installation/assembly of the appliance and
also for carrying out maintenance tasks later, you need
the minimum distances and minimum assembly clearances given below:
– side distance: 5 mm on each side
– lower side 180 mm
– upper side*: 167 mm for flue system
Ø 60/100
246 mm for flue system
Ø 80/125 mm
– front side**: 500 mm
This distance is needed for easier
access during maintenance tasks.
It is not necessary to keep a clearance between the
appliance and combustible substances or components,
as at the rated heating power of the appliance, the temperature here is always lower than the permitted temperature of 85 °C.
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’.
3 General requirements
4 Boiler installation sequence
17Installation and maintenance manual ecoTEC
4.1.1 Select position of boiler
Refer to section ‘Boiler location’ 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.
4.1.2 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 assembly templates
• Adjust the assembly template provided with the appliance with the assembly spot vertically and fix the template.
The template shows:
- the position of the fixing holes for the appliance holder,
- the position of the connecting pipe and
- the position of the flue pipe for the horizontal wall
lead-in directly above the appliance.
• Mark the position of the fixing holes and drill two
holes with Ø 8 mm for the plugs.
• If you want to guide the flue pipe horizontally directly
above the appliance through the outer wall, mark the
opening for the wall lead-in on the wall. While installing the flue pipe, follow the enclosed assembly instructions, which also describe other possible pipe layouts
for the flue system.
• Remove the assembly template from the wall.
Boiler casing
Minimum
Clearances
Reqd.
Flow
D.H.W.
out
Cold
Mains in
Gas in Return
Condensale
discharge
Minimum Clearances
Reqd.
Flue hole
(60/100 mm
flue system)
Fixing holes and
Position for
optional
pre-instalation
connection
Flue hole
(80/125 mm
flue system)
Please use
the new
Boiler hanging
bracket
ecoMAX 824/2
ecoMAX 828/2
ecoMAX 835
ecoMAX 613/2
ecoMAX 618/2
ecoMAX 622/2
Fig. 4.2 Assembly template
Boiler installation sequence 4
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