Vaillant ecoTEC plus SERIES Installation Manual

Instructions for installation and servicing

ecoTEC plus

Wall hung open vent condensing boiler

GB, IE

For the installer

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Notes on the documentation. . . . . . . . . . . . . . . . 3

1.1.1 Other instructions supplied with this appliance. . . 3

1.1.3 Safety instructions and symbols . . . . . . . . . . . . . 3

1.2 Validity of the manual . . . . . . . . . . . . . . . . . . . . . . 4

1.3 ecoTEC plus boilers . . . . . . . . . . . . . . . . . . . . . . . . 4

1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 General information . . . . . . . . . . . . . . . . . . . . . . . 4

1.5.1 Gas category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5.2 Gas safety (installation and use) regulations . . 4

1.5.3 Gas testing and certification . . . . . . . . . . . . . . . . 4

1.5.4 Control of substances hazardous to health . . . 5

1.5.5 Insulation pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.7 Manual handling guidance . . . . . . . . . . . . . . . . . . 5

1.5.8 Gas leak or fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.9 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.10 Sheet metal parts . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.11 Sealed components . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.12 Electrical supply failure . . . . . . . . . . . . . . . . . . . . 5

1.5.13 Protection against freezing . . . . . . . . . . . . . . . . . 5

1.5.14 Boilers installed in a compartment or

cupboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.15 Boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5.16 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5.17 Pluming from flue terminal . . . . . . . . . . . . . . . . . 6

1.5.18 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5.19 Maintenance and servicing . . . . . . . . . . . . . . . . . 6

1.5.20 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.6 Statutory requirements . . . . . . . . . . . . . . . . . . . . 6

1.7 Regulations, rules and guidelines. . . . . . . . . . . . 6

1.8 CE label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.9 Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.10 Gas council numbers . . . . . . . . . . . . . . . . . . . . . . . 7

2 Boiler specifications . . . . . . . . . . . . . . . . . . . . 8

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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

3.3 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.5 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.5.1 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5.2 Internal flue installation . . . . . . . . . . . . . . . . . . . . 13

3.6 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.7 Cupboard or compartment ventilation . . . . . . . 13

3.8 Domestic hot water cylinder . . . . . . . . . . . . . . . . 13

3.8.1 Unvented hot water cylinder . . . . . . . . . . . . . . . . 13

3.9 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.10 Heating system controls . . . . . . . . . . . . . . . . . . . . 13

3.11 Draining tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.12 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.13 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.14 Pump specification . . . . . . . . . . . . . . . . . . . . . . . . 13

3.15 Cleanser and inhibitor . . . . . . . . . . . . . . . . . . . . . . 14

3.16 Water pressure loss . . . . . . . . . . . . . . . . . . . . . . . . 15

3.17 Open vented heating system . . . . . . . . . . . . . . . . 16

3.18 Sealed water systems . . . . . . . . . . . . . . . . . . . . . . 16

3.18.1 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.18.2 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.18.3 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.18.4 Water make up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.18.5 Filling a sealed water system . . . . . . . . . . . . . . . 17

4 Boiler installation sequence . . . . . . . . . . . . . . 18

4.1 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.1 Sheet metal parts . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.2 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.3 Timber frame buildings . . . . . . . . . . . . . . . . . . . . . 18

4.1.4 Contents included with delivery . . . . . . . . . . . . . 18

4.2 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.1 Other flue options . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3 Fitting the boiler hanging bracket . . . . . . . . . . . 19

4.3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3.2 Removing the front casing . . . . . . . . . . . . . . . . . . 19

4.3.3 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3.4 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3.5 Condensate trap and siphonic drain

connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3.6 Installing the flue system . . . . . . . . . . . . . . . . . . . 21

4.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . 21

4.4.1 Connection to the main supply . . . . . . . . . . . . . . 21

4.4.2 Wiring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.4.3 Electrical board layout . . . . . . . . . . . . . . . . . . . . . 23

4.4.4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.4.5 External electrical controls . . . . . . . . . . . . . . . . . 25

4.4.6 Connection details for external switches

and boiler terminal strip. . . . . . . . . . . . . . . . . . . . 26

4.4.7 Vaillant optional plug in timer

accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.4.8 Connection details using the VR 65

and VR 61 control centre . . . . . . . . . . . . . . . . . . . 26

5 Commissioning (Part I) . . . . . . . . . . . . . . . . . . 27

5.1 Preliminaries - all systems . . . . . . . . . . . . . . . . . . 27

5.1.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1.2 Gas pressure statement - Natural gas . . . . . . . . 28

5.1.3 Initial Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1.4 Ignition problems . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1.5 Flue problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1.6 Testing - gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 Natural gas to LPG conversion . . . . . . . . . . . 30

7 Functional checks commissioning (part II). . 31

7.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.3 Domestic hot water (If optional VR65,
uniSTOR cylinder and Vaillant control

are installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.4 Pump exercise programme . . . . . . . . . . . . . . . . . 31

7.5 Final flush of the heating system (hot) . . . . . . . 31

7.6 Handing over to the user . . . . . . . . . . . . . . . . . . . 32

Instructions for installation and servicing ecoTEC plus 0020020828_072

Contents

Introduction 1

8 Inspection and maintenance . . . . . . . . . . . . . 32

8.1 Inspection and maintenance intervals . . . . . . . . 32

8.1.1 General inspection and maintenance

instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.1.3 Checking the CO/CO

8.1.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.1.5 Spark electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.1.6 Removing the burner . . . . . . . . . . . . . . . . . . . . . . 36

8.1.7 Combustion chamber and heat exchanger . . . . 37

8.1.8 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8.1.9 Inner casing panel seal check . . . . . . . . . . . . . . . 37

8.1.10 Checking the expansion vessel (If fitted). . . . . . 37

8.1.11 Re commissioning the boiler . . . . . . . . . . . . . . . . 38

8.1.12 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9 Combustion analysis . . . . . . . . . . . . . . . . . . . . 38

9.1 Check CO

10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 40

10.1 Logical fault finding procedure . . . . . . . . . . . . . . 40

10.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

10.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

10.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10.3 Resetting parameter to factory settings . . . . . . 44

11 Parts replacement . . . . . . . . . . . . . . . . . . . . . 45

11.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 45

11.2 Replacing the burner. . . . . . . . . . . . . . . . . . . . . . . 45

11.3 Replacing the gas valve . . . . . . . . . . . . . . . . . . . . 45

11.4 Replacing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.5 Replacing the heat exchanger . . . . . . . . . . . . . . . 45

11.6 Replacing the condense trap and

siphonic drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11.7 Replacing electronics and display . . . . . . . . . . . 46

12 Recycling and disposal . . . . . . . . . . . . . . . . . . 47

12.1 Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

12.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

content . . . . . . . . . . . . . . . . . . . . . . . . . 38

2

ratio . . . . . . . . . . . . . . . . . 33

2

1 Introduction

1.1 Notes on the documentation.

To ensure clarity of information in instructions a new
European standard of advice and symbols is being
introduced. To ensure compliance with this new standard
the following details are included.The following informa­tion is intended to help you through-out the boilers
entire instruction pack. We assume no liability for any
damage caused by non-observance of these instructions.

1.1.1 Other instructions supplied with this appliance.

For the owner:

Instructions for use no. 0020020829
Short operating instructions no. 838404
Warranty card with return envelope no. 802922

For the installer/service engineer:

Flue installation instructions no. 834449

The instructions for any accessories and controllers
used also apply.
The Benchmark gas boiler commissioning checklist
(in this manual) should be completed by the installer
and/or the commissioning engineer.
If, after reading these instructions, you have any
questions on the operation of the boiler, please contact
either your installer or Vaillant Technical Department.

1.1.2 Retention of documents

Please retain this literature and all related documents
so that they are available whenever they are required.
If you move please pass on the documents to the buyer.

1.1.3 Safety instructions and symbols

Please observe the safety instructions in this literature
for the operation of the appliance.

Danger!

d

Immediate risk of serious injury or death.

13 Factory guarantee and Vaillant service . . . . 47

13.1 Factory guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 47

13.2 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

14 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Danger!

e

Risk of death from electric shock!

Danger!

H

Risk of burns or scalding!

Caution!

a

Potentially dangerous situations for the
product and environment.

Note!

h

Useful information and instructions.

• Symbol for a necessary task

3Instructions for installation and servicing ecoTEC plus 0020020828_07

1 Introduction

Note!

h

Installation and adjustment of the boiler as well as
service, maintenance and repair may only be car­ried out by a competent person approved at the
time by the Health and Safety executive and in ac­cordance with the gas safety (installation and use)
regulations 1998.

1.2 Validity of the manual

This installation manual applies exclusively to units with
the following part numbers:
– 0010002460
– 0010002461
– 0010002724
– 0010002725

The part number of the unit can be obtained from the
identification plate.

1.3 ecoTEC plus boilers

The ecoTEC plus boilers are designed to provide central
heating from a fully pumped open-vented or sealed
water system. The central heating water temperature
can be adjusted on the boiler. The domestic hot water
can only be adjusted on the boiler if it is installed with a
Vaillant uniSTOR unvented cylinder and relevant con­trols. Once the controls are set the boiler operates auto­matically.
A frost protection programme is also included.
Please read these instructions and follow them carefully
for the correct and economical use of your boiler. These
instructions are applicable to the following ecoTEC plus
boilers, available in Natural Gas. All ecoTEC plus boilers
can be converted to LPG.

Appliance Maximum output

ecoTEC plus 415 15 kW

ecoTEC plus 418 18 kW

ecoTEC plus 428 28 kW

ecoTEC plus 438 38 kW

1.4 Intended use

The boiler has been designed for use with a open-vented
central heating system, and comes fully tested and
assembled. The boiler is easily mounted on any internal
wall and can be installed with either a horizontal or ver­tical RSF (room sealed fan assisted) flue. The boiler uses
a standard flue system (100 mm or 125 mm outside di­ameter). Flue extensions and additional bends and el­bows are available for the flue system to increase the
flexibility. If desired, an inhibitor may be used in the sys­tem. Guidance on the use of inhibitors is contained in
these instructions. The boiler has a built in diagnostic
system which indicates the operational status of the
boiler. This feature provides key information to aid com­missioning and fault finding. The data badge is fitted to

the combustion chamber cover of the boiler. See text of
General Requirements for installation requirements or
notes.
The Vaillant ecoTEC plus boiler is a state-of-the-art ap­pliance which has been constructed in accordance with
recognised safety regulations. Nevertheless, danger to
the life and limb of the user or third parties can still
occur or the appliance or other material assets be im­paired in the event of improper use.
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental capa­bilities, or lack of experience and/or knowledge, unless
they have been given supervision or instruction con­cerning use of the unit by a person responsible for their
safety.
Children must be watched to ensure that they do not
play with the unit.
The appliances are designed for central heating sys­tems. Any other use or extended use is considered to be
use other than intended. The user alone bears the risk.
The manufacturer/ supplier is not liable for any result­ing damage. Intended use includes the observance of
the operating and installation manual and the adher­ence to the inspection and maintenance conditions.

Caution!

a

Any incorrect use is forbidden. The appliances
must be installed by a competent person ap­proved at the time by the Health and Safety
Executive, who is responsible for adhering to
the existing regulations, rules and guidelines.

1.5 General information

Thank you for choosing a Vaillant boiler. The information
given in this booklet will enable you to obtain the best
performance from this boiler.

1.5.1 Gas category

The boiler is supplied factory set for use on Natural Gas
(G20). The ecoTEC plus boilers can be field adjusted for
use on LPG (propane G31), see section 6 for instructions
or contact Vaillant Service, 0870 6060 777.

1.5.2 Gas safety (installation and use) regulations

In your own interests and that of safety, it is the Law
that ALL gas appliances are installed by a competent
person approved at the time by the Health and Safety
Executive in accordance with the current issue of the
above regulations.

1.5.3 Gas testing and certification

The boiler is tested and certificated for safety and per­formance. It is, therefore, important that no alteration is
made to the boiler.

Instructions for installation and servicing ecoTEC plus 0020020828_074

Introduction 1

1.5.4 Control of substances hazardous to health

Under Section 6 of The Health and Safety at Work Act 1974,
we are required to provide information on substances haz­ardous to health. The adhesives and sealants used in this
appliance are cured and give no known hazard in this state.

1.5.5 Insulation pads

These can cause irritation to skin, eyes and the respirato­ry tract. If you have a history of skin complaint you may
be susceptible to irritation. High dust levels are usual
only if the material is broken. Normal handling should not
cause discomfort, but follow normal good hygiene and
wash your hands before eating, drinking or going to the
lavatory. If you do suffer irritation to the eyes or severe
irritation to the skin seek medical attention.

1.5.6 Spare parts

Only original Vaillant spare parts may be used.

1.5.7 Manual handling guidance

During the appliance installation (and any subsequent re­placement of the heat exchanger) it will be necessary to em­ploy caution. All installers and operatives involved from un­loading the appliance until it is fully mounted on the wall in
its final installed location must exercise full duty of care for
themselves and others with regard to safe lifting and han­dling of this appliance. Operatives should employ assistance
whilst lifting the appliance or components. In certain situa­tions it may be required to use a mechanical handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.

Caution!

a

With regards to the Manual Handling Opera­tions, 1992 Regulations, the following lift oper­ation exceeds the recommended weight for a
one man lift.
Employers and installers should refer to the
HSE web site for full advice and manual Han­dling assessment charts (MAC) tool.

Danger!

d

Smell of gas. Risk of poisoning and explosion
due to a malfunction.

1.5.8 Gas leak or fault

If you smell gas or suspect a gas leak:

• Do not switch lights on or off.

• Do not use any other electrical switches.

• Do not use a telephone in the hazardous area.

• Do not use naked flames, such as matches or cigarette

lighters.

• Do not smoke.

• Turn off the gas supply at the gas meter.

• Open the windows and doors.

• Warn other residents.

• Get out of the house.

• Consult your gas supplier, service agent or other
competent person approved at the time by the Health
and Safety Executive.

Telephone the National emergency number 0800 111 99

1.5.9 Clearances

If fixtures are positioned close to the boiler, space must
be left as shown in fig 4.1. Enough space must also be
left in front of the boiler to allow for servicing.

1.5.10 Sheet metal parts

This boiler contains metal parts (components) and care
should be taken when handling and cleaning, with par­ticular regard to edges.

1.5.11 Sealed components

Under no circumstances must the User interfere with any
sealed component as this could result in a potentially
dangerous situation arising.

Danger!

e

This boiler must be earthed.

1.5.12 Electrical supply failure

The boiler will not work without an electrical supply. Normal
operation of the boiler should resume when the electrical
supply is restored. Reset any external controls to resume
normal operation of the central heating. If the boiler does
not resume normal operation. (The burner fails to ignite
after five attempts). The overheat thermostat may have
operated. Automatic ignition can only take place after you
manually reset the fault, refer to section 5.1.3. to reset.

1.5.13 Protection against freezing

The boiler has a built in frost protection programme as long
as the electricity and gas are left switched on. This device
operates the burner and system pump when the tempera­ture inside the boiler falls to 3°C. Any other exposed areas
of the system should be protected by a separate frost ther­mostat. If the mains electricity and gas are to be turned off
for any long periods during severe weather, it is recom­mended that the whole system, including the boiler, should
be drained to avoid the risk of freezing. Make sure that, if
fitted, the immersion heater in the cylinder is switched off.
If you have a sealed water system contact your installation/
servicing company as draining, refilling and pressurising
MUST be carried out by a competent person approved at
the time by the Health and Safety Executive.
As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the
condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe. The
boiler should then restart. Contact your installation/
servicing company if the fault persists.

5Instructions for installation and servicing ecoTEC plus 0020020828_07

1 Introduction

1.5.14 Boilers installed in a compartment or cupboard

If the boiler is fitted into a compartment or cupboard it
does not require ventilation openings.
Do not use the compartment or cupboard for storage.

1.5.15 Boiler casing

Do not remove or adjust the casing in any way, as incor­rect-fitting may result in incorrect operation or failure
to operate at all.

1.5.16 Condensate drain

The condensate drain must not be modified or blocked.

1.5.17 Pluming from flue terminal

All condensing boilers produce a plume of water vapour
from the flue terminal. This is due to the high efficiency
and hence low flue gas temperature. This may increase
in wet, damp weather but this is completely normal and
indicates that the boiler is operating correctly.

1.5.18 Cleaning

This appliance contains metal parts and care should be
taken when handling and cleaning with particular regard
to edges. The boiler casing can be cleaned using a mild
liquid detergent with a damp cloth, then a dry cloth to
polish. Do not use any form of abrasive or solvent clean­er as you may damage the paint work.

1.5.19 Maintenance and servicing

For the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced
at regular intervals. The frequency of servicing will de­pend upon the installation conditions and usage, but in
general, once a year should be enough.
If this appliance is installed in a rented property there is
a duty of care imposed on the owner of the property by
the current issue of the Gas Safety (Installation and
Use) Regulations, Section 35. Servicing/maintenance
should be carried out by a competent person approved
at the time by the Health and Safety Executive in ac­cordance with the rules in force in the countries of des­tination.
Please be advised that on completion of commissioning
and servicing you should complete the Benchmark gas
boiler commissioning checklist.
All competent persons approved at the time by the
Health and Safety Executive carry a ID card, and have a
registration number. Both should be recorded there.

1.5.20 Technical data

All dimensions are given in millimetres (except as
noted). The data label is positioned on the combustion
chamber cover. The Seasonal Efficiency Domestic Boil­ers UK (SEDBUK) is: All ecoTEC plus boilers : Class ‘A’.
The value is used in the UK Government’s Standard As­sessment Procedure (SAP) for energy rating of dwell­ings. The test data from which it has been calculated
has been certified by B.S.I.

1.6 Statutory requirements

The appliance is suitable only for installation in GB and
IE and should be installed in accordance with the rules
in force. In GB the installation of the boiler must be car­ried out by a competent person as described in the fol­lowing regulations:

- The manufacturer’s instructions supplied

- The Gas Safety (Installation and Use) Regulations

- The appropriate Buildings Regulations either

- The Building Regulations

- The Building Regulations (Scotland)

- The Building Regulations (Northern Ireland)

- The Water Fittings Regulations or Water bye laws in
Scotland

- The Health and Safety at Work Act, Control of Sub­stances Hazardous to Health (COSHH)

- The Current I.E.E. Wiring Regulations

Where no specific instructions are given, reference
should be made to the relevant British Standard Code of
Practice. In IE, the installation must be carried out by a
competent person and installed in accordance with the
current edition of I.S.813 “Domestic Gas Installations”,
the current Building Regulations and reference should
be made to the current ETCI rules for Electrical Installa­tion.

In GB the following Codes of Practice apply:

BS 4814, BS 6891
BS 6798 BS 6700
BS 5440 Part 1 and 2 BS 7074 Part 1 and 2
BS 5546 Part 1 BS 7593
BS 5449 BS 7671

In IE:

I.S.813 BS 5546
BS 7074 BS 5449
BS 7593

Manufacturer’s instructions must not be taken as over­riding statutory requirements.

Note!

h

For further information, see the current issue
of the Building Regulations, approved document
L1 (in the UK) and the current issue of the fol­lowing:

• Central heating system specification (CheSS)

• Controls for domestic central heating system
and hot water (BRECSU).

Certification

This boiler certificated to the current issue of EN 483
for performance and safety. It is important that no al­teration is made to the boiler, without permission, in
writing, from Vaillant. Any alteration that is not ap­proved by Vaillant, could invalidate the warranty and
could also infringe the current issue of the Statutory
Requirements.

Instructions for installation and servicing ecoTEC plus 0020020828_076

1.7 Regulations, rules and guidelines.

This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efficiency) Regulations, and there­fore is deemed to meet the requirements of Directive
92/42/EEC on the efficiency requirements for new hot
water boilers fired with liquid or gaseous fuels. Type
test for purposes of Regulation 5 certified by: Notified
body 0087. Product/production certified by: Notified
body 0086.

1.8 CE label

The CE label on this appliance shows compliance with:

- Directive 90/396/EEC on the approximation of the laws
of the Member States relating to appliances burning
gaseous fuels.

- Directive 73/23/EEC on the harmonisation of the Laws
of the Member States relating to electrical equipment
designed for use within certain voltage limits.

- Directive 89/336/EEC on the approximation of the Laws
of the Member States relating to electromagnetic
compatibility.

- Directive 92/42/EEC on the efficiency requirements.

Introduction 1

1.9 Benchmark

Note!

h

Vaillant Ltd. support the Benchmark initiative
At the rear of the installation manual, you will
find a Benchmark gas boiler commissioning
checklist. It is very important that this is com­pleted correctly at the time of installation,
commissioning and hand over to the user.

1.10 Gas council numbers

Appliance Gas council numbers

ecoTEC plus 415 41 - 044 - 53

ecoTEC plus 418 41 - 044 - 54

ecoTEC plus 428 41 - 044 - 55

ecoTEC plus 438 41 - 044 - 57

7Instructions for installation and servicing ecoTEC plus 0020020828_07

2 Boiler specifi cations

2 Boiler specifications

2.1 Technical data

Description ecoTEC plus 415 ecoTEC plus 418 ecoTEC plus 428 ecoTEC plus 438 Unit

Maximum CH heat input (net) 15.3 18.9 28.6 38.4 kW

CH heat output (80/60 °C) 5.0 - 15.0 5.0 - 18.6 5.3 - 28.2 6.3 - 38.0 kW

CH heat output (50/30 °C) 5.3 - 16.2 5.3 - 20.0 5.7 - 30.6 6.8 - 41.0 kW

SEDBUK Band A A A A

SAP Seasonal Efficiency 90.5 90.4 90.6 90.8 %

NOx Class 5 5 5 5

lP rating IPX4D IPX4D IPX4D IPX4D

Inlet gas working pressure required
(natural gas)

Gas supply (G20) Gross CV (s.t.) 37.8 37.8 37.8 37.8 MJ/m

Maximum gas rate 1.61 2.0 3.02 4.06 M3/h

Minimum gas rate 0.53 0.53 0.56 0.71 M3/h

Burner % CO2 (Case on) 9.3 + 0.2 - 0.5 9.3 + 0.2 - 0.5 9.3 + 0.2 - 0.5 9.0 + 0.2 - 0.5 %

Gas connection (compression) 15 15 15 15 mm

Water connections (compression) 22 22 22 22 mm

Condensate drain (internal diameter) 19 min. 19 min. 19 min. 19 min. mm

Main PCB 2 2 2 2 A

Minimum flow rate of water
through the boiler

Weight 31 31 33 33 kg

Electrical supply 230/~50 230/~50 230/~50 230/~50 V~/HZ

External fuse 3 3 3 3 A

20 20 20 20 mbar

10.8 12.9 20.3 27.2 L/min.

3

Power input 60 60 60 60 W

Flue categories C13, C33, C43, C53 C13, C33, C43, C53 C13, C33, C43, C53 C13, C33, C43, C53

Case height 600 600 600 600 mm

Case width 375 375 375 375 mm

Case depth 340 340 340 340 mm

Instructions for installation and servicing ecoTEC plus 0020020828_078

Boiler specifi cations 2

2.1.2 Dimensions

1

161

2

610

3

26

48

33

113

375

53

30

133

56

6

2.1.3 Installation

5

160

4

7

Fig. 2.2 Function elements of boiler

1 Flue pipe connection
2 Fan
3 Gas valve
4 Electronics box
5 Burner module
6 Ignition electrode
7 Condense trap

8

176

Fig. 2.1 Dimensions in mm

1 Heating return pipe Ø 22
2 Heating flow pipe Ø 22
3 Gas connection Ø 15
4 Hanging bracket
5 Flue hole - flue system 303 933
6 Flue pipe connection
7 Condensate drain outlet connection (Ø 21)
8 Outside wall face

340

9Instructions for installation and servicing ecoTEC plus 0020020828_07

3 General requirements

3 General requirements

3.1 Preliminary remarks

This appliance must only be installed and commissioned
by a suitably competent person. Please check with your
installer that he is able to carryout all the necessary
works including official notification of the works to the
relevant body upon completion.

3.2 Related documents

The installation of the appliance and any associated hot
water system must be in accordance with (but not limit­ed to) the following; COSHH regulations, Gas Safety (In­stallation and Use) Regulations 1998, Health and Safety
Document No. 635 (The Electricity at Work Regulations

1989), BS7671 (IEE Wiring Regulations) and the Water

Supply (Water Fitting) Regulations 1999, or The Water
Bylaws 2000 (Scotland). It should also be in accordance
with the relevant requirements of the Local Authority,
Building Regulations, The Building Regulations (Scot­land), The Building Regulations (Northern Ireland) and
the relevant recommendations of the following British
Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired boil­ers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 35 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/UP1B (Edition 2): Tightness testing and direct
purging of small natural gas installations. For larger in­stallation sites consider also IGE/UP1A.
IGE/UP2: Gas installation pipework, boosters and com­pressors on industrial and commercial premises.
IGE/UP10: Installation of gas appliances in industrial
and commercial p
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.

remises.

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.

Caution!

a

The appliance must be installed and serviced by
a competent person approved at the time by
the Health and Safety Executive as stated in
the Gas Safety (Installation and Use) Regula­tions 1998. In IE, the installation must be in
accordance with the current edition of I.S.813
‘Domestic Gas Installations’, the current Build­ing Regulations and reference should be made
to the current ETCI rules for electrical installa­tion.

Caution!

a

When tightening or slackening screwed connec­tions always use suitable open-ended spanners
(not pipe wrench, or extensions, etc.). Incorrect
use and/or unsuitable tools can lead to damage
being caused (e.g. gas or water leakage)!

3.3 Installation site

The location chosen for the boiler must permit the provision
of a satisfactory flue termination. The location must also pro­vide adequate space for servicing and air circulation around
the boiler. The boiler may be installed in any room, although
particular attention is drawn to the requirements of BS 7671
(IEE Regulations), the electrical provisions of the Building
Standards (Scotland) Regulations, and in IE the current edi­tion of IS 813 and the current ETCI rules, in respect of the in­stallation of a boiler in a room containing a bath or shower.

Note!

h

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 IG/UP/7 Edition 2 “Gas installa-

Instructions for installation and servicing ecoTEC plus 0020020828_0710

General requirements 3

tions in timber framed and light steel framed buildings“.
Please note the safety instructions below before deciding
where to install the boiler:

Caution!

a

Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance must be operated independent of
the ambient air.

When choosing the place of installation and while operating the
appliance, make sure that the air supply is free of chemical
substances containing fluorine, chlorine, sulphur etc. Sprays,
solvents and cleaning agents, paints, adhesives etc. contain the
kind of substances that can lead to corrosion even in the ex­haust system when the appliance is operated depending on the
ambient air in the worst case scenario. Particularly in hair-cut­ting salons, lacquering and finishing, cleaning facilities, the ap­pliance must be operated independent of the ambient air! Oth­erwise, a separate installation room is required to guarantee
that the air supply is free of the above mentioned substances.

3.4 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. Pipe work from

the meter to the boiler must be of an adequate size. Do
not use pipes of a smaller size than the boiler gas con­nection (15 mm). The complete installation must be
checked for leaks and purged as described in BS 6891.

667

Fig. 3.1 Art. No. 30 39 33

Fig. 3.2 Art. No. 30 39 36

Danger!

d

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.

3.5 Flue options

There are various flue systems to choose from, as follows:
60/100 standard horizontal air/flue duct, see fig 3.1.
60/100 telescopic horizontal air/flue duct, see fig 3.2.
60/100 Vertical air/flue duct and terminal, see fig 3.3.
80/125 horizontal air/flue duct, see fig 3.4.
80/125 Vertical air/flue duct and terminal, see fig 3.5.
Flue extensions are available to extend the length, both
90° bends and 45° elbows are also available. Refer to
flue system installation instructions for full details.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at
least 3° to allow condensate to run out via the drain.

Fig. 3.3 Art. No. 30 39 00

Fig. 3.4 Art. No. 30 32 09

11Instructions for installation and servicing ecoTEC plus 0020020828_07

3 General requirements

Fig. 3.5 Vertical Flue System Art. No. 30 32 00

3.5.1 Flue termination

The following details refer to both flue systems.
a. The terminal must be located where the combustible

substances can escape freely at all times.

b. A plume of water vapour will sometimes be visible

from the flue terminal. Positions where this could be a
nuisance should be avoided.

c. If the terminal is fitted less than 2 m above a balcony,

above ground or above a flat roof to which people
have access then a suitable terminal guard must be
provided and fitted (made by Tower Flue Components,
Tonbridge, TN9 1TB, Model K3, plastic coated).

Note!

h

Vertical flues must not terminate within
600mm of an openable window, air vent or any
other ventilation opening.

The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.

Fig. 3.6 Terminal locations

Note!

h

Vertical flues must not terminate within
600mm of an openable window, air vent or any
other ventilation opening.

Terminal position mm

Directly below an opening, above an opening or hori-

A

zontal to an opening, air brick, opening window, etc.
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200

From an opening in the car port (e.g. door, window)
J

into the dwelling
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent wall for vertical Flue 500

Table 3.1 Flue terminal position for a fan assisted concentric flue

The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.

Note!

h

In addition, the terminal should not be located
closer than 150 mm from a wallopening provided
for e.g. a window. Boundary flue terminations
must as a minimum comply with Building regu­lation part „J“ 600 mm and should also be in
accordance with the Guide to Condensing Boiler
Installation which recommends 2.5 m from wall,
fence or boundary.
Where a plume diverter terminal is used this is
measured in the direction of the flow of products.

BS 5440–1: It is recommended that the fanned flue ter­minal should be positioned as follows:
a. at least 2 m from an opening in the building directly

opposite, and

b. so that the products of combustion are not directed

to discharge across a boundary.

1. Dimensions B, C and D: These clearances may be re­duced to 25 mm without affecting the performance of
the boiler. In order to ensure that the condensate
plume does not affect adjacent surfaces the terminal
should be extended as shown in Fig. 3.7.

2. Dimension F: This clearance may be reduced to 25
mm without effecting 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.

300

1200

Instructions for installation and servicing ecoTEC plus 0020020828_0712

Fig. 3.7 Flue termination under balcony/eves

3.5.2 Internal flue installation

The flue can be installed from inside the building when
access to the outside wall face is not practicable.

3.6 Air supply

Detailed recommendations for air supply are given in
BS 5440: Part 2. It is not necessary to have an air vent in
the room or internal space in which the boiler is installed.

3.7 Cupboard or compartment ventilation

The boilers are very high efficiency appliances.
As a consequence the heat loss from the appliance
casing during operation is very low. For cupboard or
compartment installations it is therefore not necessary
to provide any high or low level permanent air vents
for cooling purposes.

3.8 Domestic hot water cylinder

Caution!

a

Single feed indirect cylinders are not suitable.
The domestic hot water cylinder must be of the
double feed fully indirect coil type. It must be
suitable for working at a gauge pressure of

0.35 bar above the safety valve setting.

3.8.1 Unvented hot water cylinder

The ecoTEC plus can be connected to an unvented hot
water cylinder. Vaillant offer a range of cylinders called
uniSTOR with capacities from 125 litres to 310 litres. All
unvented domestic hot water cylinders must be installed
by a competent person approved at the time by the
Health and Safety Executive to the current building reg­ulations and water regulations at the time of installa­tion.
For building regulations refer to G3 and for water regu­lations guidance G17 to G24 and recommendation R17
to R24. For Ireland: The current issue of BS5546 and
BS6700. If fitting to an existing system the local author­ity should be informed.

General requirements 3

3.9 Condensate drain

A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the
internal household draining system. If this is not
practical, discharge can be made externally into the
household drainage system or a purpose designed soak
away, see Section 4.3.5 for more details.

3.10 Heating system controls

It is recommended that a programmer and room ther­mostat control the boiler. Vaillant have a range of op­tional easy fit controls available.
Thermostatic radiator valves must be installed, however
they must not be fitted in a room where the room ther­mostat is located.

Note!

h

All systems must have at least one radiator
not fitted with a thermostatic valve.

Note!

h

For further information, see the current issue
of the Building Regulations, approved document
L1, and the following current issues of:

1. Central heating system specification (CheSS)

2. Controls for domestic central heating system
and hot water (BRECSU).

3.11 Draining tap

A draining tap must be provided at all the lowest points
of the system, which will allow the entire system and
hot water system to be drained. Draining taps shall be
to the current issue of BS 2879.

3.12 Safety valve

A safety valve need not be fitted to an open-vented system.

3.13 Bypass

A system bypass will be required fitted at least 1.5 metres
away from the boiler, refer to the current issue of central
heating system specifications (CHeSS).

3.14 Pump specification

The pump should be fitted on the flow pipe from the
boiler and have isolating valves each side.

13Instructions for installation and servicing ecoTEC plus 0020020828_07

3 General requirements

3.15 Cleanser and inhibitor

In the case of an existing installation, it is essential that
prior to installing the new boiler the system is thorough­ly flushed. For optimum performance after installation
of a new system, the boiler and its associated central
heating system should also be flushed. Flushing should
be carried out in accordance with BS7593: 1992 using
a cleanser. For long-term corrosion protection, after
flushing, an inhibitor suitable for stainless steel heat
exchangers should be used, refer to the current issue of
BS 5449 and BS 7593 on the use of inhibitors in central
heating systems.

Caution!

a

It is essential that the cleanser is fully
removed from the system after flushing and
before adding inhibitor. Take care to ensure
that all low points in the system are fully drained.

Mixing additives with the heating water can result in ma­terial damage. However, up to now, no incompatibility
with Vaillant appliances has been detected with proper
use of the following products.

• When using additives, follow the additive manufactur­er‘s instructions without exception.

Vaillant accepts no liability for the compatibility of any
additive or its effectiveness in the entire heating sys­tem.

Additives for cleaning purposes
(subsequent flushing required)

- Fernox F3

- Jenaqua 400

- Sentinel X 300

- Sentinel X 400

Additives intended to remain permanently in the sys­tem

- Fernox F1

- Fernox F2

- Sentinel X 100

- Sentinel X 200

Additives for frost protection intended to remain per­manently in the system

Fernox Antifreeze Alphi 11

-

- Sentinel X 500

• Inform the operator of the necessary measures in
case you have used any of these additives.

• Inform the operator of the required procedures for
frost protection.

• Observe the applicable national regulations and tech­nical standards for the treatment of filling and top-up
water.

Provided the national regulations and technical stand­ards do not specify any higher requirements, the follow­ing applies:

• You must treat the heating water

- if the total volume of filling and top-up water ex-

ceeds thrice the nominal volume of the heating sys­tem over the service life of the system

or

- if the limits given in the following tables are not ad-

hered to.

Total heating
output

kW mol/m

< 50 No requirement or < 3

> 50 to ≤ 200

> 200 to ≤ 600

> 600

1) with systems equipped with wall-hung boiler and systems with electric heating elements

2) of the specific system volume (nominal capacity in litres/heating output; in case of multiple boiler systems the lowest individual
heating output should be used)
These data only apply up to 3x the system volume for filling and top-up water. Once this triple system volume is exceeded, the
water will have to be treated exactly the same as in case of exceeding the limit values given in table 3.3 (softening, desalination,
hardness stabilisation and desludging).

Table 3.2 Guidelines for the heating water: Water hardness

Total hardness at 20 l/kW
for the smallest boiler heating

2)

surface

3

1)

2 1,5 0,02

1,5 0,02 0,02

0,02 0,02 0,02

Total hardness at > 20 l/kW
< 50 l/kW for the smallest boiler
heating surface

mol/m3 mol/m

2 0,02

2)

Instructions for installation and servicing ecoTEC plus 0020020828_0714

Total hardness at > 50 l/kW
for the smallest boiler heating
surface

2)

3

General requirements 3

Heating water
qualities

Electric conductivity
at 25 °C

Appearance Free of sedimentary substances

pH-value at 25 °C 8,2-10,0

Oxygen mg/L

1) With aluminium and aluminium alloys, the ph value range is
restricted from 6.5 to 8.5.

Table 3.3 Guidelines for heating water: Salinity

Unit Low-salt saline

μS/cm < 100

1)

< 0,1 < 0,02

100-1500

8,2-10,0

1)

Caution!

b

Aluminium corrosion resulting in leakages
caused by unsuitable heating water!
Unlike materials such as steel, cast iron or cop­per, aluminium is reactive to alkalised heating
water (pH-value > 8,5) which results in signifi­cant corrosion.
With aluminium, ensure that the pH value of
the heating water ranges between 6.5 up to a
maximum of 8.5.

Caution!

b

Risk of material damage if the heating water is
treated with unsuitable frost or corrosion pro­tection agents!
Frost and corrosion protection agents may
cause changes in the seals, noises during heat­ing and possibly subsequent damage.
Do not use any unsuitable frost or corrosion
protection agents.

3.16 Water pressure loss

ecoTEC plus 415 pressure loss graph

ecoTEC plus 418 pressure loss graph

Water pressure loss (metres head of water)

Flow Rate (litres/hour)

773.86 l/hr = 20 diff @ 18 kW

Fig. 3.8.2 Pressure loss ecoTEC plus 418

ecoTEC plus 428 pressure loss graph

Water pressure loss (metres head of water)

Flow Rate (litres/hour)

1220 l/hr = 20 diff @ 30 kW

Fig. 3.8.3 Pressure loss ecoTEC plus 428

Water pressure loss (metres head of water)

Flow Rate (litres/hour)

646 l/hr = 20 diff @ 12 kW

Fig. 3.8.1 Pressure loss ecoTEC plus 415

15Instructions for installation and servicing ecoTEC plus 0020020828_07

3 General requirements

ecoTEC plus 438 pressure loss graph

Water pressure loss (metres head of water)

Flow Rate (litres/hour)

1633 l/hr = 20 diff @ 38 kW

Fig. 3.8.4 Pressure loss ecoTEC plus 438

3.17 Open vented heating system

The boiler must be supplied from an unrestricted water
supply taken from a feed and expansion cistern situated
at a maximum height of 27 metres (90ft) above the boiler.
The cold feed must be 15mm minimum size. The vent
must rise continuously and be unrestricted. It is impor­tant that the relative positions of the pump, cold feed
and open vent are as shown in fig 3.9.

Open (vented) system.

450 mm
(min.)
height

1000 mm
(min.)

Recommended
relationship between
pump, cold feed and vent.

22 mm (min.)
vent feed and
expansion cistern

15 mm (min.) cold feed

15 mm (min.)
automatic by-pass

return

flow

3.18 Sealed water systems

The installation must comply with the appropriate re­quirements of the current issue of BS4814, BS5449,
BS6759, BS6798 and BS7074 Part 1 and 2. For IE your
attention is drawn to the current edition of IS 813. It is
highly recommend to use the Vaillant Sealed System Kit
Article; 020053207 This includes all necessary compo­nents and is included in your Vaillant warranty. See also
fig 3.10.

3.18.1 Safety valve

A safety valve must be fitted to a sealed system. It shall
be preset, non-adjustable with a lift pressure of 3-bar,
incorporating seating of a resilient material, a test device
and a connection for drain. The safety valve discharge
pipe must be routed to outside the building, must not
discharge above an entrance or window or any type of
public access area, be clear of any electrical fittings and
positioned so that any discharge can be seen.

3.18.2 Expansion vessel

A diaphragm type expansion vessel, conforming to the
current issue of BS4814 (see also BS7074 Part 1 and 2).
For IE the current edition of IS 813, must be connected
at a point close to the inlet side of the circulating pump,
see the Typical installation, Fig. 3.10. unless laid down
differently by the manufacturer. The expansion vessel
volume depends on the total water system volume and
the initial system design pressure. For any system an
accurate calculation of vessel size is given in the current
issue of BS5449 and BS7074 Part 1. Example: For an
initial design pressure of 0.7 bar, the minimum total
vessel volume required is 0.063 x Total System Volume.

Note!

h

A higher initial design pressure requires a larger
volume expansion vessel.

The charge pressure must not be less than the static
head of the system, that is, the height of the highest
point of the system above the expansion vessel.

3.18.3 Pressure gauge

A pressure gauge with a set pointer and covering at least
0 to 4 bar (0 to 60 lb/in2) shall be fitted permanently to
the system in a position where it can be seen when filling
the system.

boiler

Fig. 3.9 Open vented system

150 mm (max.)

pump

cylinder

3.18.4 Water make up

Provision should be made for replacing water loss from
the system using a make up bottle mounted in a position
higher than the top point of the system, connected

heating

through a non-return valve to the return side of either
the heating circuit or the hot water cylinder. Alternatively,
provision for make up water should be made using a
proprietary filling loop.

Instructions for installation and servicing ecoTEC plus 0020020828_0716