Vaillant ecoTEC plus VU Series Installation And Maintenance Instructions Manual
For the competent person
Installation and maintenance instructions
ecoTEC plus
VU
GB
Installation and maintenance instructions
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40 D-42859 Remscheid
Telefon 021 91 18‑0 Telefax 021 91 18‑28 10
info@vaillant.de www.vaillant.de
Contents
2 Installation and maintenance instructions ecoTEC plus 0020029173_04
Contents
1 Safety .................................................................... 4
1.1 Action-related warnings ......................................... 4
1.2 Intended use ......................................................... 4
1.3 General safety information .................................... 4
1.4 Regulations (directives, laws, standards) .............. 6
2 Notes on the documentation .............................. 8
2.1 Observing other applicable documents ................. 8
2.2 Storing documents................................................. 8
2.3 Applicability of the instructions .............................. 8
3 Product description............................................. 8
3.1 Functional elements............................................... 8
3.2 Information on the identification plate.................... 8
3.3 Serial number ........................................................ 8
3.4 CE label ................................................................. 8
4 Installation............................................................ 9
4.1 Unpacking the product........................................... 9
4.2 Checking the scope of delivery.............................. 9
4.3 Transporting the product ....................................... 9
4.4 Product dimensions and connection
dimensions............................................................. 9
4.5 Minimum clearances and installation
clearances ........................................................... 10
4.6 Clearance from combustible components ........... 10
4.7 Using the installation template............................. 10
4.8 Wall-mounting the product................................... 10
4.9 Removing or installing the front casing................ 11
5 Installation.......................................................... 11
5.1 Selecting a low loss header................................. 11
5.2 Gas installation .................................................... 12
5.3 Hydraulics installation .......................................... 13
5.4 Installing and connecting the flue pipe ................ 14
5.5 Electrical installation ............................................ 14
6 Start-up ............................................................... 16
6.1 Carrying out the initial start-up............................. 16
6.2 Switching on the product ..................................... 16
6.3 Using check programmes .................................... 16
6.4 Checking and treating the heating water/filling
and supplementary water .................................... 17
6.5 Reading off the filling pressure ............................ 17
6.6 Preventing low water pressure ............................ 18
6.7 Filling and purging the heating installation .......... 18
6.8 Flushing the heating installation for the first
time ("cold") ......................................................... 18
6.9 Filling the condensate trap .................................. 19
6.10 Gas ratio setting................................................... 19
6.11 Checking function and leak-tightness.................. 21
6.12 Thoroughly flushing the heating installation
("hot")................................................................... 21
7 Adapting the unit to the heating
installation.......................................................... 22
7.1 Calling up diagnostics codes ............................... 22
7.2 Calling up the installer level (second
diagnostics level) ................................................. 22
7.3 Setting the heating partial load ............................ 22
7.4 Setting the pump overrun and pump operating
mode.................................................................... 22
7.5 Setting the maximum flow temperature ............... 23
7.6 Setting the burner anti-cycling time ..................... 23
7.7 Setting the maintenance interval ......................... 23
7.8 Adjusting the product to large flue gas pipe
lengths ................................................................. 23
7.9 Handing the product over to the operator ............ 23
8 Inspection and maintenance ............................ 24
8.1 Observing inspection and maintenance
intervals ............................................................... 24
8.2 Procuring spare parts .......................................... 24
8.3 Removing the compact thermal module .............. 24
8.4 Cleaning the heat exchanger............................... 25
8.5 Descaling the heat exchanger ............................. 25
8.6 Checking the burner ............................................ 26
8.7 Cleaning the condensate duct ............................. 26
8.8 Cleaning the air separation system ..................... 26
8.9 Installing the compact thermal module ................ 27
8.10 Draining the product ............................................ 27
8.11 Checking the pre-charge pressure of the
external expansion vessel ................................... 27
8.12 Completing inspection and maintenance work .... 27
9 Troubleshooting ................................................ 27
9.1 Contacting your service partner........................... 27
9.2 Calling up status codes........................................ 27
9.3 Reading off the fault codes.................................. 27
9.4 Querying the fault memory .................................. 28
9.5 Performing diagnostics ........................................ 28
9.6 Using check programmes .................................... 28
9.7 Resetting parameters to factory settings ............. 28
9.8 Preparing the repair work .................................... 28
9.9 Replacing defective components......................... 28
9.10 Completing repair work........................................ 28
10 Decommissioning the product ......................... 28
11 Recycling and disposal..................................... 28
12 Vaillant customer service ................................. 29
12.1 Guarantee............................................................ 29
12.2 Customer service ................................................. 29
Appendix ............................................................................ 30
A Overview of diagnostics codes........................ 30
B Inspection and maintenance work –
Overview............................................................. 32
C Status codes – Overview .................................. 33
D Overview of fault codes .................................... 34
E Connection diagram .......................................... 36
F Commissioning Checklist................................. 38
Contents
0020029173_04 ecoTEC plus Installation and maintenance instructions 3
G Opening of the flue pipe.................................... 41
G.1 Positioning of the opening of a fan-supported
flue gas guiding.................................................... 41
H Text from BS 5440-1 on fan-supported flue
gas guiding......................................................... 42
I Opening of the flue pipe below eaves and
balconies ............................................................ 42
J Technical data .................................................... 42
Index ................................................................................... 44
1 Safety
4 Installation and maintenance instructions ecoTEC plus 0020029173_04
1 Safety
1.1 Action-related warnings
Classification of action-related warnings
The action-related warnings are classified in
accordance with the severity of the possible
danger using the following warning signs and
signal words:
Warning symbols and signal words
Danger!
Imminent danger to life or risk of
severe personal injury
Danger!
Risk of death from electric shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental
damage
1.2 Intended use
There is a risk of injury or death to the user or
others, or of damage to the product and other
property in the event of improper use or use
for which it is not intended.
The product is intended for use as a heat
generator in closed central heating installations.
The products referred to in these instructions
must only be installed and operated in conjunction with the flue pipe accessories listed
in other applicable documents.
Exceptions: For C63 and B23P installation
types, follow the specifications in these instructions.
Intended use includes the following:
– observance of accompanying operating,
installation and servicing instructions for
the product and any other system components
– installing and fitting the product in accord-
ance with the product and system approval
– compliance with all inspection and main-
tenance conditions listed in the instructions.
Intended use also covers installation in accordance with the IP class.
Any other use that is not specified in these
instructions, or use beyond that specified in
this document shall be considered improper
use. Any direct commercial or industrial use
is also deemed to be improper.
Caution.
Improper use of any kind is prohibited.
1.3 General safety information
1.3.1 Required personnel qualifications
Improper work carried out on the product
may cause material damage to the complete
installation and, as a consequence, may even
cause personal injury.
▶ You should therefore only work on the
product if you are an authorised competent
person.
1.3.2 Danger due to incorrect handling
Incorrect handling may give rise to unforeseeable and dangerous situations.
▶ Read through these instructions carefully.
▶ When using the product, observe the gen-
eral safety information and warnings.
▶ When using the product, observe all ap-
plicable national regulations .
1.3.3 Risk of death from escaping gas
What to do if you smell gas in the building:
▶ Avoid rooms that smell of gas.
▶ If possible, open doors and windows fully
and ensure adequate ventilation.
▶ Do not use naked flames (e.g. lighters,
matches).
▶ Do not smoke.
▶ Do not use any electrical switches, mains
plugs, doorbells, telephones or other communication systems in the building.
▶ If it is safe to do so, close the emergency
control valve or the main isolator.
▶ If possible, close the gas isolator cock on
the product.
▶ Warn other occupants in the building by
yelling or banging on doors or walls.
▶ Leave the building immediately and ensure
that others do not enter the building.
▶ Notify the gas supply company or National
Grid Transco +44 (0) 800 111999 by telephone from outside of the building.
Safety 1
0020029173_04 ecoTEC plus Installation and maintenance instructions 5
1.3.4 Risk of death due to blocked or
leaking flue gas routes
Installation errors, damage, tampering, unauthorised installation sites or similar can cause
flue gas to escape and result in a risk of poisoning.
What to do if you smell flue gas in the property:
▶ Open all accessible doors and windows
fully to provide ventilation.
▶ Switch off the product.
▶ Check the flue gas routes in the product
and the flue gas diversions.
1.3.5 Risk of poisoning and burns caused
by escaping hot flue gases
▶ Only operate the product if the air/flue pipe
has been completely installed.
▶ With the exception of short periods for
testing purposes, only operate the product
when the front casing is installed and
closed.
1.3.6 Risk of death due to cabinet-type
casing
Cabinet-type casing can give rise to dangerous situations when used on a product which
is operated with an open flue.
▶ Ensure that the product is supplied with
sufficient combustion air.
1.3.7 Risk of death due to explosive and
flammable materials
▶ Do not use or store explosive or flammable
materials (e.g. petrol, paper, paint) in the
installation room of the product.
1.3.8 Risk of poisoning caused by
insufficient supply of combustion
air
Conditions: Open-flued operation
▶ Ensure that the air supply to the product's
installation room is permanently unobstructed and sufficient in accordance with the
relevant ventilation requirements.
1.3.9 Risk of death due to lack of safety
devices
The schematic drawings included in this document do not show all safety devices required for correct installation.
▶ Install the necessary safety devices in the
system.
▶ Observe the applicable national and inter-
national laws, standards and guidelines.
1.3.10 Risk of death from electric shock
There is a risk of death from electric shock if
you touch live components.
Before commencing work on the product:
▶ Disconnect the product from the power
supply by switching off all power supplies
(electrical partition with a contact opening
of at least 3 mm, e.g. fuse or line protection switch).
▶ Secure against being switched back on
again.
▶ Wait for at least 3 minutes until the con-
densers have discharged.
▶ Check that there is no voltage.
1.3.11 Risk of being burned or scalded by
hot components
▶ Only carry out work on these components
once they have cooled down.
1.3.12 Risk of death from escaping flue
gas
If you operate the product with an empty condensate siphon, flue gas may escape into the
room air.
▶ In order to operate the product, ensure that
the condensate siphon is always full.
1.3.13 Risk of death from escaping flue
gas
If you operate the product with an empty condensate trap, flue gas may escape into the
room air.
▶ In order to operate the product, ensure that
the condensate trap is always full.
1.3.14 Risk of scalding from hot water
There is a risk of scalding at the hot water
draw-off points if the hot water temperatures
1 Safety
6 Installation and maintenance instructions ecoTEC plus 0020029173_04
are greater than 60 °C. Young children and
elderly persons are particularly at risk, even
at lower temperatures.
▶ Select a moderate set target temperature.
1.3.15 Risk of injury during transport due
to a high product weight.
▶ Make sure that the product is transported
by at least two people.
1.3.16 Risk of material damage caused by
using an unsuitable tool
▶ Use the correct tool to tighten or loosen
screw connections.
1.3.17 Risk of material damage caused by
frost
▶ Do not install the product in rooms prone
to frost.
1.3.18 Risk of corrosion damage due to
unsuitable combustion and room
air
Sprays, solvents, chlorinated cleaning
agents, paint, adhesives, ammonia compounds, dust or similar substances may lead
to corrosion on the product and in the air/flue
pipe.
▶ Ensure that the supply of combustion air is
always free of fluorine, chlorine, sulphur,
dust, etc.
▶ Ensure that no chemical substances are
stored at the installation site.
▶ Ensure that the combustion air is not
routed through an old oil furnace hearth.
▶ If you are installing the product in
hairdressing salons, painter's or joiner's
workshops, cleaning businesses or similar
locations, choose a separate installation
room in which a combustion air supply is
ensured that is technically free of chemical
substances.
1.3.19 Risk of material damage caused by
leak detection sprays and liquids
Leak detection sprays and liquids block the
filter of the mass flow sensor on the Venturi,
and thus destroy the mass flow sensor.
▶ During repair work, do not apply any leak
detection sprays or liquids to the covering
cap on the filter of the Venturi.
1.3.20 Risk of damage to the flexible gas
pipe
The corrugated gas pipe may become damaged if weight is placed on it.
▶ Do not suspend the compact thermal mod-
ule on the flexible gas pipe, for example
during maintenance work.
1.4 Regulations (directives, laws,
standards)
Installation and maintenance of the boiler
must only be performed by a competent person with valid accreditation from the Health
and Safety Executive in accordance with the
"Gas Safety (Installation and Use) Regulations 1998" (hereinafter abbreviated to "competent person" or "heating specialist company"). The existing regulations, rules and
guidelines must be observed when doing so.
Any special requirements of Local Authorities, gas undertakings or insurers must be
complied with. The competent person is also
responsible for inspection, maintenance and
repairs to the boiler, and for checking gas
volume setting and flue gas analysis.
Installers shall carryout a full site risk assessment and put into place all necessary
steps and procedures to comply with Health
and safety at work act and ensure safety of
themselves and others with regard to manual
handling and working at height requirements.
During the appliance installation (and any
subsequent work, such as, the replacement
of major parts ) 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 safety.
When lifting and handling this appliance, operatives should employ assistance. In certain
situations it may be necessary to use mechanical handling aids. Take care to avoid trip
hazards, slippery or wet surfaces.
Employers and installers should refer
to the HSE web site for full advice and
Safety 1
0020029173_04 ecoTEC plus Installation and maintenance instructions 7
manual handling assessment charts
(MAC) tool.
In addition where no specific instructions are
given then reference shall be made, but not
restricted to, all applicable and relevant British Standards and codes of practice such as
the following:
– Gas Safety (Installation and Use) regula-
tions.
– All current Building Regulations for Eng-
land, Northern Ireland and Wales, (as
amended). This includes Approved Codes
of Practice and approved documents and
guidance for building regulations. (A to P
and 7)
– The Building Standards, Scotland, and
any requirements determined by the local
authorities within.
– The Health and safety at work act
– COSHH Control of Substances Hazardous
to Health.
– BS 7671 Requirements for electrical in-
stallations. IEE Wiring Regulations
– The Electricity at Work Regulations.
– The Water supply (water fittings) regula-
tions 1999.
– Water bylaws 2000 (Scotland)
– BS 5854 Code of practice for flues and flue
structures in buildings.
– BS EN 12828 Design of water-based heat-
ing systems.
– BS EN 806 Parts 1 - 5.
– BS 8558 Guide to the design, installation,
testing and maintenance of services supplying water for domestic use within buildings and their curtilages.
– BS 6880 Code of practice for low temper-
ature heating systems with outputs above
45 kW, Part 1, 2, and 3.
– BS 6891 Installation of low pressure gas
pipe work of up to 35mm in domestic
premises.
– BS 4814 Specification for: Expansion
vessels using an internal diaphragm, for
sealed hot water and heating systems.
– BS 7074 Application, selection and install-
ation of expansion vessels and ancillary
equipment for sealed water systems., Part
1 and 2.
– BS 7593 Code of practice for treatment of
water in domestic hot water central heating
systems.
– BS 12831 Heating systems in buildings.
Method for calculating design heat load.
– BS EN 13831 Closed expansion vessels
with built in diaphragm.
– EN 14336 Heating systems in buildings.
Installation and commissioning of water
based heating systems.
– BS 5440 – 1 Installation of flues and vent-
ilation for gas appliances of rated input not
exceeding 70kW*
– BS 5440 – 2 Flueing and ventilation for gas
appliances of rated input not exceeding
70kW*
* 1st 2nd and 3rd family gases.
– BS 5449 Forced circulation hot water sys-
tems up to 45kW.
– BS EN 6798 Installation & maintenance of
gas fired hot water boilers of rated input
not exceeding 70kW net.
– BS 5482 - Part 1 Domestic butane and
propane gas burning installations
Institute of Gas Engineers Publications:
– IGE/UP/1B (Edition 2) Tightness testing
and direct purging of small natural gas
installations.
– IGE/UP/ 7 (Edition 2) Gas in timber and
light steel framed buildings.
Additionally for gas boilers systems with outputs greater than 70KW.
– BS 6644 Installation of gas boilers
between 60 kW and 2 MW (2nd and 3rd
family gases)
– BS 5449
– IGE/UP/1 (Edition 2) Strength testing,
tightness testing and direct purging of industrial and commercial gas installations.
– IGE/UP/1A (Edition 2) Strength testing,
tightness testing and direct purging of
small, low pressure industrial and commercial natural gas installations.
– IGE/UP/10 Installation of gas appliances
in industrial and commercial premises.
Part 1 Flued appliances.
– The installation must comply with the cur-
rent version of the Clean Air Act.
2 Notes on the documentation
8 Installation and maintenance instructions ecoTEC plus 0020029173_04
2 Notes on the documentation
2.1 Observing other applicable documents
▶ You must observe all the operating and installation in-
structions included with the system components.
2.2 Storing documents
▶ Pass these instructions and all other applicable docu-
ments on to the system operator.
2.3 Applicability of the instructions
These instructions apply only to:
Product article number
VU GB 656/4‑5
0010004140
3 Product description
3.1 Functional elements
1
2
3
4
5
6
7
10
9
8
14
15
11
12
13
16
18
17
1 Connection for the flue
pipe
2 Integrated condensation
heat exchanger
3 Air intake pipe
4 Compact thermal mod-
ule
5 Ignition electrode
6 Water pressure sensor
7 Pump
8 Filling connection (com-
bined filling and emptying valve)
9 Connection for expan-
sion vessel
10 Electronics box
11 Condensate trap
12 Filling and drainage tap
flow
13 Connection for expan-
sion relief valve
14 Gas valve
15 Air separator
16 Volume flow sensor
17 Automatic air vent
18 Flow switch with control
lines
3.2 Information on the identification plate
The identification plate is mounted on the underside of the
product in the factory.
Information on the
identification plate
Meaning
Serial number for identification; 7th to 16th digits =
product article number
VU… Vaillant gas-fired wall-hung boiler for
heating
ecoTEC plus Product description
2H, G20 - 20 mbar
(2 kPa)
Gas group and gas connection pressure
as set at the factory
Cat. Approved gas category
Types Approved flue gas connections
PMS Permissible total overpressure in heating
mode
PMW Permissible total overpressure during hot
water generation
T
max.
Max. flow temperature
ED 92/42 Current efficiency directive fulfilled with
4* rating
230 V 50 Hz Electric connection
W Max. electrical power consumption
IP Level of protection
Heating mode
P Nominal heat output range
Q Heat input range
CE label → "CE label" section
→ "Recycling and disposal" section
Note
Make absolutely sure that the product is compatible with the gas group at the installation site.
3.3 Serial number
The serial number can be found on the identification plate.
3.4 CE label
The CE label shows that the products comply with the basic
requirements of the applicable directives as stated on the
identification plate.
The declaration of conformity can be viewed at the manufacturer's site.
Installation 4
0020029173_04 ecoTEC plus Installation and maintenance instructions 9
4 Installation
4.1 Unpacking the product
1. Remove the product from its box.
2. Remove the protective film from all parts of the product.
4.2 Checking the scope of delivery
▶ Check that the scope of delivery is complete and intact.
4.2.1 Scope of delivery
Number
Description
1
Hanging bracket
1
Heat generator
1
Condensate drain hose
1
Expansion relief valve
1 Compression joint, gas G 1
1 Seal
1
Condensate trap's cartridge installation kit
1
Enclosed documentation
1
Bag with small parts
4.3 Transporting the product
4.3.1 General
▶ Hold the load as close as possible to your body. Do not
twist your body – instead, reposition your feet.
▶ If the unit is being lifted by two persons, ensure your
movements are coordinated during lifting.
▶ Avoid bending your upper body – do not lean forwards or
to the side.
▶ Wear appropriate cut-resistant and non-slip gloves to
protect yourself against sharp edges and maintain a safe
and secure grip.
▶ If required, get somebody to assist you in this.
4.3.2 Unloading the box from the delivery van
▶ It is recommended that two people lift the unit together.
▶ Lift the box using the straps provided.
▶ Use safe lifting techniques – keep your back straight and
bend your legs at the knee.
▶ Hold the load as close as possible to your body.
▶ If the unit is being lifted by two persons, ensure your
movements are coordinated during lifting.
▶ If required, get somebody to assist you in this.
4.3.3 Transporting the box from the delivery
point to the installation site – ground floor
▶ It is recommended that two people lift the unit together.
▶ Use safe lifting techniques – keep your back straight and
bend your legs at the knee.
4.4 Product dimensions and connection
dimensions
A
Ø 80/125
R 1
172
172
32
224 224
121
140
75
211
800
61
94
119
Ø 25, R1
G 1 1/
2
Rp 1 Rp 1
G 1 1/
2
R 3/
4
480
472
6
7
5
4
3
9
11
10
8
1
2
4 Installation
10 Installation and maintenance instructions ecoTEC plus 0020029173_04
1 Flue gas connection,
80/125 diameter
2 Hanging bracket
3 Gas pipe, 25 mm dia-
meter, gas connection
R1“
4 Expansion vessel con-
nection
5 Heating return connec-
tion
6 Heating flow connection
7 Expansion relief valve
connection
8 Condensate discharge
connection
9 Flow drain opening
10 Filling connection option
(combined filling and
emptying valve)
11 Condensate trap's
cartridge
Consult the installation template that is supplied to find the
dimension A.
4.5 Minimum clearances and installation
clearances
AB
A 500 mm B 400 mm
▶ When using the accessories, observe the minimum clear-
ances/installation clearances.
4.6 Clearance from combustible components
It is not necessary to ensure that there is a clearance
between the product and combustible components, as the
temperature of the product will never exceed the maximum
permissible temperature of 85 °C at its nominal heat output.
4.7 Using the installation template
1. Position the installation template vertically over the in-
stallation site.
2. Secure the template to the wall.
3. Mark on the wall all the points required for the installa-
tion.
4. Remove the installation template from the wall.
5. Drill all the holes required.
6. Make any perforations necessary.
4.8 Wall-mounting the product
1. Check whether the wall has sufficient load-bearing capacity to bear the operational weight of the product.
2. Check if the supplied fixing material may be used for
the wall.
Conditions: The load-bearing capacity of the wall is sufficient; the fixing
material is permitted for the wall
▶ Wall-mount the product as described.
Conditions: The load-bearing capacity of the wall is not sufficient
▶ Ensure that wall-mounting apparatus on-site has a suf-
ficient load-bearing capacity. Use individual stands or
primary walling, for example.
▶ Do not wall-mount the product if you cannot provide
wall-mounting apparatus with a sufficient load-bearing
capacity.
Conditions: The fixing material may not be used for the wall
▶ Wall-mount the product as described using the permitted
fixing material provided on-site.
Installation 5
0020029173_04 ecoTEC plus Installation and maintenance instructions 11
4.9 Removing or installing the front casing
4.9.1 Removing the front casing
1
2
1. Undo the bolt (1).
2. Push in both retaining clips (2) so that the front casing
is released.
3. Pull the front casing forwards at the bottom edge.
4. Lift the front casing upwards from the bracket.
4.9.2 Installing the front casing
1. Place the front casing on the upper brackets.
2. Push the front casing onto the product until both retaining clips (2) snap into place at the front casing.
3. Secure the front casing by tightening the bolt (1).
5 Installation
Danger!
Risk of explosion or scalding caused by
incorrect installation.
Stresses in the supply line can cause leaks.
▶ Make sure there is no voltage in the sup-
ply lines when they are installed.
Caution.
Risk of damage caused by contaminated
lines.
Foreign bodies, such as welding remnants,
sealing residues or dirt in the water pipes,
may cause damage to the product.
▶ Flush the heating installation thoroughly
prior to installation.
Seals made of rubber-like materials may be subject to plastic
deformation, which can lead to pressure losses. We recommend using seals made of a paste-like fibre material.
You must only start up the product if a sufficiently dimensioned low loss header has been installed between the heat
generation circuit and the heating circuit or cylinder charging
circuit.
5.1 Selecting a low loss header
The low loss header disconnects the heat generator from
the heating system. This means that the system is no longer
dependent on the heat generator's remaining feed head.
In conjunction with the heating pump, the low loss header
ensures that a sufficiently high minimum quantity of water is
always circulating through the heat generator.
Heating system output Heating system spread
10 K 15 K 20 K
Individual unit WH 160 WH 95 WH 95
Dual cascade WH 280 WH 160 WH 95
Three-unit cascade WH 280 WH 280 WH 160
For old systems in particular, we recommend installing a
heating dirt filter in the return to the low loss header (not to
the product). This protects the product against dirt from the
system. Ensure that there is sufficient dimensioning in order
to prevent it from blocking quickly and to prevent high pressure losses.
You do not need any electrical accessories when using a
low loss header. You can connect simple systems directly
inside the electronics box; see the connection diagram
(→ Page 36).
5.1.1 Heating circuit connection with low loss
header
1
2
3
4
1 Product with internal
pump
2 Low loss header
3 External heating pump
4 Consumer (e.g. heating
circuit)
The product can directly operate a heating circuit via the low
loss header.
▶ Downstream of the low loss header, select a heating
pump that is appropriate for the system.
▶ For multi-circuit systems, pay additional attention to the
control system accessories.
The settings for the internal pump are made at the factory.
▶ Connect the external heating pump to the grey ProE plug
X13.
▶ Set the diagnostics code D.26 to 2.
5 Installation
12 Installation and maintenance instructions ecoTEC plus 0020029173_04
5.1.2 Cylinder priority switching via low loss
header
1
2
3
4
1 Product with internal
pump
2 Low loss header
3 External cylinder char-
ging pump
4 Consumer (e.g. cylinder
charging circuit)
The product's electronics are designed in such a way that
you can connect one cylinder charging circuit and one heating circuit directly without the need for accessories. The cylinder charging circuit connection downstream of the low loss
header means that you can select an individual cylinder size
and a cylinder charging pump.
▶ Note that non-return valves or mixer circuits may be re-
quired in order to eliminate cross-flow to other circuits or
the effects of high temperatures from the cylinder charging circuit.
▶ Connect the cylinder charging pump to the ProE plug X6.
To start up the cylinder charging pump, it is not necessary to
set a diagnostics code. The slot on the PCB is reserved for
the cylinder charging pump.
5.1.3 Cylinder priority switching and heating
circuit via low loss header
1
2
3
4
5
6
1 Product with internal
pump
2 Low loss header
3 External heating pump
4 Consumer (e.g. heating
circuit)
5 External cylinder char-
ging pump
6 Cylinder
The product's electronics are designed in such a way that
you can connect a standard system (one heating circuit and
one cylinder charging circuit) without the need for special accessories. If several circuits are required, special accessories and/or controllers are required. The product's remaining feed head for the low loss header is sufficient. You can
individually design the cylinder charging circuit connection
downstream of the low loss header (cylinder size, cylinder
charging pump size, etc.).
▶ Note that non-return valves or mixer circuits may be re-
quired in order to eliminate cross-flow to other circuits or
the effects of high temperatures from the cylinder charging circuit.
To start up the cylinder charging pump, it is not necessary to
set a diagnostics code. The slot on the PCB is reserved for
the cylinder charging pump.
The settings for the internal pump are made at the factory.
▶ Connect the cylinder charging pump to the ProE plug X6.
▶ Connect the external heating pump to the grey ProE plug
X13.
▶ Set the diagnostics code D.26 to 2.
5.2 Gas installation
5.2.1 Performing the gas installation
Caution.
Risk of material damage due to the gas
leak-tightness test.
At a test pressure of >11 kPa (110 mbar), gas
leak-tightness tests may cause damage to
the gas valve.
▶ If, during gas leak-tightness tests, you
also place the gas lines and the gas valve
in the product under pressure, use a max.
test pressure of 11 kPa (110 mbar).
▶ If you cannot limit the test pressure to
11 kPa (110 mbar), close any gas isolator
cocks that are installed upstream from the
product before you carry out the gas leaktightness test.
▶ If, during gas leak-tightness tests, you
have closed the gas isolator cock that is
installed upstream of the product, relieve
the gas line pressure before you open this
gas isolator cock.
Note
Do not reduce the gas pipe dimension downstream of the gas meter. Maintain the dimension
right up to the product. Select the correct gas isolator cock. When using an atmospheric sensing
device, select the next-highest pipe cross-section.
Installation 5
0020029173_04 ecoTEC plus Installation and maintenance instructions 13
1
▶ Install the gas line without tension in accordance with the
recognised rules of technology.
▶ Make sure that the existing gas meter is capable of
passing the rate of gas supply required.
▶ Remove the residues from the gas line by blowing
through the gas line beforehand.
▶ Screw the gas pipe (1) to the (preinstalled) gas isolator
cock so that it is gas-tight. To do this, use the enclosed
compression joint G 1.
▶ Purge the gas line before start-up.
▶ Check the gas connection for leak-tightness.
5.3 Hydraulics installation
Caution.
Risk of material damage due to corrosion.
If non-diffusion-tight plastic pipes are used in
the heating installation, this may cause air to
enter the heating water and lead to corrosion
of the heat generation circuit and the product.
▶ If using non-diffusion-tight plastic pipes
in the heating installation, separate the
system by installing an external heat exchanger between the product and the
heating installation.
Caution.
Risk of material damage due to heat trans-
fer during soldering.
Heat that is transferred during soldering may
cause damage to the seals in the service
valves.
▶ Do not solder the connection pieces if
the connection pieces are screwed to the
service valves.
▶ If you are using plastic pipes in the heating installation,
you must install a suitable limit thermostat on-site at the
heating flow. The limit thermostat is required to protect
the heating installation against temperature-related damage if a fault occurs.
▶ Install an expansion vessel on-site in the heating return,
as close to the product as possible.
5.3.1 Connecting the heating flow and heating
return
21
1. Install service valves properly at the flow connection (1)
and the return connection (2).
2. Establish the heating connections in accordance with
the relevant standards.
5.3.2 Installing the expansion relief valve
1
1. Install the enclosed expansion relief valve.
2. Lay as short a drain line as possible for the expansion
relief valve, at a downward gradient.
3. Terminate the drain line in such a way that escaping
water or steam cannot cause injury to persons or damage to electronic components.
4. Make sure that the line end is visible.
5.3.3 Connecting the condensate drain pipework
Danger!
Risk of death from escaping flue gases!
The condensate drain pipework of the condensate trap must not be connected tightly to
waste-water piping because, otherwise, the
internal condensate trap may be drained fully
and flue gas may escape.
▶ Do not connect the condensate drain
pipework tightly to the waste-water piping.
5 Installation
14 Installation and maintenance instructions ecoTEC plus 0020029173_04
1
2
Condensate forms in the product during combustion. The
condensate drain pipework (1) routes the condensate to the
waste water connection via a tundish (2).
▶ Install the enclosed condensate drain pipework (hose)
(1).
Note
If the length of the enclosed hose is not sufficient, use only pipes that are made from
acid-resistant material (e.g. plastic) for the
condensate drain pipework and also for the
waste-water piping.
▶ Suspend the condensate drain pipework above the prein-
stalled tundish (2).
5.4 Installing and connecting the flue pipe
1. You can find out which flue pipes may be used by consulting the enclosed flue pipe installation manual.
2. Observe the information on positioning the opening
for the flue pipe. This information can be found in the
appendix.
Caution.
Risk of poisoning due to escaping flue
gas.
Mineral-oil-based greases can damage the
seals.
▶ Instead of grease, use only water or com-
mercially available soft soap to aid installation.
3. Install the flue pipe using the installation manual.
5.5 Electrical installation
Danger!
Risk of death from electric shock as a res-
ult of an improper electrical connection!
An improper electrical connection may negatively affect the operational safety of the
product and result in material damage or personal injury.
▶ Only carry out the electrical installation if
you are a trained competent person and
are qualified for this work.
▶ Observe all applicable laws, standards
and directives in the process.
▶ Earth the product.
Danger!
Risk of death from electric shock!
Touching live connections may cause serious personal injury. Since mains connection
terminals L and N also remain live even if the
boiler main switch is turned off:
▶ Switch off the power supply.
▶ Secure the power supply against being
switched on again.
5.5.1 Opening or closing the electronics box
5.5.1.1 Opening the electronics box
1. Remove the front casing. (→ Page 11)
2
1
3
2. Tilt the electronics box (3) forwards.
3. Detach the left and right clips (1) from the brackets.
4. Fold up the cover (2).
Installation 5
0020029173_04 ecoTEC plus Installation and maintenance instructions 15
5.5.1.2 Closing the electronics box
1. Close the cover (2) by pushing it downwards onto the
electronics box (3).
2. Ensure that all of the clips (1) audibly click into the
brackets.
3. Tilt the electronics box upwards.
5.5.2 Establishing the power supply
1. Observe the relevant regulations and the enclosed connection diagram.
2. Provide one common electricity supply for the boiler
and for the corresponding controller:
– Power supply: Single-phase, 230 V, 50 Hz
– Fuse protection: ≤ 3 A
3. Connect the product using a fixed connection and a
partition with a contact opening of at least 3 mm (e.g.
fuses or power switches), see Connection diagram
(→ Page 36).
4. Use a flexible line for the mains connection line, which
is routed through the cable duct into the product.
5. Carry out the wiring. (→ Page 15)
6. Screw the ProE plug supplied to a suitable three-core
mains connection cable which complies with the relevant standards.
7. Close the electronics box. (→ Page 15)
8. Make sure that access to the mains connection is always available and is not covered or blocked.
5.5.3 Carrying out the wiring
Caution.
Risk of material damage caused by incor-
rect installation.
Mains voltage at the incorrect plug terminals
on the ProE system may destroy the electronics.
▶ Do not connect any mains voltage to the
eBUS terminals (+/-).
▶ Only connect the mains connection cable
to the terminals marked for the purpose.
1. Route the supply lines of the components to be connected through the cable duct provided on the underside of
the product on the left.
2. Use strain reliefs.
3. Shorten the supply lines as necessary.
4. Only strip the outer sheathing of flexible lines to a maximum of 30 mm to prevent short circuits if a strand accidentally comes loose.
5. Ensure the inner conductor insulation is not damaged
when stripping the outer sheathing.
6. Only strip inner conductors just enough to establish
good, sound connections.
7. To avoid short circuits resulting from loose individual
wires, fit conductor end sleeves on the stripped ends of
the conductors.
8. Screw the respective ProE plug to the supply line.
9. Check whether all conductors are sitting mechanically
securely in the terminals of the ProE plug. Remedy this
if necessary.
10. Plug the ProE plug into the associated PCB slot.
5.5.4 Installing the controller
▶ Install the controller if necessary.
5.5.5 Connecting controllers to the electronic
system
1. Carry out the wiring. (→ Page 15)
2. If you do not connect a room/timer thermostat, bridge
terminals 3 and 4, if no bridge exists.
3. If you connect a room/timer thermostat to terminals 3
and 4, remove the bridge.
4. If you connect a weather compensator or room thermo-
stat (continuous control – connection terminals 7, 8, 9),
leave the bridge inserted between terminal 3 and 4.
5. If you connect a limit thermostat (contact thermostat)
for underfloor heating systems, remove the bridge on
the blue ProE plug (contact thermostat) and connect the
limit thermostat here.
6. Close the electronics box. (→ Page 15)
7. To access pump operating mode 1 (continuously run-
ning pump) for multi-circuit controllers, set D.18 Pump
operating mode (→ Page 22) from 3 (intermittent pump)
to 1.
5.5.6 Connecting a low loss header sensor
1. Connect the low loss header sensor to the edge con-
nector X41 at terminal RF or to the controller. When doing so, observe the instructions for the controller.
2. Plug the edge connector into the PCB slot X41.
3. Activate the low loss header function at the controller.
5.5.7 Connecting a cylinder charging pump
▶ Connect an external cylinder charging pump (to be fitted
on-site) to the pink ProE plug X6.
5.5.8 Connecting additional components
You can actuate an additional component with the aid of the
auxiliary relay that is installed, and you can actuate two other
components with the multi-functional module.
The following components can be actuated:
1. Circulation pump
2. External pump
3. Cylinder charge pump
4. Extractor hood
5. External solenoid valve
6. External fault signal
7. Not active
8. eBUS remote control (not active)
9. Legionella protection pump (not active)
10. Not active.
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