Vaillant ecoTEC plus 612, ecoTEC plus 615, ecoTEC plus 618, ecoTEC plus 624, ecoTEC plus 630 Instructions For Installation And Servicing
...
For the installer
Instructions for installation and servicing
ecoTEC
Wall hung room sealed fan assisted condensing boiler
ecoTEC plus 612
ecoTEC plus 615
ecoTEC plus 618
ecoTEC plus 624
ecoTEC plus 630
ecoTEC plus 824
ecoTEC plus 831
ecoTEC pro 28
GB
Contents
Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notes on the documentation . . . . . . . . . . . . . . . 4
1.1.1 Applicable documents. . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Preservation of documents . . . . . . . . . . . . . . . . 4
1.1.3 Safety instructions and symbols. . . . . . . . . . . . 4
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Boiler specifications . . . . . . . . . . . . . . . . . . . 6
2.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 General requirements . . . . . . . . . . . . . . . . . . 10
3.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Scope of delivery and accessories . . . . . . . . . . 10
3.4 Installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Flue pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6.1 Standard 100 mm flue system . . . . . . . . . . . . . . 13
3.6.2 Optional 125 mm flue system . . . . . . . . . . . . . . . 13
3.7 Flue termination. . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.8 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.10 Guide to system requirements. . . . . . . . . . . . . . 15
3.10.1 Water circulation system . . . . . . . . . . . . . . . . . . 15
3.10.2 Filling and preparing heating system. . . . . . . . 15
3.10.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . 15
3.10.4 Pressure gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.10.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.11 Pump specifications . . . . . . . . . . . . . . . . . . . . . . 16
3.11.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11.2 System by-pass. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11.3 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.12 Condensate trap. . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Boiler installation sequence. . . . . . . . . . . . . 16
4.1 Required minimum distances/assembly
clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1.1 Select position for boiler . . . . . . . . . . . . . . . . . . 17
4.1.2 Unpack the boiler. . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.3 Using boiler template . . . . . . . . . . . . . . . . . . . . . 17
4.2 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Fitting the boiler hanging bracket . . . . . . . . . . 18
4.4 Installing flue system. . . . . . . . . . . . . . . . . . . . . . 18
4.5 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.6 Removing the front case . . . . . . . . . . . . . . . . . . 18
4.7 General instructions for heating system . . . . . 18
4.8 Gas connection. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.9 Cold water mains inlet and hot water outlet
(ecoTEC plus 800 and pro only) . . . . . . . . . . . . 19
4.10 Heating connection . . . . . . . . . . . . . . . . . . . . . . 20
4.10.1 Heating flow and return connection. . . . . . . . . 20
4.10.2 Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . 21
4.11 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . 22
4.12 Connecting the flue system to the boiler . . . . 22
4.13 Electrical connection. . . . . . . . . . . . . . . . . . . . . . 22
4.13.1 General requirements . . . . . . . . . . . . . . . . . . . . . 22
4.13.2 Connection to the main supply . . . . . . . . . . . . . 23
4.13.3 Electric board layout . . . . . . . . . . . . . . . . . . . . . . 24
4.13.4 Connection of programmable thermostats . . . 27
4.14 Controls (ecoTEC plus 800 and pro only) . . . . 27
4.14.1 External electrical controls . . . . . . . . . . . . . . . . 27
4.14.2 Connection of external controls . . . . . . . . . . . . 27
4.14.3 Connection details for programmable room
thermostats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.14.4 Connection of time switches . . . . . . . . . . . . . . . 28
4.14.5 Connection details for external time switches
and boiler terminal strip . . . . . . . . . . . . . . . . . . . 29
4.14.6 Vaillant optional plug in timer accessories . . . 29
4.15 Controls (600 series) . . . . . . . . . . . . . . . . . . . . . 29
4.15.1 External electrical controls . . . . . . . . . . . . . . . . 29
4.15.2 Connection of external electrical controls . . . 29
4.15.3 Connection details using an external wiring
centre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.16 Thermostatic radiator valves. . . . . . . . . . . . . . . 29
4.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.19 Anticycling ‘economiser’ control. . . . . . . . . . . . 29
4.20 Automatic pump spin control (APS). . . . . . . . . 29
5 Commissioning Part I . . . . . . . . . . . . . . . . . . 32
5.1 Preliminary electrical checks. . . . . . . . . . . . . . . 32
5.2 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Cold water supply (only 800 series). . . . . . . . . 32
5.4 Filling the heating system . . . . . . . . . . . . . . . . . 32
5.4.1 Checking the filling pressure of the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4.2 ecoTEC plus filling loop (800 series) . . . . . . . . 32
5.4.3 Filling the heating system in ecoTEC pro and
ecoTEC plus (600 series) . . . . . . . . . . . . . . . . . . 33
5.4.4 Filling the heating system for the first time . . 33
5.5 Initial system flush (“cold”) . . . . . . . . . . . . . . . . 33
5.6 Filling the condensation water siphon . . . . . . . 34
5.7 Adjusting the pumping capacity . . . . . . . . . . . . 34
5.8 Adjusting the by-pass . . . . . . . . . . . . . . . . . . . . . 34
5.9 Checking the gas supply. . . . . . . . . . . . . . . . . . . 35
5.9.1 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9.2 Gas inlet working pressure. . . . . . . . . . . . . . . . . 35
5.9.3 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . 35
5.10 Refitting the case. . . . . . . . . . . . . . . . . . . . . . . . . 36
5.11 Adjusting the central heating output (range
rating). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6 Functional checks (commissioning part II). 36
6.1 Functional checks. . . . . . . . . . . . . . . . . . . . . . . . . 36
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.1.2 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1.3 Water heating (only 800 series) . . . . . . . . . . . . 37
6.1.4 Final flush of the heating system (“hot”) . . . . 37
6.2 Handing over to the user . . . . . . . . . . . . . . . . . . 38
2
Instructions for installation and servicing ecoTEC
7 Inspection and maintenance . . . . . . . . . . . . 38
7.1 Initial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.4 Overview of the maintenance tasks . . . . . . . . . 39
7.1.5 Functional check of boiler operation . . . . . . . . 39
7.2 Servicing the compact thermal module. . . . . . 40
7.2.1 Removing the compact thermal module . . . . . 40
7.2.2 Cleaning the integral condensation heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . 41
7.2.4 Refitting the compact thermal module . . . . . . 41
7.3 Cleaning the condensation water siphon . . . . 42
7.4 Checking the expansion vessel . . . . . . . . . . . . . 43
7.5 Recommissioning the boiler. . . . . . . . . . . . . . . . 43
7.6 Test operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 44
8.1 Logical fault finding procedure . . . . . . . . . . . . . 44
8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.2 Diagnosis codes . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4 Test programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5 Resetting parameter to factory settings . . . . . 49
Contents
9 Parts replacement. . . . . . . . . . . . . . . . . . . . . 49
9.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Replacing fan or gas valve . . . . . . . . . . . . . . . . . 50
9.4 Replacing expansion vessel . . . . . . . . . . . . . . . . 50
9.5 Replacing primary heat exchanger. . . . . . . . . . 51
9.6 Replacing electronics and display. . . . . . . . . . . 52
9.7 Check CO
(air-ratio adjustment) . . . . . . . . . . . . . . . . . . . . . 53
10 Recycling and disposal . . . . . . . . . . . . . . . . . 54
10.1 Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
content and if necessary set
2
3Instructions for installation and servicing ecoTEC
1 Introduction
1 Introduction
1.1 Notes on the documentation
The following information is intended to help you
throughout the entire documentation.
Further documents apply in combination with this installation and maintenance manual.
We assume no liability for any damage caused by
non-observance of these manuals.
1.1.1 Applicable documents
The following additional documents are provided with
the appliance:
For the owner of the system:
Brief users instructions
(only ecoTEC plus) no. 838404
Benchmark logbook no. 800371
Warranty card with return envelope no. 802922
For the qualified technician:
Installation and maintenance manual no. 839592
Assembly manual for flue accessories no. 835296
The manuals for any accessories and controllers used
also apply.
1.1.2 Preservation of documents
Please pass on this installation manual to the owner of
the system. The owner shall preserve the manuals so
that they are available when required.
1.1.3 Safety instructions and symbols
Please observe the safety instructions in this manual for
the installation of the appliance!
Symbols used in the manual are explained below:
Danger!
Immediate danger to life and limb!
Caution!
Potentially dangerous situation for the product
and environment!
Note
Useful information and instructions.
• Symbol for a necessary task
- List for function descriptions or general list
1.2 Introduction
Note
This boiler must be installed and serviced by a
competent person in accordance with the Gas
Safety (Installation and Use) Regulations 1998.
In the UK ‘CORGI’ registered installers undertake the work in compliance with safe and satisfactory standard.
ecoTEC 800 and pro range
The ecoTEC 800 and pro range is a fully automatic, wall
mounted, room sealed condensing (high efficiency) combination boiler for central heating and domestic hot
water.
Domestic hot water is supplied directly from the boiler,
without requiring a copper cylinder, cold water tank,
feed and expansion vessel and associated pipework.
Domestic hot water has priority over central heating.
The ecoTEC 800 range consists of 2 models with outputs of 23 kW and 31 kW for domestic hot water and a
pro version with an output of 28 kW for domestic hot
water.
All versions are available in natural gas. The ecoTEC plus
831 is also available in LPG.
ecoTEC combination boilers incorporate a warm start
facility that keeps the domestic hot water heat exchanger hot, providing an instantaneous delivery of domestic
hot water. The temperature in the domestic hot water
heat exchanger is limited by the boiler control system
and it is not necessary to install a scale reducer on the
cold mains to the boiler. However, in areas that get
exceptionally hard water, a scale reducer may be fitted
to prevent scale formation in the hot water system
pipes. The heating system can be filled using the built–in
filling loop contained within the boiler.
ecoTEC plus 600 range
The ecoTEC plus 600 range is a fully automatic, wall
mounted, room sealed condensing (high efficiency) system boiler for central heating and domestic hot water
(where a separate indirect hot water storage cylinder is
also incorporated in the system). The ecoTEC 600 range
consists of models with outputs of 12, 15, 18, 24 and 30
kW. All ecoTEC 600 range boilers are available in Natural
Gas. The ecoTEC plus 618 and 630 are also available in
LPG.
1.3 General Notes
The boilers have been designed for use with a sealed
central heating system, and come fully tested and
assembled with a built in circulating pump, expansion
vessel and diverter valve (ecoTEC plus 800 and pro).
The boilers are easily mounted on any internal wall and
can be installed with either a horizontal or vertical RSF
(room sealed fan assisted) flue.
The boilers use a standard flue system (100 mm or
125 mm outside diameter). Flue extensions and additional bends and elbows are available for the flue system to
increase the flexibility. If desired, an inhibitor may be
used in the system. Guidance on the use of inhibitors is
contained in these instructions.
All boilers have a built in diagnostic system which indicates the operational status of the boiler. This feature
provides key information to aid commissioning and fault
finding. The data badge is fitted to the underside of the
boiler. See text of General Requirements for installation
requirements or notes.
4 Instructions for installation and servicing ecoTEC
The Valliant ecoTEC are state-of-the-art appliances
which have been constructed in accordance with recognised safety regulations. Nevertheless, danger to the life
and limb of the user or third parties can still occur or
the appliance or other material assets be impaired in the
event of improper use.
The appliance is designed to generate heat for connecting to hot water central heating systems and for instantaneous hot water supply (ecoTEC 800 and pro only).
Any other use or extended use is considered to be use
other than intended. The manufacturer/supplier is not
liable for any resulting damage.
Intended use includes the observance of the operating
and installation manual and the adherence to the inspection and maintenance conditions.
Danger!
Any incorrect use is forbidden.
The appliances must be installed by a qualified engineer,
who is responsible for adhering to the existing regulations, rules and guidelines.
Introduction 1
1.4 CE marking
The CE marking shows that the appliances comply
with the basic requirements of the following directives:
- Gas appliances directive (90/396/EEC)
- Electromagnetic compatibility directive with threshold
class B (89/336/EEC)
- Low voltage directive (73/23/EEC)
The appliances satisfy the basic requirements of the efficiency directive (92/42/EEC) as condensing appliance.
- The Gas Applaince (Safety) Regulations 1992
- The boiler (Efficiency) Regulations 1993
Vaillant Ltd. supports the Benchmark initiative.
In the information pack, you will find a
Benchmark Logbook. It is very important that
this is completed correctly at the time of
installation, commissioning and hand over to
the user.
5Instructions for installation and servicing ecoTEC
2 Boiler specifications
2 Boiler specifications
2.1 Technical data
Technical data
CH heat output range
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
Drinking water capacity 23.0 31.0 28.0 kW
Maximum DHW output 23.5 31.6 28.6 kW
Maximum output for heating 18.4 24.5 24.5 kW
Minimum output 6.1 8.9 8.9 kW
Category II
SEDBUK Band A A A Band
Inlet gas working pressure required (G20, natural gas) 20 mbar
Inlet gas working pressure required (G31, Propane) 37 mbar
Connected load (if needed, related to stored charge/
water heating) at 15 °C and 1013 mbar
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
Permitted total overpressure 3.0 bar
Circulation water volume (∆T=20 K)
Approx. condensation volume
at 40 °C flow/30 °C return heating
Pump delivery height 250 mbar
Minimum DHW volume 1.5 1.5 1.5 l/min
Hot water volume (∆T=30 K)
Permitted overpressure 10 bar
Required connecting pressure 0.35 bar
Hot water discharge temperature range 35 – 65 °C
Exhaust flue 60/100 mm
10 l expansion vessel pre-charge pressure 0.75 0.75 0.75 bar
Maximum CH system pressure 2.5 2.5 2.5 bar
Connections heating flow/return 3/4“ 3/4“ 3/4“
Gas inlet 15 15 15 mm
Pressure relief discharge pipework (min.) 15 15 15 mm
Condensate drain (min. internal drain) 19 19 19 mm
Weight (boiler only) 36 37 37 kg
Primary water content 1.9 2.3 2.1 l
Electrical supply voltage 230/50 230/50 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input min.
max.
at 30 % efficiency
Table 2.1 Technical data plus 800 and pro series
6.0 – 18.0
6.1 – 18.6
6.3 – 19.1
6.5 – 19.5
G31: 1.43
ecoTEC plus
824 831
8.7 – 24.0
9.0 – 24.7
9.3 – 25.5
9.4 – 26.0
2H3P
G20: 1.9
2.8
8.3
774 1032 1032 l/h
1.7 2.2 2.2 l/h
11.0 14.8 13.4 l/min
G20: 3.3
G31: 2.45
4.1
14.2
40
70
40 – 85 °C
70
130
65
ecoTEC pro
28
8.7 – 24.0
9.0 – 24.7
9.3 – 25.5
9.4 – 26.0
G20: 3.0
G31: 2.22
4.1
12.9
Units
kW
kW
kW
kW
3
/h
m
kg/h
g/s
g/s
°C
°C
W
W
W
6 Instructions for installation and servicing ecoTEC
Boiler specifications 2
Technical data
CH heat output range
80 °C flow/60 °C return
60 °C flow/40 °C return
50 °C flow/30 °C return
40 °C flow/30 °C return
Memory charging capacity 12.0 15.0 18.0 24.0 30.0 kW
Maximum output during memory charging 12.2 15.3 18.4 24.5 30.6 kW
Maximum output for heating 12.2 15.3 18.4 24.5 30.6 kW
Minimum output 4.1 4.1 6.1 8.9 10.2 kW
Category II
SEDBUK Band AAAAABand
Inlet gas working pressure required (G20, natural gas) 20 mbar
Inlet gas working pressure required (G31, Propane) 37 mbar
Connected load (if needed, related to stored charge/
water heating) at 15 °C and 1013 mbar
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return
at maximum thermal load (80 °C flow/60 °C return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return)
at maximum thermal load (80 °C flow/60 °C return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
Default setting: max. 75 °C
Permitted total overpressure 3.0 bar
Circulating water volume (∆T=20 K)
Approx. condensation volume
at 40 °C flow/30 °C return heating
Pump delivery height 250 mbar
Adjustable storage target value (15 °C at left stop,
spare adjusting range 40 – 70 °C
Exhaust flue 60/100 mm
10 l expansion vessel pre-charge pressure 0.75 0.75 0.75 0.75 0.75 bar
Maximum CH system pressure 2.5 2.5 2.5 2.5 2.5 bar
Connections heating flow/return 3/4“ 3/4“ 3/4“ 3/4“ 3/4“
Gas inlet 15 15 15 15 15 mm
Pressure relief discharge pipework (min.) 15 15 15 15 15 mm
Condensate drain (min. internal drain) 19 19 19 19 19 mm
Weight (boiler only) 36 36 36 37 39 kg
Primary water content 1.9 1.9 1.9 2.1 2.3 l
Electrical supply voltage 230/50 230/50 230/50 230/50 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input min.
max.
at 30 % efficiency
Table 2.2 Technical data 600 series
612 615 618 624 630
4.0 – 12.0
4.1 – 12.3
4.3 – 12.7
4.4 – 12.9
G20: 1.3
G31: 0.95
1.9
5.5
516 645 774 1032 1290 l/h
1.1 1.4 1.7 2.2 2.7 l/h
4.0 – 15.0
4.1 – 15.5
4.3 – 15.9
4.4 – 16.2
G20: 1.6
G31: 1.19
1.9
6.9
ecoTEC plus
6.0 – 18.0
6.1 – 18.6
6.3 – 19.1
6.5 – 19.5
2H3P
G20: 1.9
G31: 1.43
2.8
8.3
40
70
40 – 85 °C
15 – 70 °C
70
130
65
8.7 – 24.0
9.0 – 24.7
9.3 – 25.5
9.4 – 26.0
G20: 4.1
G31: 1.90
4.1
11.1
10.0 – 30.0
10.3 – 30.9
10.6 –31.8
10.8 – 32.4
G20: 3.2
G31: 2.38
4.7
13.8
Units
kW
kW
kW
kW
3
/h
m
kg/h
g/s
g/s
°C
°C
W
W
W
7Instructions for installation and servicing ecoTEC
2 Boiler specifications
2.2 Dimensions
440
10
190
8
7
65
241
883
720
642
20
Fig. 2.1 Dimensions in mm
175
35 35
6
9
125
5
4
3
2
130
1
100100
180
300
12345
Legend:
1 Heating return pipe Ø 22 mm
2 Cold water connection Ø 15 mm (only 800 series)
3 Gas connection Ø 15 mm
4 Hot water connection Ø 15 mm (only 800 series)
5 Heating flow pipe Ø 22 mm
6 Hanging bracket
7 Flue hole - flue system 60/100
8 Flue hole - flue system 80/125
9 Flue pipe connection
10 Spacer frame accessory (Art. No.: 308 650)
Note
With the spacer frame (Art. No 308 650), the
pipes can be run behind the boiler. The distance
of the appliance from the wall thus increases by
65 mm.
8 Instructions for installation and servicing ecoTEC
Boiler specifications 2
2.4 Installation
14
13
12
11
10
14
1
13
1
2
3
4
5
12
6
10
7
2
3
4
5
7
Fig. 2.2 Function elements of 800 series
Legend:
1 Expansion vessel
2 Air intake pipe
3 Compact thermal module
4 Ignition electrode
5 Fan
6 Diverter valve with by-pass
7 Pump
8 Aqua-Sensor
9 Electronics box
10 Pressure sensor
11 Hot water heat exchanger
12 Gas valve
13 Heat exchanger
14 Flue pipe connection
8
9
Fig. 2.3 Function elements of 600 series
Legend:
1 Expansion vessel
2 Air intake pipe
3 Compact thermal module
4 Ignition electrode
5 Fan
7 Pump
9 Electronics box
10 Pressure sensor
12 Gas valve
13 Heat exchanger
14 Flue pipe connection
9
9Instructions for installation and servicing ecoTEC
2 Boiler specifications
3 General requirements
2.5 Type plate
The type plate of the Valliant ecoTEC is attached to the
bottom of the appliance at the factory.
Fig. 2.4 Type plate (example)
3 General requirements
3.1 Preliminary remarks
This appliance shall only be installed in conjunction with
a Vaillant flue system. Install the flue system as detailed
in the separate flue installation instructions supplied
with this boiler.
3.2 Related documents
ecoTEC appliances satisfy the Gas Appliance (Safety)
Regulations 1992 and the Boiler (Efficiency) Regulations
1993.
The installation of the boiler must be in accordance with
the relevant requirements of Gas Safety (Installation and
Use) Regulations 1998, Health and Safety Document No.
635 (The Electricity at Work Regulations 1989), BS7671
(IEE Wiring Regulations) and the Water Supply (Water
Fitting) Regulations 1999, or The Water Bylaws 2000
(Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building
Regulations, including amendments to the Approved
Documents Part L and J 2002, The Building Regulations
(Scotland). The Building Regulations (Northern Ireland)
and the relevant recommendations of the following
British Standards and regulations:
BS 5440: Flues and ventilation of gas fired boilers not
exceeding 70 kW net:
– Part 1: Flues
– Part 2: Ventilation
BS 5449: Specification for forced circulation hot water
for domestic premises.
BS 5546: Specification for gas hot water supplies for
domestic premises.
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired boil-
ers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water cen-
tral heating systems.
Institute of Gas Engineers Publication IGE/UP/7/1998:
“Guide for gas installations in timber framed housing”
European installation directive
Important:
The appliance must be installed and serviced by
a competent person as stated in the Gas Safety
(Installation and Use) Regulations 1998. In IE,
the installation must be in accordance with the
current edition of I.S.813 ‘Domestic Gas
Installations’, the current Building Regulations
and reference should be made to the current
ETCI rules for electrical installation.
Important:
When tightening or slackening screwed connections always use suitable open-ended spanners
(not pipe wrench, or extensions, etc.).
Incorrect use and/or unsuitable tools can lead
to damage being caused (e.g. gas or water leakage)!
3.3 Scope of delivery and accessories
The Vaillant ecoTEC is delivered pre-mounted in a package unit. Check that all the parts have been delivered
intact (see Fig. 3.1 and Table 3.1, Fig. 3.2 and Table 3.2
and Fig. 3.3 and Table 3.3).
10 Instructions for installation and servicing ecoTEC
General requirements 3
9
8
7
6
5
1
9
2
8
7
3
6
4
5
1
2
3
4
Fig. 3.1 Scope of delivery for ecoTEC plus 600 series
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Appliance
3 1 Bottom cover
4 4 Connecting pipes (gas, heating, safety valve)
5 3 Isolating cocks
6 1 Template
7 1 Benchmark logbook
83
9 2 Bag with small items
Table 3.1 Scope of delivery for ecoTEC plus 600 series
User, installation and maintenance and flue
assembly manuals
For LPG appliances, extra: 1 sticker each for
2
tank and ventilation (above Fig.)
Fig. 3.2 Scope of delivery for ecoTEC plus 800 series
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Appliance
3 1 Bottom cover
46
5 4 Isolating cocks
6 1 Template
7 1 Benchmark logbook
83
9 2 Bag with small items
Table 3.2 Scope of delivery for ecoTEC plus 800 series
Connecting pipes (gas, heating, water, safety
valve)
User, installation and maintenance and flue
assembly manuals
For LPG appliances, extra: 1 sticker each for
2
tank and ventilation (above Fig.)
11Instructions for installation and servicing ecoTEC
3 General requirements
8
7
P
F
i
r
a
b
6
5
4
Fig. 3.3 Scope of delivery for ecoTEC pro
DO NOT remove the boiler from the polystyrene base at
this stage.
Item Quantity Description
1 1 Hanging bracket
2 1 Appliance
32
4 4 Isolating cocks
5 1 Template
6 1 Benchmark logbook
71
8 2 Bag with small items
Table 3.3 Scope of delivery for ecoTEC pro
Connecting pipes (hot water, heating safety
valve)
User, installation and maintenance and flue
assembly manuals
1
2
3
3.4 Installation site
The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location must
also provide adequate space for servicing and air circulation around the boiler. The boiler may be installed in
any room, although particular attention is drawn to the
requirements of BS7671 (IEE Regulations), the electrical
provisions of the Building Standards (Scotland)
Regulations, and in IE the current edition of IS813 and
the current ETCI rules, in respect of the installation of a
boiler in a room containing a bath or shower.
Note
If a room sealed boiler is installed in a room
with a bath or shower, electrical switches or
boiler controls using the mains power supply
must be placed at locations that cannot be
reached by the person in the bath or shower.
If the boiler is installed in an unusual location, special
procedures may be necessary and BS 5546 and BS 6798
give detailed guidance on this aspect. The boiler must be
mounted on a flat, vertical wall, which must be sufficiently robust to take the weight of the boiler. The boiler
may be installed on a combustible wall, subject to the
requirements of the Local Authorities and Building
Regulations.
A compartment used to enclose the boiler must be
designed and constructed specifically for this purpose.
(An existing cupboard or compartment may be used provided that it is modified for the purpose). Details of
essential features of cupboard/compartment design
including airing cupboard installations are given in BS
6798. If the boiler is to be fitted in a timber framed
building, it should be fitted in accordance with Institute
of Gas Engineers Publication IGE/UP/7/1998 “Guide for
Gas Installation in Timber Framed Housing”.
Please note the safety instructions below before deciding where to install the boiler:
Caution!
Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance must be operated independent of
the ambient air.
When choosing the place of installation and while operating the appliance, make sure that the combustion air
is technically free of chemical substances containing fluorine, chlorine, sulphur etc. Sprays, solvents and cleaning agents, paints, adhesives etc. contain this kind of
substances that can lead to corrosion even in the
exhaust system when the appliance is operated depending on the ambient air in the worst case scenario.
Particularly in hair-cutting salons, lacquering and finishing, cleaning facilities, the appliance must be operated
independent of the ambient air! Otherwise, a separate
installation room is required to guarantee that the com-
12 Instructions for installation and servicing ecoTEC
bustion air supply is technical free of the above mentioned substances.
3.5 Gas supply
The gas supplier should ensure the availability of an
adequate supply of gas. A gas meter may only be connected to the service pipe by the supplier of gas or their
contractor. An existing meter should be checked to
ensure that it is capable of passing the rate of gas supply required.
Installation pipes should be fitted in accordance with
BS 6891. In IE the current edition of IS 813. Pipework
from the meter to the boiler must be of an adequate
size. Do not use pipes of a smaller size than the boiler
gas connection (15 mm). The complete installation must
be checked for leaks and purged as described in
BS 6891.
3.6 Flue pipe
General requirements 3
550
10
1435
70
Danger!
Vaillant appliances are certified only for use
with genuine Vaillant flue pipes. Only use genuine Vaillant flue pipes. Malfunctions can occur if
you use other accessories. These may result in
damage and injury. You will find a list of genuine
flue pipes in the Vaillant installation manual for
flue pipes.
The CE mark is valid only if the appliance is
operated with Vaillant flue pipes.
3.6.1 Standard 100 mm flue system
48
30
600
Fig. 3.4 Art. No. 303 933
65.5
74
The standard 100 mm flue system (Art. No. 303 933) is
suitable for installations up to 666 mm measured from
the centre of the boiler flue outlet to the outside face of
the wall.
Flue extensions are available to extend this length up to
8 m. Both 90° bends and 45° elbows are also available
to increase siting flexibility.
Fig. 3.5 Art. No. 303 900
3.6.2 Optional 125 mm flue system
A concentric flue system of 125 mm outside diameter is
available and can be used to achieve flue lengths up to
25 m.
A vertical flue system is also available. Refer to flue system installation instructions for full details.
1103
70
70
15
Fig. 3.6 Art. No. 303 209
1530
880
Fig. 3.7 Art. No. 303 200
70
13Instructions for installation and servicing ecoTEC
3 General requirements
3.7 Flue termination
The following details refer to both flue systems.
a. The terminal must be located where the combustible
substances can escape freely at all times.
b. A plume of water vapour will sometimes be visible
from the flue terminal. Positions where this could be
a nuisance should be avoided.
c. If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people
have access then a suitable terminal guard must be
provided and fitted (made by Tower Flue
Components, Tonbridge, TN9 1TB, Model K3, plastic
coated).
A
G
F
J
H, I
Fig. 3.8 Flue termination
BCD
A
A
A
E
G
B
F
M
G
L
F
F
K
K
L
Note
In addition, the terminal should not be nearer
than 150 mm to an opening in the building fabric formed for the purpose of accommodating a
built-in element such as a window.
BS 5440–1: It is recommended that the fanned flue terminal should be positioned as follows:
a) at least 2 m from an opening in the building directly
opposite, and
b) so that the products of combustion are not directed
to discharge across a boundary.
1) Dimensions B, C and D:
These clearances may be reduced to 25 mm without
affecting the performance of the boiler. In order to
ensure that the condensate plume does not affect
adjacent surfaces the terminal should be extended as
shown in Fig. 3.9.
2) Dimension F:
This clearance may be reduced to 25 mm without
affecting the performance of the boiler. However, in
order to ensure that the condensate plume does not
affect adjacent surfaces a clearance of 300 mm is
preferred. For IE, recommendations are given in the
current edition of IS 813.
Note
Vertical flues must not terminate within
600 mm of an openable window, air vent or any
other ventilation opening.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
Terminal position mm
Directly below an opening, above an opening or hori-
A
zontal to an opening, air brick, opening window, etc.
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
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 for vertical Flue 500
Table 3.4 Terminal position for a fan assisted concentric flue
300
1200
Fig. 3.9 Flue termination under balcony/eaves
3.8 Air supply
Detailed recommendations for air supply are given in
BS 5440: Part 2.
It is not necessary to have an air vent in the room or
internal space in which the boiler is installed.
Cupboard or compartment ventilation
The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during
operation is very low. For cupboard or compartment
installations it is therefore not necessary to provide any
high or low level permanent air vents for cooling purposes.
14 Instructions for installation and servicing ecoTEC
General requirements 3
3.9 Electrical supply
A 230 V, ~ 50 Hz single phase electricity supply fused to
3 Amp. must be provided in accordance with the latest
edition of BS 7671 (IEE Wiring Regulations) and any
other local regulations that may apply. In IE reference
should be made to the current edition of the ETCI rules.
The method of connection to the mains electricity supply must provide a means of completely isolating the
boiler and its ancillary controls. Isolation is preferably by
the use of a fused three pin plug and unswitched shuttered socket outlet, both complying with the requirements of BS 1363. Alternatively, a 3 Amp. fused double
pole switch with a 3 mm contact separation on both
poles may be used.
Danger!
This appliance must be earthed.
3.10 Guide to system requirements
3.10.1 Water circulation system
Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449: Part 1 (for small
bore and micro bore central heating systems). Pipework
not forming part of the useful heating surface should be
insulated to help prevent heat loss and possible freezing,
particularly where pipes are run through roof spaces
and ventilated underfloor spaces. Draining taps must be
located in accessible positions which permit the draining
of the whole system including the boiler and the hot
water system. Draining taps should be at least 1/2 in.
BSP nominal size and be in accordance with BS 2879.
The boiler is suitable for use with minibore or microbore
systems. Copper tubing to BS 2871: Part 1 should be used
for water carrying pipework. All capillary joints in all
DHW pipework must be made with lead free solder.
Particularly where a new boiler is to be fitted to an existing system, it is good practice that the system is thoroughly cleansed. This cleansing should take place prior
to the fitting of the new boiler and be in accordance with
BS 7593. For advice on the application of system cleansers contact Sentinel, Betz Dearborn Ltd. Widnes,
Cheshire, WA8 8UD. Tel: 0151 420 9595, or Fernox, Alpha
Fry Technologies, Tandem House, Marlow Way, Croydon,
CR0 4XS. Tel 0870 8700362.
3.10.2 Filling and preparing heating system
The system can be filled using the built in filling loop
(ecoTEC plus 800 series only) or via a separate filling
point fitted at a convenient position on the heating circuit. The connection must be removed when filling is
completed. Where local Water Authority regulation does
not allow temporary connection, a sealed system filler
pump with break tank must be used. The heating system
will not be filled automatically from the domestic hot
water side. (Alternative methods of filling sealed systems are given in BS 5449).
3.10.3 Pressure relief valve
A pressure relief valve is provided with the boiler. This
safety device is required on all sealed C.H. systems and
is preset at 3 bar and provided with a 15 mm compression connection for a discharge pipe, which must be of
no less than 15 mm in diameter. The pressure relief valve
must not be used for draining purposes.
3.10.4 Pressure gauge
This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing.
3.10.5 Expansion vessel
ecoTEC boilers incorporate a 10 litre expansion vessel
which is suitable for a sealed heating system with a maximum water content of 100 litres.
If the nominal capacity of the built in expansion vessel is
not sufficient for the heating system (for instance in
case of modernisation of old open systems) an additional expansion vessel can be installed external to the boiler. It should be fitted in the return pipe as close as possible to the boiler in accordance with BS 5449: Part 1.
Guidance on the sizing of an additional expansion vessel
is given in Table 3.5.
Vessel Volume [L]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0
Total water content of system litres
25 2.7 3.9
50 5.4 7.8
100 10.9 15.6
125 13.6 19.5
150 16.3 23.4
175 19.1 27.3
200 21.8 31.2
225 24.5 35.1
250 27.2 39.0
275 30.0 42.9
300 32.7 46.8
325 35.7 50.7
350 38.1 54.6
375 40.9 58.5
400 43.6 62.4
425 46.3 66.3
450 49.0 70.2
475 51.8 74.1
500 54.5 78.0
For system volumes other than those given
above, multiply the system volume by the
factor across
Table 3.5 Sizing of additional expansion vessel
0.109 0.156
15Instructions for installation and servicing ecoTEC
3 General requirements
4 Boiler installation sequence
3.11 Pump specifications
3.11.1 Circulating pump
only ecoTEC plus:
The circulating pump is included in the boiler. The residual pump discharge height depending on the by-pass
valve is shown in Fig. 3.10.
The operating mode of the 2-step pump can be adjusted
below the diagnosis point d.19, see Section 8.1.2.
]
400
mbar
[
300
Lift
200
100
0
0 200 400 600 800 1000 1200 1600
Fig. 3.10 Pump specifications ecoTEC plus
2. Step1. Step
1400
Volumeflow [l/h
1800
only ecoTEC pro:
The circulating pump is included in the boiler. The ecoTEC pro appliances are fitted with a single-stage pump.
The residual pump discharge height depending on the
by-pass valve is shown in Fig. 3.11.
]
400
mbar
[
300
Lift
200
100
0
0 200 400 600 800 1000 1200 1600
Fig. 3.11 Pump specifications ecoTEC pro
1400
Volumeflow [l/h
1800
]
4 Boiler installation sequence
4.1 Required minimum distances/assembly clearances
min
165/246*
min 5
]
Fig. 4.1 Distances during installation (dimensions in mm)
min 5
min 180
The boiler should be mounted on a flat and vertical area
of wall of sufficient area for the boiler plus the required
clearances for installation and servicing (fig. 4.1). These
are shown on the installation template supplied with the
boiler and are:
– 5 mm either side of the boiler
– 180 mm below the boiler
– 165 mm* above the boiler when utilising the 100 mm
outside diameter flue
– 246 mm* above the boiler when utilising the 125 mm
outside diameter flue
– 500 mm in front of the boiler to enable easy access
for servicing (may be provided by an opening door)
Note
If the boiler is to be fitted in a timber framed
building, it should be fitted in accordance with
British Gas publication DM2 ‘Guide for gas
installations in timber framed housing’.
min 500**
3.11.2 System by-pass
An automatic system by-pass is provided in the boiler.
The boiler is suitable for use in systems with thermostatic radiator valves and no additional by-pass is required.
The by-pass valve is adjustable, see Section 5.8.
3.11.3 Venting
The boiler is fitted with an automatic air vent. Additional
provision should be made to enable the heating system
to be vented during filling and commissioning either by
automatic air vents or manually.
3.12 Condensate trap
The boiler is fitted with a siphonic condensate discharge
(ecoTEC plus) or a condensate trap (ecoTEC pro) incorporating a water trap of 140 mm.
16 Instructions for installation and servicing ecoTEC
4.1.1 Select position for boiler
Refer to section ‘Boiler location’ for information regarding the appliance location. In general the boiler must be
positioned such that:
• There is adequate space around the boiler for service
and maintenance
• The boiler can be correctly flued, i.e. the flue terminal
position is located in accordance with these instructions and the air/flue duct can be installed in accordance with the flue installation instructions supplied.
• All necessary pipework can be connected, including
the pressure relief valve and condensate drain.
4.1.2 Unpack the boiler
To unpack the boiler, cut both plastic carton straps, open
box and lift out the polystyrene top packing. Lift the
cardboard box upwards.
Boiler installation sequence 4
20
165
5
60/100
25
95
175
5
Note
Care should be taken not to scratch the white
surface of the boiler casing
4.1.3 Using boiler template
• Fix the paper template to the wall ensure that the
template is vertical.
The template shows:
– The position of the fixing holes for the boiler mounting
bracket.
– The position of the connections.
– The position of the flue exit hole.
• Mark the position of the hanging bracket fixing holes.
• Drill 2 holes Ø 8 mm for the hanging bracket.
Note
Use alternative fixing holes where necessary.
A
A
A
1065
A
A
180
45°
256723_01 11 2004
450
Fig. 4.2 Assembly template
17Instructions for installation and servicing ecoTEC
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