Vaillant ecoTEC VU, ecoTEC VUW Installation And Maintenance Instructions Manual

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Installation and maintenance instructions
For the competent person
Installation and maintenance instructions
ecoTEC
VU, VUW
Channel Islands
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Table of contents
BEFORE PROCEEDING - ENSURE BOILER IS
CORRECT FOR GAS GROUP SUPPLIED!
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Table of contents
1 Notes on the documentation .....................................4
1.1 Storing documents ..........................................................4
1.2 Symbols used .................................................................... 4
1.3 Applicability of the instructions ...................................4
1.4 Identification plate ...........................................................4
1.5 CE label ...............................................................................4
1.6 Benchmark .........................................................................4
1.7 Type overview ...................................................................5
2 Safety .................................................................................6
2.1 Safety and warning information ..................................6
2.1.1 Classification of warnings ..............................................6
2.1.2 Structure of warnings .....................................................6
2.2 Intended use ......................................................................6
2.3 Basic safety instructions ................................................6
2.4 General requirements ..................................................... 7
2.4.1 Related documents ..........................................................7
2.4.2 Installation site .................................................................8
2.4.3 Gas supply .........................................................................8
2.4.4 Air supply ........................................................................... 9
2.4.5 Compartment ventilation ............................................... 9
2.4.6 Electrical supply ............................................................... 9
2.4.7 Water supply Combination boilers ...............................9
2.4.8 Water circulation system................................................9
2.4.9 Pressure relief valve ...................................................... 10
2.4.10 Venting ............................................................................. 10
3 Description of the appliance ......................................11
4 Installation ......................................................................12
4.1 Accessories .......................................................................12
4.1.1 Controller ..........................................................................12
4.1.2 Installation and operation .............................................12
4.2 Scope of delivery ............................................................12
4.2.1 Unpacking the boiler ......................................................12
4.2.2 Checking the scope of delivery ...................................12
4.2.3 Disposing of the packaging ..........................................13
4.3 Transporting the appliance ..........................................13
4.4 Requirements for the installation site .......................15
4.4.1 Required minimum clearances/
installation clearances ...................................................15
4.4.2 Using installation templates .........................................15
4.5 Dimension drawing and connection
measurements .................................................................17
4.6 Wall-mounting the boiler .............................................. 18
4.7 Removing/fitting the front casing ............................. 18
4.8 Removing/fitting the side panel ..................................19
5 Gas installation ............................................................ 20
5.1 Preparing for installation ............................................ 20
5.2 Connecting the gas pipe .............................................20
6 Hydraulic installation ..................................................21
6.1 Preparing for installation ..............................................21
6.2 Connecting the hot and cold water (VUW boiler) ..22
6.3 Connecting the domestic hot water cylinder ..........22
6.4 Connecting the heating flow and heating return...22
6.4.1 VUW boiler .......................................................................22
6.4.2 VU boiler ..........................................................................22
6.5 Low loss header .............................................................23
6.6 Connecting the condensate discharge pipework ...23
6.7 Connecting the discharge pipe to the expansion
relief valve on the boiler ..............................................23
7 Flue gas installation ...................................................25
7.1 Air/flue gas duct .............................................................25
7.2 Flue termination .............................................................26
8 Electrical installation .................................................29
8.1 Preparing for installation .............................................29
8.2 Opening/closing the electronics box .........................29
8.3 Establishing the mains connection ............................29
8.4 Connecting the controller ........................................... 30
8.4.1 Fitting the controller .................................................... 30
8.4.2 Connecting controllers to the electronic system ....31
8.5 Connecting additional components via VR 40 –
connecting a "2 in 7" multi-functional module .......31
8.6 Connection wiring diagrams .......................................32
9 Operation ....................................................................... 34
9.1 Overview of the read-off and setting options ........ 34
9.2 Calling up the installer level ....................................... 34
10 Commissioning ..............................................................35
10.1 Switching on the boiler .................................................35
10.2 Using test programs ......................................................35
10.3 Preparing the heating water .......................................36
10.4 Read off the filling pressure ........................................36
10.5 Filling and purging the heating installation ............36
10.5.1 Filling the heating installation ....................................36
10.5.2 Purging the heating system ........................................37
10.5.3 Flushing the system for the first time ("cold") ......37
10.6 Avoiding low water pressure .......................................37
10.7 Fill and purge the hot water system ......................... 37
10.8 Filling the condensate trap ......................................... 38
10.9 Converting the boiler for operation on the
Channel Islands ............................................................. 38
10.10 Adjusting the boiler to the gas used on the
Channel Islands ..............................................................39
10.11 Checking for tightness of the flue gas installation
and flue gas recirculation ...........................................40
10.12 Checking the gas flow rate .......................................41
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10.13 Carrying out a full function test..................................41
10.13.1 Checking the heating mode ....................................... 42
10.13.2 Checking the hot water generation (VUW
boilers only) .................................................................... 42
10.13.3 Checking hot water generation
(VU boilers only)............................................................ 42
10.14 Final flush of the heating system ("hot") ............... 42
11 Adapting the boiler to the heating installation 43
11.1 Diagnosis codes – Overview ....................................... 43
11.1.1 Setting the heating partial load .................................47
11.1.2 Setting pump overrun time and pump operating
mode .................................................................................47
11.1.3 Setting the maximum flow temperature ..................47
11.1.4 Setting the return flow temperature control ..........47
11.1.5 Burner anti-cycling time ...............................................47
11.1.6 Setting the maintenance interval ............................. 48
11.1.7 Setting the by-pass valve ............................................ 48
11.2 Handing over the boiler to the operator ................. 49
12 Inspection and maintenance ................................... 50
12.1 Inspection and maintenance intervals .....................50
12.1.1 General inspection and maintenance instructions 50
12.1.2 Safety instructions .........................................................51
12.1.3 Checking the CO/CO
ratio and the CO2
2
concentration ...................................................................51
12.1.4 Adjusting the CO
concentration (or the air ratio) .52
2
12.2 Inspection and maintenance work steps ................. 54
12.2.1 Filling the boiler and the heating installation ........ 55
12.2.2 Draining the boiler ........................................................ 55
12.2.3 Draining the entire heating installation .................. 55
12.3 Carrying out maintenance work ................................ 55
12.3.1 Removing the compact thermal module ................. 55
12.3.2 Cleaning the heat exchanger ..................................... 56
12.3.3 Checking the burner .................................................... 56
12.3.4 Cleaning the condensate trap .....................................57
12.3.5 Cleaning the filter in the cold water inlet (VUW
boilers only) .....................................................................57
12.3.6 Installing the compact thermal module .................. 58
12.3.7 Checking the charge pressure of the expansion
vessel ............................................................................... 58
12.4 Checking the gas flow pressure ................................ 59
12.4.1 Checking CO
content .................................................. 59
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13.2.4 Service messages ...........................................................61
13.2.5 Calling up diagnosis levels ............................................61
13.2.6 Reading off the fault codes ..........................................61
13.2.7 Querying the fault memory ..........................................61
13.2.8 Resetting the fault memory .........................................61
13.2.9 Overview of fault codes ................................................62
13.3 Running test programs .................................................63
13.4 Resetting parameters to factory settings ................63
14 Replacing components .............................................. 64
14.1 Preparing for and completing replacement work . 64
14.1.1 Preparing for replacement work ............................... 64
14.1.2 Completing replacement work ...................................64
14.2 Replacing the burner ...................................................64
14.3 Replacing the fan or the gas valve ........................... 64
14.4 Replacing the expansion vessel................................. 65
14.5 Replacing the heat exchanger ................................... 66
14.6 Replacing the PCB and/or the display ......................67
14.6.1 Replacing either the display or the PCB ..................67
14.6.2 Replacing the PCB and the display at the same
time ...................................................................................67
15 Decommissioning ........................................................ 68
15.1 Temporarily shutting down the boiler .....................68
15.2 Taking the boiler permanently out of service ....... 68
15.3 Disposing of the boiler ................................................68
16 Guarantee and customer service ...........................68
16.1 Factory guarantee ......................................................... 68
16.2 Vaillant Service .............................................................. 68
17 Technical data .............................................................. 69
18 Glossary ..........................................................................70
19 Appendix ..........................................................................71
Index ...........................................................................................74
13 Troubleshooting ........................................................... 60
13.1 Contact Vaillant Service Solutions
(0870 6060 777) .......................................................... 60
13.2 Performing diagnostics ............................................... 60
13.2.1 Calling up Live Monitor (status codes) .................... 60
13.2.2 Status codes – Overview ............................................. 60
13.2.3 Status codes – Overview ............................................. 60
3Installation and maintenance instructions ecoTEC 0020173113_01
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Notes on the documentation
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1 Notes on the documentation
The following instructions are intended to guide you throughout the entire documentation. Further documents apply in combination with these installation and mainte­nance instructions. We accept no liability for any damage caused by non­observance of these instructions.
Other applicable documents
> When installing the ecoTEC, follow all installation instruc-
tions for the various parts and components of the sys-
tem without exception. These installation instructions are enclosed with the various system components as well as additional components.
> Also observe all the operating instructions included with
the system components.
1.1 Storing documents
> Pass these installation instructions and all other applica-
ble documents and, if necessary, any required aids to the
system operator. The system operator should retain these instructions and tools so that they are available when required.
1.2 Symbols used
The symbols used in the text are explained below:
Symbol that denotes useful tips and information
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> Symbol for a required action
1.3 Applicability of the instructions
These installation instructions are only valid for boilers with the following article numbers:
1.4 Identification plate
The identification plate of the Vaillant ecoTEC is attached to the underside of the boiler in the factory. The article number of the gas fired wall hung boiler can be found in the serial number. The seventh to sixteenth num­bers constitute the article number. The serial number can also be found on the lift out badge located at the bottom of the front casing of the boiler. The serial number can also be shown on the display of the boiler (¬ Operating instructions).
1.5 CE label
The CE label shows that the products comply with the basic requirements of all applicable directives as stated on the identification plate.
The conformity declaration can be checked with the manu­facturer.
1.6 Benchmark
Vaillant Ltd. supports the Benchmark Initiative. You will find the Benchmark Logbook on the last pages of this instruction manual. It is very important that this docu­ment be filled out properly when installing, commissioning, and fully explained at hand over to the operator of the installation. Installers should point out also the service record section for completion following service calls to this appliance. Vaillant Ltd. is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water sys­tems in the UK and to encourage regular servicing to opti­mize safety, efficiency and performance. Benchmark is managed and promoted by the Heating and Hot water Industry Council.
> For more information visit www. centralheating .co .uk
Boiler Type designation Article number
ecoTEC 22 (VU GB 226/5-3) 0010015190
ecoTEC 26 (VUW GB 266/5-3) 0010015189
1.1 Appliance types and article numbers
The article number of the boiler can be found on the identi­fication plate.
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Vaillant supply a special self adhesive sticker on
top of the boiler for use in entering the serial number details straight onto the commissioning checklist found in the last pages of this docu­ment.
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1.7 Type overview
Notes on the documentation
1
Unit type ecoTEC
22 (VU GB 226/5-3)
26 (VUW GB 266/5-3)
1.2 Type overview
Designated coun­try (designation in accordance with ISO 3166)
GB (Great Britain) IE (Ireland)
GB (Great Britain) IE (Ireland)
Approval category
II
2H3P
II
2H3P
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2 Safety
2.1 Safety and warning information
> When installing the ecoTEC, take account of the general
safety instructions and the warning notes that appear
before all of the actions.
2.1.1 Classification of warnings
The warning notes are classified in accordance with the severity of the possible danger using the following warning symbols and signal words:
Warning symbol
a
e
Signal word
Danger!
Danger!
Warning. Risk of minor personal injury
Explanation
Immediate danger to life or risk of severe personal injury
Risk of death from electric shock
a
Caution.
b
2.1 Classification of warnings
Risk of material or environ­mental damage
2.2 Intended use
The Vaillant ecoTEC boilers are constructed using state-of­the-art technology in accordance with recognised safety rules and regulations. Nevertheless, there is still a risk of injury or death to the operator or others or of damage to the boiler and other property in the event of improper use or use for which it is not intended. This boiler is not designed to be used by persons (including children) with limited mental and sensory capabilities or by persons who do not have enough experience and/or knowl­edge, unless they are supervised by a person who is respon­sible for their safety or they have been instructed by him/ her about how to use the boiler. Children must be supervised to ensure that they do not play with the boiler. The boiler is intended as a heater for closed hot water/cen­tral heating installations and for hot water generation. The use of the ecoTEC in vehicles, such as mobile homes and caravans, is not classed as intended use. Units that are not classed as vehicles are those that are installed in a fixed and permanent location and that do not have any wheels (fixed installation). Any other use, or use beyond that specified, shall be con­sidered as improper use. Any direct commercial or indus­trial use is also deemed to be improper. The manufacturer or supplier is not liable for any damage resulting from such use. The user alone bears the risk. Intended use includes the following:
– observance of accompanying operating, installation and
maintenance instructions for Vaillant products as well as for other parts and components of the system
– installing and fitting the appliance in accordance with the
boiler and system approval
– complying with all of the inspection and maintenance
conditions listed in the instructions.
Caution. Any improper use is forbidden.
2.1.2 Structure of warnings
Warning signs are identified by an upper and lower separat­ing line and are laid out according to the following basic principle:
Signal word!
Type and source of danger!
a
Explanation of the type and source of danger
> Measures for averting the danger
2.3 Basic safety instructions
> Observe the following safety instructions at all times.
European installation directive
Installation and maintenance of the appliance should only be undertaken by a competent person (referred to in these instructions as "competent person" or "skilled trade com­pany", thus making these terms gender-neutral) approved at the time by the Health and Safety executive and in accordance with the gas safety (installation and use) regu­lations 1998. The existing regulations, rules and guidelines must be observed when doing so. The competent person is also responsible for inspection, maintenance and repairs to the unit, as well as alterations to the gas volume setting. Only IE: The installation must comply with the current Ver­sion of I.S.813 "Domestic Gas Installations" and the current Building Regulations.
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The current ETCI Regulations for installing electrical equip­ment must also be observed.
Installation and settings
In the following cases, the boiler must be operated only with the front casing fitted and closed and with a com­pletely mounted air/flue gas duct:
– starting up – test purposes
– continuous operation, Otherwise, under unfavourable operating conditions, injury, death or material damage may occur. Exclusively for test purposes such as gas working pressure testing the boiler may be operated with the front casing removed for short durations ONLY but must have a com­pletely mounted air/flue gas duct.
What to do if you smell gas
Installation errors, damage, manipulation, an unauthorised installation site or similar can cause gas to escape and result in a risk of poisoning and explosion. If there is a smell of gas in the building, proceed as follows:
> Avoid rooms that smell of gas. > If possible, open doors and windows fully and ensure air
is circulating. > Avoid the use of naked flames (e.g. lighters, matches). > Do not smoke. > Do not use any electrical switches, plugs, doorbells, tele-
phones or other communication systems in the building. > Close the gas meter isolator device or the main isolator
device. > If possible, close the gas stop cock on the unit. > Warn the occupants in the building by knocking or call-
ing. > Leave the building. > If you can actually hear gas leaking, leave the building
immediately and ensure that no third parties enter the
building. > Alert the police and fire brigade when you are outside
the building. > Use a telephone outside the building to inform the gas
supply company or National Grid Transco 0800 111999.
What to do if you smell exhaust fumes
Installation errors, damage, manipulation, unauthorised installation sites or the like can cause flue gas to escape and result in a risk of poisoning. If there is a smell of exhaust fumes in the building, proceed as follows:
> If possible, open doors and windows fully and ensure
adequate ventilation. > Switch the boiler off. > Check the flue gas route in the boiler and the flue gas
pipes.
Material damage caused by corrosion
To prevent corrosion on the boiler and also on the air/flue gas duct, note the following:
> Do not use sprays, solvents, chlorinated cleaning agents,
paint, adhesives or similar substances in the vicinity of
the boiler. Under unfavourable circumstances, these substances may cause corrosion.
Material damage due to improper use and/or unsuitable tools
The use of unsuitable tools or improper use thereof may cause damage, such as gas or water leaks.
> When tightening or loosening threaded connections,
always use suitable open-end spanners, but do not use
pipe wrenches, extensions, etc.
2.4 General requirements
2.4.1 Related documents
To ensure the safe installation and continued satisfactory operation of your appliance, all works shall be carried out by a competent installer fully conversant with the required current and up to date, acts standards, laws and regulations relevant for this range of equipment at the time of installa­tion. In addition any special requirements of Local Authori­ties, gas undertakings or insurers must be complied with. 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. Attention shall be paid to (but not restricted to) the following:
– Gas Safety (Installation and Use) regulations. – All Building Regulations 2000 for England and Wales,
(as amended).
– (Includes Approved Codes of Practice and Approved Doc-
uments for building regulations e.g. L1, L1A, L1B, L8.)
– The Building Standards, Scotland, and any requirements
determined by the local authorities within.
– The current Version of I.S.813 „Domestic Gas Installa-
tions“ and the current Building Regulations for IE.
– The current ETCI Regulations for installing electrical
equipment for IE.
BS 7671 Requirements for electrical installations.
IEE Wiring Regulations
– The Electricity at Work Regulations. – The Water supply (water fittings) regulations 1999. – BS 5854 Code of practice for flues and flue structures
in buildings.
BS EN 12828 Design of water-based heating systems.BS EN 806 parts 1 - 5BS 8558BS 6880 Code of practice for low temperature heating
systems with outputs greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
Installation and maintenance instructions ecoTEC 0020173113_01 7
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BS 6981 Installation of low pressure gas pipework of up
to 35 mm 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 installation of expan-
sion vessels and ancillary equipment for sealed water systems. Part 1 Code of practice for domestic heating and hot water. Part 2 Code of practice for low and medium temperature hot water systems.
BS 7593 Code of practice for treatment of water in
domestic hot water central heating systems
BS EN 13831 Closed expansion vessels with built in dia-
phragm
BS EN 14336 Heating systems in buildings. Installation
and commissioning of water based heating systems.
BS 5440 – 1 Installation of flues and ventilation for gas
appliances of rated input not exceeding 70 kW*
BS 5440 – 2 Flueing and ventilation for gas appliances
of rated input not exceeding 70 kW* * 1st 2nd and 3rd family gases.
BS EN 6798 Installation & maintenance of gas fired hot
water boilers of rated input not exceeding 70 kW net
Institute of Gas Engineers Publications:
IGE/UP/1B (Edition 2) Tightness testing and direct purg-
ing of small natural gas installations.
IGE/UP/ 7 (Edition 2) Gas in timber and light steel
framed buildings.
I.S. 813 – Domestic Gas Installations - 2nd edition
( Ireland)
BS 5482 – Part 1 Domestic butane and propane gas
burning installations
2.4.2 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. Before commencement of any works the installer should carry out a full risk assessment in accordance with Health and Safety executive regulations. 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 Regula­tions (Scotland) 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. In case of installation of the boiler 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 6891. In IE the current edition of IS 813.
If the boiler is to be installed in an airing
cupboard it is not required to separate the
i
b
> Observe the following when choosing the installation site
and operating the boiler,
> Please ensure that the boiler is room sealed or in a sepa-
rate installation room if
> Do not route the combustion air through an old oil fur-
nace chimney, as this can also cause corrosion.
2.4.3 Gas supply
An existing gas 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 in accordance with the current issue 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. The complete installation must be tested and purged in accordance with:
boiler with a non-combustible partition. However installation and servicing clearances must be maintained, and the boiler kept clear of any clothing.
Caution.
Risk of damage caused by aggressive vapours and dust.
Aggressive vapours and dust in the installa­tion room may cause corrosion damage to the boiler and to the flue gas installation.
> Ensure that the boiler is room sealed if
the air in the installation room contains aggressive vapours or dust.
– Do not install the boiler in rooms prone to frost. – Do not install the boiler in rooms in which the com-
bustion air contains chemical substances, such as flu­oride, chlorine, sulphur, dust, etc. (e.g. sprays, sol­vents, cleaning agents, paint, adhesives).
– the combustion air supply contains the aforemen-
tioned substances,
– you install the boiler in hairdresser salons, painter's or
joiner's workshops, cleaning businesses or similar.
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– IGE/UP /1B for systems up to 0.035 m3 capacity – for larger systems IGE/UP/1A and – for LPG installations refer to BS 5482 - 1 or – IGE/UP1 Edition 2 for larger volume installations.
2.4.4 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.
2.4.5 Compartment ventilation
The boilers are very high efficiency appliances. As a conse­quence the heat loss from the appliance casing during operation is very low. Compartment ventilation is required if the flue used is not concentric and air is supplied from the room or compartment the boiler is installed in.
2.4.6 Electrical supply
Danger!
Risk of death from electric shock.
a
If the appliance is not earthed, it may hold voltage if a defect occurs.
> Earth the appliance.
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 controllers. 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 doublepole switch with a 3 mm contact opening on both poles may be used.
2.4.7 Water supply Combination boilers
Designers and installers must ensure that all pipe work and fittings connected to the ecoTEC complies with the neces­sary water fittings regulations. See related documents above (ref BS 6700 and new BSEN 806 parts 1 - 5 plus BS
8558) For combination boilers the incoming water supply should be checked to ensure that sufficient pressure and flow rate are available to suite the intended use, see the technical data at the back of this manual. All mains water heated by the ecoTEC combination boiler will be classed as Category 2 fluid and small expansion vol­umes created during warm up must be allowed to flow back
into the supply pipe. No back flow prevention is necessary with this appliance as the very small expansion volume is unlikely to heat the incoming service pipe above 25 Deg C. Note that where back flow prevention devices are fitted (this may include water meters) these can prevent the per­mitted expansion into the cold supply. This along with the effects of pumping and / or water hammer can result in a pressure build-up that may cause damage to the boiler (and other household devices such as showers). Vaillant cannot accept responsibility for damage caused to the boiler or its surroundings where an appliance has been fitted to sup­plies with mechanical back flow prevention. In these cases the requirement would be that a competent installer cor­rectly installs a suitable shock arrestor / mini-expansion vessel adjacent to the boiler in the cold water supply pipe.
2.4.8 Water circulation system
Detailed recommendations concerning the water circuit sys­tem can be taken from BS 6798 and BS 5449, Part 1 (for "Small Bore" and "Micro Bore" central heating installa­tions). Lines which do not form part of the usable heating surface should be insulated to prevent heat losses and pos­sible freezing up, especially where the lines run under rooves and ventilated cellar rooms. The drain connections must be easily-accessible, so that the entire system includ­ing the boiler and hot water system can be drained. The drain connections should be at least 1/2 " (BSP nominal size) and must be in accordance with BS 2879. The boiler is suitable for Minibore and Microbore systems. Water lines are to be copper pipes in accordance with BS 2871, Part 1. These must be thoroughly cleaned, espe­cially when connecting a new boiler to an existing system.
Risk of damage if the heating water is treated with unsuitable frost or corrosion protection agents.
Frost and corrosion protection agents can cause changes to seals, noise during heating mode and may lead to other consequential damage.
> Do not use any unsuitable frost or corrosion protection
agents.
Mixing additives with the heating water can result in mate­rial damage. However no incompatibility with Vaillant boil­ers has been detected with proper use of the following products over a long period.
> When using additives, follow the manufacturer's instruc-
tions without exception. Vaillant accepts no liability for the compatibility of any addi­tive or its effectiveness in the rest of the heating installa­tion.
Additives for cleaning measures (subsequent flushing required)
– Fernox F3 – Sentinel X 300 – Sentinel X 400
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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 if you
have used these additives.
> Inform the operator about the required measures for
frost protection.
Permissible water hardness
> Observe all valid national and technical regulations when
conditioning filling and supplementary water. Provided the national regulations and technical standards do not stipulate more stringent requirements, the following applies:
> You must condition the heating water in the following
cases:
– If the entire filling and supplementary water quantity
during the operating life of the system exceeds three times the nominal volume of the heating installation or
– If the limit values shown in the tables are not
observed.
2.4.9 Pressure relief valve
The boiler is equipped with a pressure relief valve. This safety device is required for all sealed central heating sys­tems, is preset to 3 bar and is fitted with a 15 mm compres­sion connection for the discharge pipe, whose diameter must not be less than 15 mm. The pressure relief valve must not be used for draining purposes. For situations where the discharge cannot be easily routed Vaillant have a remote pressure relief valve mounting kit available which can be used to provide a suitable way to achieve this.
2.4.10 Venting
The boiler is fitted with an automatic air vent. Other meas­ures need to be taken to allow the heating system to be either automatically or manually vented during filling and during commissioning.
Total heating output
kW
< 50
> 50 to £ 200
>200 to £ 600
> 600
1) on systems with circulation water heaters and for systems with
electric heating elements
2) from the specific system volume (nominal capacity in litres/
heating output; for multiple boiler systems, the lowest individual
heating output should be used).
This data only applies up to 3 times the system volume for fill-
ing and top-up water. If 3 times the system volume figure is
exceeded, the water must be treated in exactly the same way as
if the limits quoted in table 2.2 were exceeded (softening, desali-
nation, hardness stabilisation or desludging).
2.2 Guideline values for heating water: water hardness
Overall hardness at smallest boiler heating
2)
surface
3
1)
> 20 l/kW <
50 l/kW
3
mol/m
(mg/l CaCO3)
2
(200)
1.5
(150)
0.02
(2.0)
0.02
(2.0)
> 50 l/kW
mol/m
(mg/l CaCO3)
0.02 (2.0)
0.02 (2.0)
0.02 (2.0)
0.02 (2.0)
20 l/kW
mol/m
(mg/l CaCO3)
No require-
ment or
1)
< 3
< (300)
2
(200)
1.5
(150)
0.02
(2.0)
3
Page 11
3 Description of the appliance
Design
Description of the appliance
3
4
5
6
3
2
1
15
7
8
9
10
11
12
13
14
4
5
6
3
2
1
18
17
16
7
8
9
10
11
12
13
14
15
3.1 Functional elements of the VU system boiler
Key
1 Gas valve 2 Water pressure sensor 3 Heat exchanger 4 Connection for the air/flue gas duct 5 Expansion vessel 6 Air intake pipe 7 Compact thermal module 8 Ignition electrode 9 Fa n 10 Automatic air vent 11 Pressure gauge 12 Internal pump 13 Expansion relief valve 14 Electronics box 15 By-pass valve
3.2 Functional elements of the VUW combination boiler
Key
1 Gas valve 2 Water pressure sensor 3 Heat exchanger 4 Connection for the air/flue gas duct 5 Expansion vessel 6 Air intake pipe 7 Compact thermal module 8 Ignition electrode 9 Fa n 10 Automatic air vent 11 Pressure gauge 12 Internal pump 13 By-pass valve 14 Expansion relief valve 15 Electronics box 16 Diverter valve 17 Impeller sensor (hot water) 18 Secondary heat exchanger
Installation and maintenance instructions ecoTEC 0020173113_01 11
Page 12
Installation
4
4 Installation
BEFORE PROCEEDING - ENSURE BOILER IS
CORRECT FOR GAS GROUP SUPPLIED!
i
The work described in this section must only be carried out by a competent person.
4.1 Accessories
4.1.1 Controller
To control the ecoTEC, Vaillant offers various controller ver­sions for connecting to the switching rail or for plugging into the operator control screen.
Room Thermostats
VRT 30 – Room Thermostat (230 V) VRT 50 – Room Thermostat eBUS
Timers / Programmers
timeSWITCH 150 – mechanical clock timeSWITCH 160 – 7 day programmer
Digital Room Temperature Controls
VRT 350 – Programmable Room Control VRT 392f – RF Programmable Room Control * VRT 350f – RF Programmable Room Control
Weather Compensating Controls
VRC 470 – Weather Compensator VRC 470f – RF Weather Compensator
Communication
vrnetDIALOG comDIALOG
Accessories
VR 65 – Control Centre VR 66 – Control Centre VR 61/2 – Two Zone Wiring Centre VR 81/2 – Remote Control Unit VR 68/2 – Solar Module
4.1 Controller accessories
The pipes can be routed upwards behind the
boiler in front of the wall (surface installation)
i
using the spacer frame. Which means the dis­tance between the wall and the boiler increases by 65 mm.
4.2 Scope of delivery
The Vaillant ecoTEC is delivered pre-mounted in a packag­ing unit.
4.2.1 Unpacking the boiler
> Remove the boiler from its box. > Remove the protective film from all parts of the boiler.
4.2.2 Checking the scope of delivery
> Check that all parts have been delivered and are intact
(¬fig.4.1 and ¬table4.2 or ¬fig.4.2 and ¬table4.3).
8
7
6
5
1
2
3
4
* Note 392f RF transmitter wired external to boiler
4.1.2 Installation and operation
Optional accessories are available for use in conjunction with the installation and operation of the ecoTEC. The current price list shows the complete range of hydraulic accessories for the ecoTEC series.
4.1 Scope of delivery for ecoTEC VU boiler
Page 13
Installation
4
Item Qty Description
1 1 Wall bracket 2 1 Boiler 3 1 Flow restrictor
44 5 3 Service valves
6 1 Montageschablone 7 1 Enclosure documentation 8 2 Bags with parts
4.2 Scope of delivery for ecoTEC VU boiler
8
7
6
Supply pipes (gas, heating, expansion relief valve)
4.2.3 Disposing of the packaging
> Dispose of the cardboard packaging used on the ecoTEC
at a cardboard recycling site.
> Dispose of the plastic film and plastic filling at an appro-
priate plastic recycling site.
> Observe national regulations.
4.3 Transporting the appliance
Important:
1
With regards to the Manual Handling Operations, 1992 Reg­ulations, the following lift operation exceeds the recom­mended weight for a one man lift.
2
General recommendations when handling
> Clear the route before attempting the lift. > Ensure safe lifting techniques are used – keep back
straight – bend using legs.
> Keep load as close to body as possible. Do not
twist – reposition feet instead.
> If 2 persons performing lift, ensure co-ordinated move-
ments during lift.
> Avoid upper body/top heavy bending - do not lean
3
4
forward/sideways.
> Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip.
> Always use assistance if required.
5
4.2 Scope of delivery for ecoTEC VUW boiler
Item Qty Description
1 1 Wall bracket 2 1 Boiler 3 1 Flow restrictor
46
5 4 Service valves 6 1 Installation template 7 1 Enclosure documentation 8 2 Bags with parts
4.3 Scope of delivery for ecoTEC VUW boiler
Supply pipes (gas, heating, water, expansion relief valve)
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack truck.
> If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck.
> Recommend secure appliance onto truck with suitable
straps.
> Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Keep load as close to body as possible. > If 2 persons performing lift, ensure co-ordinated move-
ments during lift. > Always use assistance if required.
Carriage of carton from point of delivery to point of installation – ground floor.
Recommend 2 person lift or 1 person with use of sack truck.
> If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck. > Recommend secure appliance onto truck with suitable
straps. > Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Keep load as close to body as possible. > If 2 persons performing lift, ensure co-ordinated move-
ments during lift. > Clear the route before attempting the lift.
Installation and maintenance instructions ecoTEC 0020173113_01 13
Page 14
Installation
4
> If removing boiler from truck straddle the load and tilt
forwards to facilitate secure grip.
> Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Do not twist – reposition feet instead. > Take care to avoid trip hazards, slippery or wet
surfaces and climbing steps and stairs. > Always use assistance if required.
Carriage of carton from point of delivery to point of installation – first or higher floor, cellar.
Recommend 2-person lift or 1 person with use of sack truck.
> If 1 person is performing lift, straddle the load, tilt and
place carton into position on truck. > Recommend secure appliance onto truck with suitable
straps. > Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Keep load as close to body as possible. > If 2 persons performing lift, ensure co-ordinated move-
ments during lift. > Avoid upper body/top heavy bending - do not lean
forward/sideways. > Clear the route before attempting the lift. > If removing boiler from truck straddle the load and tilt
forwards to facilitate secure grip. > Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Do not twist – reposition feet instead. > Take care to avoid trip hazards, slippery or wet
surfaces and climbing steps and stairs. > Always use assistance if required.
Carriage of carton from point of delivery to point of installation – roofspace.
> Recommend 2-person lift. > Ensure co-ordinated movements during lift. > Avoid upper body/top heavy bending - do not lean
forward/sideways. > Clear the route before attempting the lift. > Take care to avoid trip hazards, slippery or wet
surfaces and climbing steps and stairs. > When transferring appliance into roofspace,
recommend 1 person to be in roofspace to receive the
appliance and other person to be below to pass up and
support appliance. > Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Keep load as close to body as possible. > Always use assistance if required. > It is assumed safe access, flooring and adequate
lighting are provided in the roof space. > It is recommended a risk assessment of the roof space
area be carried out before moving the appliance into the
area to take into account access, stability of flooring,
lighting and other factors, and appropriate measures
taken.
Unpacking of appliance from carton.
> Recommend 2 persons unpack appliance from carton. > Always keep working area clear. > Recommend straps and open carton flaps, then remove
items from the top including the polystyrene packing and remove carton by sliding up over the boiler.
> Ensure safe lifting techniques are used – keep back
straight – bend using legs. > Keep load as close to body as possible. > Always use assistance if required. > Dispose of packaging in a responsible manner. > Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip
when handling appliance outside packaging.
Positioning of Appliance for Final Installation – no obstructions.
> If appliance weight is over 25 kg always use 2 persons to
move where practical. > Fit bracket securely onto wall before lifting appliance
into position. > Obtain firm grip on front and sides of appliance, lift
upwards, ensure stable balance achieved and lift
upwards to position in place on bracket. > Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from floor
level. > Do not twist – reposition feet instead. > Keep boiler as close as possible to body throughout lift
to minimise strain on back. > Ensure co-ordinated movements to ensure equal spread
of weight of load. > Always use assistance if required. > Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip
when handling appliance.
Positioning of Appliance for Final Installation – above worktop, foreseeable obstructions etc.
> If appliance weight is over 25 kg always use 2 persons to
move where practical. > Fit bracket securely onto wall before lifting appliance
into position. > Obtain firm grip on front and sides of appliance, lift
upwards, onto worktop if practicable. > Ensure stable balance achieved and lift upwards to
position in place on bracket. > If 2 persons positioning onto bracket obtain firm grip at
front and sides/base of boiler. > Ensure coordinated movements during 2 person lifts to
ensure equal spread of weight of load. > Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from floor
level. > Do not twist – reposition feet instead. > Keep boiler as close as possible to body throughout lift
to minimise strain on back. > Avoid upper body/top heavy bending - do not lean
forward/sideways.
Page 15
Installation
4
> Always use assistance if required. > Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – within compartment etc. restricting installation.
> If appliance weight is over 25 kg always use 2 persons to
move where practical.
> Fit bracket securely onto wall before lifting appliance
into position.
> Obtain firm grip on front and sides of appliance, lift
upwards, onto worktop if practicable.
> Ensure stable balance achieved and lift upwards to drop
into place onto bracket.
> If 2 persons positioning onto bracket obtain firm grip at
front and sides/base of boiler.
> Ensure coordinated movements during 2 person lifts to
ensure equal spread of weight of load.
> If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler.
> Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from floor
level. > Do not twist – reposition feet instead. > Keep boiler as close as possible to body throughout lift
to minimise strain on back. > Always use assistance if required. > Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip
when handling appliance.
flooring, lighting and other factors, and appropriate measures taken.
4.4 Requirements for the installation site
4.4.1 Required minimum clearances/ installation clearances
> When using accessories, observe the minimum clear-
ances/installation clearances (¬ fig. 4.3).
AB
CC
Positioning of Appliance for Final Installation – in roof space restricting installation.
> If appliance weight is over 25 kg always use 2 persons to
move where practical.
> Obtain firm grip on front and sides of appliance, lift
upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket.
> If 2 persons positioning onto bracket obtain firm grip at
front and sides/base of boiler.
> Ensure co-ordinated movements during 2 person lifts to
ensure equal spread of weight of load.
> If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler.
> Ensure safe lifting techniques are used - keep back
straight – bend using legs - when lifting load from floor
level. > Do not twist – reposition feet instead. > Keep boiler as close as possible to body throughout lift
to minimise strain on back. > Always use assistance if required. > Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip
when handling appliance. > It is recommended a risk assessment of the roof
space area be carried out before moving the appliance
into the area to take into account access, stability of
4.3 Recommended minimum clearances/installation clearances
Key
A 165 mm (air/flue gas duct Æ 60/100 mm) 246 mm (air/flue gas duct Æ 80/125 mm) B 180 mm C 5 mm; optimum approx. 50 mm
500 mm in front of the boiler to enable easy access for servicing (may be provided by an opening door).
Clearance at the side is not required, but the side panels can also be removed if there is adequate side clearance (at least approx. 50 mm) in order to facilitate maintenance or repair work (¬ section 4.8). It is not necessary to ensure sufficient clearance between the boiler and combustible materials or components as the temperature of the boiler will always be less than the maxi­mum permissible temperature of 85 °C due to its nominal heat output.
4.4.2 Using installation templates
An installation template is supplied with the boiler to aid wall mounting. The template shows the following:
– The position of the fixing holes for the hanging bracket.
Installation and maintenance instructions ecoTEC 0020173113_01 15
Page 16
Installation
4
– The position of the connections. – The position of the wall breakthrough of the air/flue gas
duct.
Position the installation template vertically over the instal­lation site.
> Attach the template to the wall, using tacks for example. > Mark the drill holes for the hanging bracket on the wall. > If necessary, mark the position for the wall breakthrough
for the air/flue gas duct. > Remove the installation template from the wall. > Drill 2 holes > If necessary, cut the wall breakthrough for the air/flue
gas duct.
Æ 10 mm for the hanging bracket in the wall.
Page 17
4.5 Dimension drawing and connection measurements
Installation
4
440
1
A
2
720
624
3 4 5 6 7
20
35 35
3 4 5
6
8
125
7
11
335
180
125
100100
4.4 Connection measurements in mm
Key
1 Wall breakthrough for air/flue gas duct 2 Hanging bracket 3 Heating flow (Æ 22 x 1.5) 4 Hot water connection (Æ 15 x 1.5) 5 Gas connection (Æ 15 x 1.5) 6 Cold water connection (Æ 15 x 1.5) 7 Heating return (Æ 22 x 1.5) 8 Air/flue gas duct connection 9 Condensate trap 10 Condensate discharge connection, Æ 19 mm 11 Heating expansion relief valve drain line connection, Æ 15 mm
Minimum dimension from wall bracket to center line of air/flue gas duct wall breakthrough
60/100 with elbow 87°, PP 175 80/125 with elbow 87°, PP 223
4.4 Dimension A for air/flue gas duct wall breakthrough with
VU and VUW boilers
Dimension A [mm]
9 10
Installation and maintenance instructions ecoTEC 0020173113_01 17
Page 18
Installation
4
4.6 Wall-mounting the boiler
Danger!
Risk of death if the load-bearing capacity
a
1
of the fixing elements used is insuffi­cient!
If the fixing elements or wall do not have sufficient load-bearing capacity, the boiler can come loose and fall down. This may also cause leaks in the gas line, which is potentially fatal.
> When fitting the boiler, ensure that the
fixing elements and the wall have a suffi­cient load-bearing capacity.
> Check the quality of the wall.
4.7 Removing/fitting the front casing
2
1
4.6 Removing the front casing
2
3
4.5 Wall-mounting the boiler
> Mount the hanging bracket (1) on the wall using the wall
plugs and screws (2) provided with the unit.
> Hang the boiler (3) on the hanging bracket from above
using the hanging bracket.
Removing the front casing
> Loosen the screw (1) on the bottom of the boiler using a
screwdriver or small spanner.
> Push in both retaining clips (2) on the bottom of the
boiler so that the front casing is released. > Pull the front casing forwards using the bottom edge. > Lift the front casing upwards from the bracket.
Fitting the front casing
> Place the front casing on the upper brackets. > Push the front casing onto the boiler so that until both
retaining clips (2) snap into place at the front casing. > Fasten the front casing by screwing in the bolt (1) on the
underside of the boiler.
Page 19
4Installation
4.8 Removing/fitting the side panel
You can also remove a side panel for installation or mainte­nance purposes.
Caution.
Risk of damage caused by mechanical
b
tension.
Removing both side panels may cause mechanical distortion in the boiler, which can cause damage to the piping and poten­tially result in leaks.
> Always only remove one side panel,
never both side panels at the same time.
2.
> Unscrew the two screws (2.) from the top and bottom of
the side panel. > Hold onto the side panel (3.) when doing this. > Swivel the side panel outwards and remove it from below
by pulling it downwards (4.). > Install the side panel in reverse order.
3.
1.
4.
4.7 Removing/fitting the side panel
Caution
Risk of damage to the side panel.
b
> Fold the electronics box (1.) forwards.
Unscrewed side panels that are merely sus­pended from the back wall can fall down.
> Hold onto the side panel when you are
unscrewing it, and always remove it from the boiler.
Installation and maintenance instructions ecoTEC 0020173113_01 19
Page 20
Gas installation
5
5 Gas installation
The work described in this section must only be carried out by a competent person.
5.1 Preparing for installation
Danger!
Risk of death from incorrectly installed
a
a
b
gas system!
An incorrect gas installation can result in leaks and an explosion.
> During installation, the legal directives
and the local regulations for gas supply companies must be observed.
Danger!
Risk of death from incorrectly installed gas system!
Tension in the gas line can result in leaks or an explosion.
> Make sure there are no stresses in the
gas lines when it is installed.
Caution.
Risk of damage caused by incorrect gas installation.
Excess test pressure or operating pressure can cause damage to the gas valve.
> When the entire gas installation is tested
for leaks, the maximum pressure at the gas valve must not exceed 0.75 kPa (75 mbar).
Caution.
Risk of damage caused by using the
b
5.2 Connecting the gas pipe
wrong type of gas and by improper start­up.
The boiler is specially designed ex-works for the types of gas that are used on the Channel Islands. However, when delivered, the boiler is not preset to the gas used on the Channel Islands. Starting up the boiler without first carrying out the conversion and adjustment meas­ures will lead to fault shutdowns or may lead to the boiler becoming damaged.
> Use this boiler only with the gas used on
the Channel Islands.
> Before starting up the boiler for the first
time with this gas, you must carry out the required conversion and adjustment measures
tion 10.10)
(¬ section 10.9 and sec-
.
Caution.
Risk of damage caused by contaminated
b
lines.
Foreign bodies such as welding remnants, sealing residue or dirt in the supply lines for gas can cause damage to the boiler.
> Blow the gas line clean prior to installa-
tion.
5.1 Fitting the gas connection (example: VUW boiler)
> Make the gas connection as shown.
Page 21
Hydraulic installation
6
6 Hydraulic installation
The work described in this section must only be carried out by a competent person.
6.1 Preparing for installation
Danger!
Risk of death caused by an incorrectly
a
b
b
installed system!
Heating water that leaks from the discharge pipe of the expansion relief valve can cause severe burns.
> Install the expansion relief valve and the
opening for the drain line in such a way that there is no danger to any persons in or around the building. This may be out­side or to a suitable open drain in the installation room.
> Make sure that the drain is visible.
Caution.
Risk of damage caused by contaminated lines.
Foreign bodies such as welding remnants, sealing residue or dirt in the water pipes can cause damage to the boiler.
> Flush the heating installation thoroughly
prior to installation.
Caution.
Risk of damage from corrosion.
If non-diffusion-tight plastic pipes are used in the heating installation, this may cause air to enter the heating water and corrosion of the heat generation circuit and the boiler.
> If using non-diffusion-tight plastic pipes
in the heating installation, separate the system by installing an external heat exchanger between the boiler and the heating installation.
Caution.
Risk of damage caused by heat transfer
b
i
The Vaillant ecoTEC boiler is equipped with an 8 l expan­sion vessel with a gas-side filling pressure of 0.075 MPa (0.75 bar), which is suitable for a closed heating system with a maximum water volume of 80 litres.
> Before installing the boiler, check whether the volume of
the installed expansion vessel is sufficient. > If the volume of the expansion vessel is insufficient, then
install an additional expansion vessel connected as close
to the boiler as possible into the boiler return pipe.
i
Initial system pressure (in bar) 1.0 1.5 Expansion relief valve setting
(in MPa (bar))
With system volumes greater than 80 l, multiply the volume by the adjacent factor.
when soldering.
Heat that is transferred during soldering can 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.
Seals made of rubber-like materials may be sub-
ject to plastic deformation, which can lead to pressure losses. We recommend using seals made of a paste-like fibre material.
When using an external expansion vessel
together with a VUW boiler, it is advisable to install a non-return valve in the outlet (boiler flow) or take the internal expansion vessel out of service. Otherwise, the warm start function may be more frequently activated because of backflow, which causes unnecessary energy loss.
Vessel volume (in l)
0.3 (3.0)
0.109 0.156
Danger!
Risk of scalding and/or damage due to
a
Installation and maintenance instructions ecoTEC 0020173113_01 21
incorrect installation leading to leaking water.
Stresses in the supply line can cause leaks.
> Make sure there are no stresses in the
supply lines when they are installed.
6.1 Size of an additional expansion vessel
Page 22
Hydraulic installation
6
6.2 Connecting the hot and cold water (VUW boiler)
6.1 Fitting the hot and cold water connection
> Make the domestic hot and cold water connections as
shown.
> Ensure correct water pressure and flow requirements
and that any expansion can be accommodated with the cold supply pipe work (¬section2.4.7).
6.4 Connecting the heating flow and heating return
6.4.1 VUW boiler
6.2 Fitting the heating flow and heating return (VUW boiler)
> Make the water connections as shown.
6.3 Connecting the domestic hot water cylinder
> When connecting the domestic hot water cylinder to the
ecoTEC, follow the ¬ installation instructions for the domestic hot water cylinder.
6.4.2 VU boiler
6.3 Fitting the heating flow and heating return (VU boiler)
> Make the water connections as shown.
Page 23
Hydraulic installation
6
6.5 Low loss header
A low loss header disconnects the boiler from the heating system. The system is no longer dependent on the remain­ing feed head of the boiler. In conjunction with the heating pump, the low loss header ensures that a sufficiently high minimum quantity of water is always circulating through the boiler. No electrical accessories are required in order to use a low loss header.
6.6 Connecting the condensate discharge pipework
Danger!
Risk of death from flue gases!
a
a
ecoTEC boilers are equipped with a condensate trap that continually deposits the contents to the discharge pipe.
An empty or insufficiently filled condensate trap may allow flue gas to escape into the room air.
> Make sure that the condensate trap is
filled with water when switching on the boiler.
Danger!
Risk of death from flue gases!
If the condensate discharge pipework is connected tightly to a fixed connection to the waste water piping, the internal conden­sate trap can be drained fully.
> Do not connect the condensate discharge
pipework tightly to the waste water piping.
> Connect the condensate discharge (1) of the boiler to a
condensate discharge pipework (3) which has a minimum internal diameter of 19 mm (22 mm outside diameter for all external pipes) and is made from an acid-resistant material (e.g. plastic overflow pipe).
The condensate drain pipework must have a
continuous fall (45 mm per metre) and should
i
> During installation remove all burs from inside of cut
pipe work and avoid excessive adhesive which may trap small pockets of water close to the pipe wall which can freeze and build into a larger ice plug.
> As with other pipe work insulate the condensate dis-
charge pipe to minimise any risk of freezing and beware when crossing cavities that the fall is maintained and the pipe sleeved.
> The condensate discharge pipework must terminate in a
suitable location. Further information can be obtained from "BS 6798 Specifi­cation for installation of gas–fired boilers of rated input not exceeding 70 kW net". Before starting up the boiler, the condensate trap (2) must be filled with water, as described in the relevant section.
6.7 Connecting the discharge pipe to the
The expansion relief valve for the heating installation is integrated in the boiler.
> Install the discharge pipe for the expansion relief valve
so that it does not interfere with the removal and fitting
of the condensate trap.
whenever possible terminate at a suitable drain point within the heated envelope of the build-
ing that will remain frost free under long peri­ods of low external temperatures.
expansion relief valve on the boiler
4
a
3
Internal stackpipe
6.4 Condensate discharge pipework (example: VUW boiler)
Installation and maintenance instructions ecoTEC 0020173113_01 23
b
3
Internal discharge system
5
c
Gulley
We recommend not to shorten the discharge
pipe supplied.
i
> Leave an installation space of at least 180 mm beneath
the condensate trap.
1
2
3
d
6
7
Soakaway
Page 24
Hydraulic installation
min.
180
6
1 2
3
6.5 Fit the discharge pipe on the expansion relief valve (exam­ple: VUW boiler)
> Insert a seal (1) in the cap nut (2). > Screw the discharge pipe (3) onto the expansion relief
valve.
> Make the drain line routing as short as possible and slop-
ing away from the boiler.
> Allow the line to terminate in such a way that nobody
can be injured and no cable or other electrical compo-
nents can be damaged if water or steam is ejected. > Note that the end of the line must be visible. > If the pipe cannot fall to a safe discharge point then the
Vaillant remote pressure relief valve mounting kit can be
used to provide a suitable way to achieve this. > Ensure the discharge pipe work is installed, routed and
terminated correctly to minimise the risk of freezing up.
Page 25
Flue gas installation
7
7 Flue gas installation
7.1 Air/flue gas duct
Danger!
Risk of death and risk of damage from
a
The CE mark is valid only if the appliance is operated with Vaillant air/flue gas ducts.
The ecoTEC boilers that are described in these installation and maintenance instructions are designed only to be oper­ated on the Channel Islands. However, the installation man­ual (which is enclosed with the units) for the air/flue gas system does not explicitly list these boilers; the specifica­tions for the reference type in accordance with ¬ Table 7.1 are valid for these units.
ecoTEC unit type in the instal­lation and maintenance instructions
7.1 Reference types for the air/flue gas systems
use of non-approved air/flue gas ducts!
Vaillant boilers are certified only with gen­uine Vaillant air/flue gas ducts. The use of other accessories can cause personal injury and material damage as well as operating faults.
> Only use genuine Vaillant air/flue gas
ducts.
ecoTEC unit type as a refer­ence in the installation manual for the air/flue gas system
22 (VU GB 226/5-3) plus 630
26 (VUW GB 266/5-3) plus 630
You can also get a vertical system. For more information refer to the ¬ installation manual for the air/flue gas duct. 87° elbows and 45° elbows are also available for greater flexibility during the installation.
542
1456
8 4
901
7.2 Scope of delivery for the vertical air/flue gas duct Article number 0020060570 and 0020065937
Optional 125 mm air/flue gas duct
A concentric air/flue gas ducting with an outer diameter of 125 mm is available that can be extended depending on the boiler output range. The flues gas spigot Ø 80/125 (with 2 measuring apertures) Art. No.: 0020147469 will be required. You can also get a vertical system. For more information refer to the ¬ installation manual for the air/flue gas duct.
1020
5 1
All ecoTEC boilers feature a Æ 60/100 mm diameter air/flue gas connection as standard. Selecting the most suitable system depends on the individual installation and applica­tion conditions.
Standard 100 mm air/flue gas duct
667
7.1 Scope of delivery for the horizontal air/flue gas duct Article number 303933
A concentric air/flue gas ducting with an outer diameter of 100 mm that can be extended depending on the boiler out­put range is available.
Installation and maintenance instructions ecoTEC 0020173113_01 25
87
65
74
48
30
7.3 Scope of delivery for the horizontal air/flue gas duct Article number 303209
70
0 7
Page 26
Flue gas installation
7
1430
70
7.4 Scope of delivery for the vertical air/flue gas duct Article number 303200
7.2 Flue termination
The following details refer to all flue systems. a. The terminal must be positioned such that the prod-
ucts of combustion can disperse 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 (contact Tower Flue Components, Tonbridge, TN9 1TB).
Vertical flues must not terminate within
600 mm of an openable window, air vent or any
i
The flue system shall be so placed or shielded as to prevent ignition or damage to any part of the building.
other ventilation terminal.
Page 27
Flue gas installation
P
R
Q
Q
I
F
J
L
Q
B
G
A
Q
D, E
C
I
I
S
T
Q
O
H
H
N
MM
N
K
7
7.5 Termination of the air/flue gas duct
Location
Directly below an opening, air brick, opening win-
A
dows, etc.
B Above an opening, air brick, opening window, etc. 300 mm
Horizontally to an opening, air brick, opening win-
C
dow, etc. Below temperature-sensitive building components
D
e.g. plastic gutters, soil pipes or drain pipes
E Below eaves 200 mm F Below balconies or car port roof 200 mm G From a vertical drain pipe or soil pipe 150 mm H From an internal or external corner 200 mm I Above ground, roof or balcony level 300 mm J From a surface facing the terminal 600 mm K From a terminal facing the terminal 1200 mm
From an opening in the car port (e.g. door, win-
L
dow) into the dwelling
M Vertically from a terminal on the same wall 1500 mm N Horizontally from a terminal on the same wall 300 mm O From the wall on which the terminal is mounted 0 mm P From a vertical structure on the roof N/A Q Above intersection with roof 300 mm
Horizontally to a window or opening on pitched or
R
flat roofs Above a window or opening on pitched or flat
S
roofs Below a window or opening on pitched or flat
T
roofs
7.2 Position of the termination in a fan-assisted air/flue gas
duct
Minimum dimensions
300 mm
300 mm
75 mm
1200 mm
600 mm
600 mm
2000 mm
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 straightly
directed to discharge across a boundary.
1) Dimensions D, E, F and G: 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. 7.6.
2) Dimension H: 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.
For 1 and 2 above you can use the Variable Termination Kit to move the termination point away from the building fabric. Article numbers: 0020060584 - White 0020060585 - Black
Installation and maintenance instructions ecoTEC 0020173113_01 27
Page 28
Flue gas installation
7
7.6 Termination of air/flue gas duct under balcony or eaves
Page 29
Electrical installation
8
8 Electrical installation
8.1 Preparing for installation
Danger!
Risk of death from electric shock!
e
e
Touching live connections can cause seri­ous personal injury.
> Switch off the power supply. > Secure the power supply against being
switched on again.
Danger!
Risk of electrocution as a result of an improper electrical connection!
An improper electrical connection may neg­atively affect the operational safety of the boiler and result in material damage or per­sonal injury.
> The electrical connection must be car-
ried out by a suitably qualified compe­tent person who is responsible for com­plying with the existing standards and guidelines.
> Connect the boiler in accordance with
BS 7671 (IEE Regulations).
> For IE: Please observe the latest edition
of the ETCI regulations (Electro-Technical Council for Ireland).
> Earth the boiler.
3
4
8.1 Opening the back wall of the electronics box
> Fold the electronics box (1) forwards. > Undo the 4 clips of the rear cover (2) of the electronics
box from the brackets (3) at the rear and sides of the electronics box.
> Fold up the cover.
Closing the electronics box
> Close the rear panel on the electronics box. > Push in the panel until it clicks into place in the clips. > Fold up the electronics box. > Push the right and left clips of the box against the side
panels on the boiler until they click into place.
> Replace the front casing on the boiler (¬ section 4.7).
1
2
8.3 Establishing the mains connection
8.2 Opening/closing the electronics box Danger!
Risk of death from electric shock!
Opening the electronics box
> Remove the front casing from the boiler (¬ section 4.7).
e
b
Installation and maintenance instructions ecoTEC 0020173113_01 29
Mains connection terminals L and N remain live even if the continuous voltage on/off switch is turned off.
> Before establishing a mains connection,
switch off the power supply.
Caution.
Risk of damage from erroneous con­nected voltage.
At mains voltages greater than 253 V and less than 190 V, the functions may be impaired.
> Make sure that the rated voltage of the
mains is 230 V.
Page 30
Electrical installation
8
Caution.
Risk of damage caused by incorrect
b
b
i
In IE, reference should be made to the current edition of the ETCI (Electro-Technical Council for Ireland) rules. The boiler is supplied for connection to 230 V, ~ 50Hz sup­ply fused at 3 A rating. Connection to the mains supply shall be made via a fused 3 pin plug to an unswitched shut­tered socket, both complying with the requirements of BS 1363. (Alternatively, connection may be made via a 3 A fused double pole isolator having a contact opening of at least 3 mm in all poles and supplying the boiler and control­lers only). The point of connection to the mains supply must allow complete electrical isolation of the boiler and its ancil­lary controllers. It should be readily accessible and adjacent to the boiler. A flexible cord fulfilling BS6500 or compara­ble standard, conductor diameter between 0,75 and 1,5mm and an allowed temperature range including 90°C should be used. The nominal voltage of the mains must be 230 V; at mains voltages greater than 253 V and less than 190 V the func­tions may be impaired.
installation.
A mains voltage at the incorrect plug termi­nals on the ProE system can destroy the electronics.
> Only connect the mains connection cable
to the terminals marked for the purpose.
Caution.
Risk of damage caused by incorrect installation.
Connecting wires that have been stripped too far can cause short circuits and damage the electronics if a strand accidentally comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits. > Lay the lines correctly. > Use strain reliefs.
If you install the boiler in safety area 2, it can
only be operated if it is room sealed. Installation method B53P is not permitted in this case. Observe the latest edition of the "IEE Wiring Regulations – BS7671, Requirements for Electri­cal Installation".
1
3
8.2 Cable routing of the mains connection cable
> Use the strain reliefs (1) provided. > Shorten the mains connection cable as necessary. > Only strip the outer sheathing of flexible cables to a
maximum of 3 cm.
> Ensure inner conductor insulation is not damaged during
stripping of outer sheathing.
> Only strip inner conductors sufficient to make good
sound connections.
> Fit the stripped ends of the conductors with crimp pin
terminals to ensure a secure connection free from loose strands to prevent short circuits.
> Take the turquoise ProE plug (2) for the mains connec-
tion out of the bracket in the electronics box and con­nect the plug professionally to the mains connection cable.
> Insert the ProE plug into the corresponding PCB slot
(L, N and earth) (¬ fig. 8.2).
> Lay the lines correctly. > Secure the cable in the electronics box using the strain
reliefs.
> Close the electronics box (¬ section 8.2).
2
Make sure that the connection cables are
securely fastened to the plug terminals.
i
8.4 Connecting the controller
2
> Open the electronics box (¬ section 8.2). > Use a normal commercial mains connection cable that is
compliant with standards.
> Route the mains connection cable through the left cable
duct (¬ fig. 8.1, pos. 4) on the base of the boiler.
8.4.1 Fitting the controller
> Fit the controllers in accordance with the relevant oper-
ating and installation instructions.
Page 31
Electrical installation
8
8.4.2 Connecting controllers to the electronic system
Caution.
Risk of damage caused by incorrect
b
b
installation.
Connecting wires that have been stripped too far can cause short circuits and damage the electronics if a strand accidentally comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits. > Lay the lines correctly. > Use strain reliefs.
Caution.
Risk of damage caused by incorrect installation.
A mains voltage at the incorrect plug termi­nals on the ProE system can destroy the electronics.
> Do not connect a mains voltage to the
eBUS terminals (+/-).
Make sure that the conductors are securely fas-
tened to the plug terminals of the ProE plug.
i
> Open the electronics box (¬ section 8.2). > Route the supply lines of the components to be con-
nected (e.g. external controllers, external sensors) through the left cable duct (¬ fig. 8.1, pos. 4) on the
underside of the boiler. > Use the strain reliefs provided. > Shorten the supply lines as necessary. > Only strip the outer sheathing of flexible cables to a
maximum of 3 cm. > Ensure inner conductor insulation is not damaged during
stripping of outer sheathing. > Only strip inner conductors sufficient to make good
sound connections. > Fit the stripped ends of the conductors with crimp pin
terminals to ensure a secure connection free from loose
strands to prevent short circuits. > Connect the ProE plug to the supply lines of the control-
ler using a screwdriver. > Insert the ProE plug into the associated PCB slot
(¬ fig. 8.3). > Lay the lines correctly. > Secure the cable in the electronics box using the strain
reliefs. > If you connect a 230V AC time and temperature control
to the boiler, then remove the bridge at input 24V = RT
(X100 or X106) if a bridge exists.
> If you connect a weather compensator or room tempera-
ture control via eBUS, then bridge input 24V = RT (X100 or X106) if no bridge exists.
> I If using low voltage (24V) controls connect these in
place of the bridge marked RT 24V (X100 or X106).
> Close the electronics box (¬ section 8.1). > In order to achieve pump operating mode "Comfort"
(continuously running pump) for multi-circuit controllers, change diagnosis code D.018 Pump operating mode from 3 = (¬ section 11.1.2).
i
8.5 Connecting additional components via
b
You can connect additional components to the ecoTEC using the Vaillant multi-functional module 2 in 7 (accesso­ries).
> Fit the components in accordance with the correspond-
ing operating and installation instructions.
> Select diagnostic code "D.027" to actuate relay 1 on the
multi-functional module at installer level (¬ section 11.1).
> Select diagnostic code "D.028" to actuate relay 2 on the
multi-functional module at installer level (¬ section 11.1).
The following components can be actuated: 1 = Circulation pump 2 = External pump 3 = Cylinder charging pump 4 = Extractor hood 5 = External solenoid valve 6 = External fault message 7 = Solar pump (not active) 8 = Remote control eBUS (not active) 9 = Legionella protection pump (not active) 10 = Collective solar valve (not active)
"Eco" (intermittent pump) to 1 = "Comfort"
Please note that the bridge at the ProE plug
(Burner off) must be removed when connecting a maximum thermostat (contact thermostat) for underfloor heating.
VR 40 – connecting a "2 in 7" multi­functional module
Caution.
Risk of damage caused by incorrect installation.
Connecting wires that have been stripped too far can cause short circuits and damage the electronics if a strand accidentally comes loose.
> Only strip the outer sheathing of flexible
cables for a maximum of 3 cm to prevent
short circuits. > Lay the lines correctly. > Use strain reliefs.
Installation and maintenance instructions ecoTEC 0020173113_01 31
Page 32
Electrical installation
8
8.6 Connection wiring diagrams
X51
Display Connection
24 V 230 V~
X2
blue
X20
pink
X41
Edge connector
X106
8
17
7 18 14 13
11
3
2
6
4 12
orange
1
2
3
M
4
5
6
Diverter valve
1
Water pressure
3
sensor
4
1
2
Impeller sensor
3
Warm start sensor
J
5
1
5
7
8
7 12 13
2 15
16
4
3
red
blue
+
Safety fuse
Gas valve
J
J
Flow sensor
Return sensor
17
45
12
PWM
Earth
+ 24 V
FB
6
AF
RF
DCF
1
Burner
off
RT
24
Bus
­+
Circulation pump remote control External sensor Flow sensor (optional) DCF connection
0
Earth
0
Earth
Contact thermostat/burner off
24 V DC room thermostat Bus connection
(Controller/room th. digital)
Hall signal
Fan
X18
green
Ignition trans­former
X1
turquoise
8.3 Wiring diagram for the ecoTEC 26 (VUW) electronics box
L
N
Internal pump *
Ignition
RT
L
N
No function * 230 V AC room thermostat *
Mains connection
Appliance earth
electrode
* ... variant-dependent
Page 33
X51
Display Connection
X2
blue
Electrical installation
8 17
7 18 14 13
11
3
2
6
1 3 4
Water pressure sensor
8
4
12
5
1
24 V 230 V~
X20
pink
X41
Edge connector
X106
5 7 8
7 12 13
2 15
16
4
3
red
blue
+
Safety fuse
Gas valve
J
J
Flow sensor
Return sensor
17
45
12
PWM
Earth
+ 24 V
FB
6
AF
RF
DCF
1
Burner
off
RT
24
Bus
­+
Circulation pump remote control External sensor Flow sensor (optional) DCF connection
0
Earth
0
Earth
Contact thermostat/burner off
24 V DC room thermostat Bus connection
(Controller/room th. digital)
Hall signal
Fan
X18
green
Ignition trans­former
X1
turquoise
8.4 Wiring diagram for the ecoTEC 22 (VU) electronics box
Installation and maintenance instructions ecoTEC 0020173113_01 33
L
N
Internal pump *
Ignition
RT
L N
No function * 230 V AC room thermostat *
Mains connection
Appliance earth
electrode
* ... variant-dependent
Page 34
Operation
9
9 Operation
The Vaillant ecoTEC pro boiler is fitted with a digital infor­mation and analysis system (DIA). You can use the DIA to display the current status of your boiler (Live monitor) and fault codes, to view and change parameters and to start test programs.
The operating concept and operation of the boiler is described in the ¬ operating instructions for the boiler. The read-off and setting options for the installer level are also described in the ¬ operating instructions. You can find further read-off and setting options in ¬ sec- tion 13.2.1. The following overview shows the read-off and setting facili­ties of the installer level.
9.1 Overview of the read-off and setting options
S.31
Code
D.---
PF
P.--
DF
9.2 Calling up the installer level
Caution.
Risk of damage caused by incorrect
b
Installer level is secured against unauthorised access with a password, as incorrect parameter settings at this level can cause functional faults and damage to the heating installation.
> Press the left
The Live monitor is shown in the display (current status of the boiler).
> Press the right selection button
menu point.
"Code" and the value "00" appear in the display.
> Select the value 17 (code) using the minus button
> Press the right selection button
the entered code. You are at the installer level. The diagnostic codes are shown in the display. Use the left-hand selection button
– to cancel the change to a set value. – to return to the basic display.
Use the right-hand selection button
– to access the test programs (P), to access the fault codes
(F) and to return to the diagnostic codes (D).
– to confirm a set value or the start of a test program.
i
handling.
Incorrect settings at installer level can cause damage to the heating installation.
> You should only access installer level if
you are an approved competent person.
and right selection buttons
("i") at the same time
to select the
or the plus button .
to confirm
:
:
If you exit the installer level and then access it
again within 15 minutes, you do not have to enter the code again.
--/--
9.1 Overview of the read-off and setting options for the installer level
DP
Page 35
Commissioning
10
10 Commissioning
At the time of commissioning, complete all relevant sec­tions of the benchmark checklist found within the back pages of this document. Ensure that the filling and purging programs P.06 and P.00 have been allowed to run fully before the boiler is ignited for the first time. Ensure that all of the conversion and adjustment measures have been carried out before you start up the boiler for the first time. (¬ section 10.9). up to (¬ section 10.10).
Danger!
Risk of poisoning and burns caused by
a
escaping hot flue gas!
Hot flue gas can escape and cause poison­ing and burns if the boiler is operated with an incompletely mounted or open air/flue gas duct or if the boiler is operated with internal leaks with the front casing open.
> Operate the boiler
- for commissioning
- for testing purposes
- in continuous operation only when the front casing is fitted and closed and the air/flue gas duct is com­pletely fitted.
> Exclusively for test purposes such as gas
working pressure testing the boiler may be operated with the front casing removed for short durations ONLY but must have a completely mounted air/flue gas duct.
10.2 Using test programs
You can call up the test programs for the commissioning (¬ section 9.2).
By activating various test programs, you can trigger special functions on the boilers. The following four test programs are available:
Display Meaning
1)
P.00
P.01 Maximum load test program:
P.02 Minimum load test program:
P.06 Filling mode test program:
10.1 Overview of the test programs
Purging test program The heating circuit and the hot water circuit are purged using the automatic air vent (the cap of the automatic air vent must be released).
1 x right selection button: Start heating circuit purging 2 x right selection button (" -> "): Start purging
hot water circuit
3 x right selection button (" -> "): Restart heating
circuit purging
1 x left selection button ("Cancel"): Exit purging pro-
gram
The internal pump is cyclically actuated. Note: The purge program runs 7.5 min per circuit.
The boiler is operated at maximum heat input after suc­cessful ignition.
The boiler is operated at minimum heat input after suc­cessful ignition.
The diverter valve (VUV) is moved to the mid-position. The burner and pump are switched off (to fill or drain the boiler).
The automatic air vent cap must be released
before filling the heating circuit or recharging
i
circuit and during operation. Purge the heating circuit or the recharging cir­cuit using the purge program P.00 (¬ sec-
tion 10.2).
Auxiliary service equipment:
The following test and measuring equipment is required for commissioning:
measuring instrument
– CO
2
– Digital or U-tube manometer
10.1 Switching on the boiler
> Close the gas valve on the boiler while you are filling and
purging the heating installation.
> Only open the gas valve again once you are requested to
do so (¬ section 10.10).
> Press the on/off button (¬ Operating instructions).
The basic display appears on the display.
1)
Purging the heating circuit:
Diverter valve in heating position, actuation of internal pump for 9 cycles: 30 sec. on, 20 sec. off. Display: "Active heating cir­cuit".
Purging the hot water circuit:
After the above-mentioned cycles have run or the right-hand selection button has been pressed again: Diverter valve in the hot water position, actuation of the internal pump as above. Display: "Active hot water circuit".
If you do not press a button for more than
15 minutes. the test programs are stopped auto-
i
To terminate the test programs, you can press the left-hand selection button "
matically. The boiler switches to normal operat­ing mode.
" ("Back", "Cancel") at any time.
Installation and maintenance instructions ecoTEC 0020173113_01 35
Page 36
Commissioning
10
domestic hot water side. (Alternative methods of filling sealed systems are given in BS 5449)
P.0 0
1,0 bar
10.1 Boiler in error condition
If the boiler is in error condition, you cannot
start any test programs. You can detect an error
i
10.3 Preparing the heating water
Pay attention to the specifications concerning heating water preparation in (¬ section 2.4.7).
10.4 Read off the filling pressure
The boiler is equipped with an analogue pressure gauge (¬ fig. 3.1) and also has a symbolic bar display for the filling pressure of the heating system and a digital pressure and temperature display. You can see the pressure gauge once you have removed the front casing of the boiler. Press the right selection button twice to read off the digital filling pressure value.
10.5 Filling and purging the heating installation
b
condition by the fault symbol shown in the left bottom corner of the display (¬ fig. 10.1). You must first reset.
Caution.
Risk of damage caused by contaminated lines.
Foreign bodies such as welding remnants, sealing residue or dirt in the water pipes can cause damage to the boiler.
> Flush the heating installation thoroughly
prior to commissioning.
To ensure the correct operation of the heating installation, the indicator on the pressure gauge must point to the upper half of the grey area or in the middle of the bar graph display (marked by the dashed limit value) when the heating installation is cold. This corresponds to a filling pressure of between 0.1 MPa and 0.2 MPa (1.0 bar and
2.0 bar). You can display the exact filling pressure (¬ section 10.4). If the heating installation extends over several storeys, higher filling pressures may be required to avoid air enter­ing the heating installation.
> Remove the front casing from the boiler (¬ section 4.7).
1
10.2 Automatic air vent
> Release the cap of the automatic air vent (1) by up to
two rotations.
> Open all thermostatic radiator valves.
The ecoTEC pro purges the heating circuit inde-
pendently during continuous operation via the
i
> Only for VUW boilers: Select test program P.06 (¬ sec-
tion 10.2).
The diverter valve moves to the mid-position, the pumps do not run and the boiler does not switch to heating mode.
automatic air vent.
The system is filled via a customer-installed filling connec­tion, which must be attached in a suitable position in the heating circuit. This connection must be removed again after the filling process is complete. If the local Water Authority regulations do 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
10.5.1 Filling the heating installation
Ensure that the filling and drainage cock on the
heating installation is connected to a cold water
i
valve as per standard.
Page 37
Commissioning
10
> In order to fill the heating installation, first open the cold
water valve. > Open all thermostatic radiator valves. > Check that both service valves on the boiler are open. > Slowly open the stop valve on the filling line so that the
water flows into the heating system.
If the water pressure in the heating system is
too low, the display switches between fault mes-
i
> Purge the lowest radiator until water flows out of the
purging valve without bubbles. > Purge all other radiators until the entire heating system
has been filled with water. Close all purging valves. > Use the display to monitor the rising filling pressure in
the heating installation. > Top up with water until the pressure gauge display is in
the middle of the grey area and the required filling pres-
sure appears on the display. > After filling, close the stop valve at the filling line and the
cold water valve. > Check all connections and the entire system for leaks.
sage F.22 and the display of the current pressure when the boiler is switched on.
10.5.2 Purging the heating system
> To purge the heating installation, select test program
P.00 (¬ section 10.2).
The boiler does not start up, the internal pump operates intermittently and, as an option, purges the heating circuit or the hot water circuit. The display shows the filling pres­sure of the heating installation.
> Check whether all thermostatic radiator valves and both
service valves on the boiler are open.
> Connect a hose to the drain valve that is located at the
lowest position in the heating system.
> Open the drain cocks and all the purging valves on the
radiators so that the water flows quickly and completely out of the heating system and the boiler, in order to remove the contamination caused during installation out
of the heating system before the boiler is started up. > Close the drain cocks. > Refill the heating system with water, as described in
(¬ section 10.5). > Check that the expansion relief valve of the heating sys-
tem is functioning correctly by turning the handle on the
valve. > Check the pressure in the heating system and top up
with water if necessary. > Close the filling valve and the cold water valve.
10.6 Avoiding low water pressure
To prevent damage to the heating installation caused by low water pressure, the ecoTEC pro is fitted with a water pressure sensor. If the water pressure falls below 0.08 MPa (0.8 bar), the boiler indicates low pressure by displaying a flashing pres­sure value. If the water pressure falls below 0.05 MPa (0.5 bar), the boiler switches off. The fault message F.22 appears in the display.
> Top up the water and switch the boiler on again.
A flashing pressure value appears on the display until a pressure of 1.1 bar or higher has been reached.
> The filling pressure of the heating system must not fall
below 0.08 MPa (0.8 bar) when purging is in progress as, otherwise, this will not be carried out properly.
The test program P.00 runs for 7.5 minutes per circuit. At the end of the filling procedure, the filling pressure of the heating installation should be at least 0.02 MPa (0.2 bar) above the counterpressure of the expansion vessel
³ P
(P
Installation
> If there is still too much air in the heating installation at
the end of test program P.00, repeat the test program.
> Check all connections for leaks.
+ 0.02 MPa (0.2 bar)).
Exp
i
10.7 Fill and purge the hot water system
> Open the cold water stop valve on the boiler. > Fill the hot water system by opening all the hot water
As soon as water comes out of all the hot water draw-off points, the hot water circuit is filled completely and also purged.
If you notice frequent drops in pressure, then
determine and eliminate the cause, i.e water leaks in the system. Failure to do so along with frequent topping up will result in system corro­sion and subsequent failures.
draw-off points until water comes out.
10.5.3 Flushing the system for the first time ("cold")
The entire heating system must be flushed
through completely at least twice: once cold and
i
Installation and maintenance instructions ecoTEC 0020173113_01 37
once hot, in accordance with the following instructions.
Page 38
Commissioning
10
10.8 Filling the condensate trap
Danger!
Risk of poisoning from escaping flue gas!
a
An empty or insufficiently filled condensate trap may allow flue gas to escape into the room air.
> Fill the condensate trap with water
before starting up the boiler.
1
10.4 Installing the flow restrictor
> Place the supplied flow restrictor (1) on the opening of
the air intake pipe.
> Check that the flow restrictor sits tightly on the opening.
1
10.3 Filling the condensate trap
> Remove the lower part (1) of the condensate trap by
turning the bayonet fitting anti-clockwise.
> Fill the lower section with water until about 10 mm below
the upper edge.
> Re-attach the lower section to the condensate trap.
10.9 Converting the boiler for operation on the Channel Islands
Before implementing the conversion measures, the boiler must be fully installed. The heating installation has been filled and purged. The gas valve on the boiler remains closed.
> Switch off the power supply to the boiler. > Remove the front cladding of the boiler.
1
2
10.5 Removing the covering cap for the air index setting adjusting screw (gas ratio setting) and making the air index setting
The adjusting screw for the air index setting is located beneath a blue covering cap (1), which is easy to unscrew.
> Remove the yellow sticker. > Remove the covering cap. > Adjust the air ratio presetting by turning the bolt (2)
four full rotations in an anti-clockwise direction. Use a
2.5mm Allen key for this.
Page 39
10.10 Adjusting the boiler to the gas used on the Channel Islands
The gas ratio can only be correctly set if the gas flow pres­sure is within the permissible tolerances at the same time. For this reason, the two measurements are taken at the same time.
> Restore the power supply to the boiler. > Switch on the boiler. > Change the value of diagnostics code D.051, which was
preset at the factory, to 0 (¬ section 11.1).
> Change the value of diagnostics code D.050, which was
preset at the factory, to 1000 (¬ section 11.1).
Commissioning
10
1
10.6 Measuring connection for flue gas
> Connect a CO2 measuring instrument to the measuring
connection (1) of the boiler.
Information for making adjustments with a flue
gas analyser:
i
Many flue gas analysers work internally with an
sensor. The CO2 value that is displayed is cal-
O
2
culated using the measured O that the gas ratio setting works properly with these units, the correct energy source [repre­sentative CO uid gas [LPG] must be selected as the energy source.
value] must be set. For this, liq-
2 max
value. To ensure
2
1
10.7 Measuring the gas inlet working pressure
> Undo the sealing screw of the measuring nipple (1)
(lefthand screw) at the gas valve using a screwdriver.
> Connect a digital pressure gauge or U-tube manometer
(2) to the measuring nipple (1).
> Open the gas isolation valve of the boiler. > Start the boiler by activating the test program P.01 as
described in ¬section10.2.
> In addition, ensure that maximum heat can be dissipated
into the heating system by turning up the room thermo­stat.
> Only for VUW-boilers: Alternatively, fully open the hot
water taps to ensure full flow rate through the boiler.
> With the boiler operating at full load check that the gas
inlet working pressure at the reference test point (1) complies with the requirements of ¬table 10.2.
> Should the pressure recorded at the reference test point
in the boiler be lower than indicated (¬table 10.2) check if there is any blockage in the pipework or if the pipe­work is undersized.
2
Installation and maintenance instructions ecoTEC 0020173113_01 39
Page 40
Commissioning
10
Gas used on the Channel Islands
Boiler
22 1.0 (10) 1.7 (17)
26 1.0 (10) 1.7 (17)
10.2 Gas inlet working pressure at the reference test point
If the supply pressure is out of tolerance contact your Emergency Service Provider.
If the gas inlet working pressure at the reference test point (1) is not within the permissible range and you cannot cor­rect the failure, notify the gas supply company or the Vail­lant Service Solutions (0870 6060 777) and proceed as fol­lows:
> Take the boiler out of operation by
– terminating test program P.01 as described in ¬sec-
– Only for VUW-boilers: Allow the boiler to cool down by
> Close the gas isolation valve of the boiler. > Remove the pressure gauge and retighten the sealing
screw (1) for the measuring nipple.
> Turn on gas at the gas isolation valve. > Make sure that there is no leakage at the sealing screw. > Turn off gas at the gas isolation valve. > Put the front casing back on. > Turn off electrical supply to the boiler. > You must not start up the boiler.
If the gas inlet working pressure is within the permissible range, proceed as follows:
> After five minutes in full load mode, compare the meas-
ured CO front casing removed ¬ Table 10.3).
> If this value deviates from the target value, adjust the
corresponding CO (¬ Fig. 10.5). Use a 2.5mm Allen key for this.
– Turn to the left: higher CO – Turn to the right: lower CO
Minimum pressure at
reference test point in
kPa (mbar)
tion10.2.
turning off water taps and allow pump overrun to operate for a minimum of two minutes.
value with the target CO2 value (value with
2
value by turning the bolt (2)
2
2
Maximum pressure at
reference test point in
concentration,
concentration.
2
kPa (mbar)
Gas used on the
Settings
after 5 minutes full load mode
CO
2
with boiler front casing fitted
CO2 after 5 minutes full load mode with boiler front casing removed
Set for Wobbe index Ws kWh/m CO value with full load ppm < 250 CO/CO
2
10.3 Target values for the gas ratio setting
Unit
Vol.–%
Vol.–%
Channel Islands
10.0 ± 0.
9.8 ± 0.
3
6.6
< 0.0026
Danger!
Risk to life due to poisoning!
a
CO is an extremely toxic gas. Risk to life due to excessive CO concentrations.
> If you are not able to adjust the boiler
correctly and the flue gas values remain higher than allowed in ¬table10.3, call the Vaillant Service Solutions (0870 6060 777).
> Do not start up the boiler!
> Take the boiler out of operation by
– terminating test program P.01 as described in ¬sec-
tion10.2.
– Only for VUW-boilers: Allow the boiler to cool down by
turning off water taps and allow pump overrun to
operate for a minimum of two minutes. > Close the gas isolation valve of the boiler. > Remove the pressure gauge and retighten the sealing
screw (1) for the measuring nipple.
> Open the gas isolation valve of the boiler. > Make sure that there is no leakage at the sealing screw. > After the adjusting work is complete, put the covering
cap back on again (1) (¬ Fig.10.5).
> Remove the CO
ing connection and close the measuring connection
again. > Put the front casing back on. > Reset boiler controls for normal operation. > Record the appliance gas inlet working pressure (kPa
resp. mbar) in the Benchmark gas boiler commissioning
checklist.
measuring instrument from the measur-
2
5
5
Gas used on the Channel Islands: Only perform
the adjustment in small increments (approxi-
i
mately 1/4 turns), and wait approximately 1 min­ute after each adjustment until the value stabi­lises.
10.11 Checking for tightness of the flue gas installation and flue gas recirculation
> Check the integrity off the flue gas installation according
to TB 008.
> Should the flue gas installation be longer than 2 m we
strongly recommend to check the system for flue gas recirculation as described below.
Page 41
Commissioning
> Take the boiler out of operation by
– terminating test program P.01 as described in ¬ sec-
1
tion 10.2.
– Only for VUW boilers:
Allow the boiler to cool down by turning off water taps and allow pump overrun to operate for a minimum of two minutes.
> Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
10
2
10.8 Flue gas and air measure points
Legend:
1 Flue gas measure point 2 Air measure point
For checking the system for recirculation use the air meas­ure point (2).
> Use the flue gas analyser. > If you detect any CO or CO
in the fresh air, search for
2
the flue gas leakage or recirculation. > Correct the defects. > Check again as described before, if there is any CO or
in the fresh air.
CO
2
> If you cannot correct the defects you must not start up
the boiler.
10.12 Checking the gas flow rate
The boiler is fitted with a multifunctional automatic gas valve which ensures that the precise air/gas ratio is pro­vided under all operating conditions. The gas flow rate has been set during production and does not require adjust­ment. With the front casing fitted check the gas flow rate of the boiler as follows:
> Start the boiler by activating the test program P.01 as
described in ¬ section 10.2. > In addition, ensure that maximum heat can be dissipated
into the heating system by turning up the room thermo-
stat. > Only for VUW boilers: Alternatively, fully open the hot
water taps to ensure full flow rate through the boiler. > Wait at least 5 minutes until the boiler has reached its
operating temperature. > Ensure that all other gas appliances in the property are
turned off. > Measure the gas flow rate at the gas meter. > Check that the gas flow rate is as stated in ¬ table 10.4.
If the measured gas flow rate lies outside the tolerance lim­its specified in ¬ table 10.4, do not operate the boiler and inform the Vaillant Service Solutions (0870 6060 777).
If the measured gas flow rate is within the tolerance limits shown in ¬ table 10.4, then proceed as follows:
Boiler
22 4.2 4.4 3.8 26 4.2 4.4 3.8
10.4 Gas flow rates
Gas flow rate (as per BS EN 483)
Gas in m
nominal + 5 % - 10 %
3
/h
10.13 Carrying out a full function test
> After completing the installation and the gas setting,
perform a complete function check of the boiler before starting up the boiler and handing it over to the opera­tor.
> Start up the boiler in accordance with the relevant oper-
ating instructions.
10.9 Checking for leaks
> Check the gas supply line, the flue gas installation, the
heating installation and the hot water pipes for leaks. > Check the air/flue gas duct for correct installation. > Make absolutely sure that the front casing is properly
fitted. > Check the heating mode (¬ section 10.13.1) > Check the operation of the hot water generation (¬ sec-
tion 10.13.2)
Installation and maintenance instructions ecoTEC 0020173113_01 41
Page 42
Commissioning
10
You can display the current operating condition of the boiler in the "Live monitor" on the boiler display (¬ sec-
tion 13.2.1).
10.13.1 Checking the heating mode
> Switch on the boiler. > Make sure that there is a heat requirement. > Activate the Live monitor (¬ section 13.2.1).
S.04
10.10 Live monitor – display during heating mode
If the boiler is operating correctly, the display will show sta­tus code "S.04".
10.13.2 Checking the hot water generation (VUW boilers only)
> Switch on the boiler. > Open a hot water valve all the way. > Activate the Live monitor (¬ section 13.2.1).
If hot water generation is working correctly, the display shows "S.14".
S.14
10.11 Display for hot water generation (VUW boilers only)
10.13.3 Checking hot water generation (VU boilers only)
> Switch on the boiler. > Switch on the connected domestic hot water cylinder. > Make sure that the cylinder thermostat is requesting
heat.
> Activate the Live monitor(¬Kap.13.2.1).
If the cylinder is being charged correctly, status code “S.24” appears in the display.
S.24
10.12 Display during cylinder charging (VU boilers only)
> If you have connected the controller for the heating
installation using a two-wire eBUS line, then set the hot water temperature at the boiler to the maximum possible temperature (¬table11.1).
djust the target temperature for the connected domes-
> A
tic hot water cylinder to the controller.
10.14 Final flush of the heating system ("hot")
> Operate the appliance until the boiler and the heating
system are up to temperature. > Check the heating system for leaks. > Connect a hose to the drain valve located at the lowest
position of the heating system. > Shut off the boiler, open the drain valve and all purge
valves on the radiators and allow the water to flow out of
the heating system and the boiler quickly and fully. > Close the drain valve. > Fill the heating system again with water as described in
¬ section 10.5.3. > Re-fill the system until the system design pressure of
0,1 MPa (1,0 bar) is attained. (The actual reading on the
digital pressure gauge should ideally be 0,05 MPa
(0,5 bar) plus an additional pressure corresponding to
the highest point of the system above the base of the
boiler – 10 m head equals an additional 1 bar reading on
the pressure gauge. The minimum pressure should not
be less than 0,1 MPa (1 bar) in any installation.) If the sys-
tem is to be treated with an inhibitor it should be applied
at this stage in accordance with the manufacturer’s
instructions. Further information can be obtained from
Sentinel, Betz Dearborn Ltd., Tel: 0151 420 9595, or Fer-
nox, Alpha–Fry technologies. Tel: 0870 8700362. > Refit the boiler casing (¬ section 4.7). > Attach the bottom cover to the boiler by sliding the front
edge of the cover into the lip at the bottom front edge of
the appliance chassis. > Carefully push the rear of the bottom cover upwards
until the spring retaining clips engage at the side of the
appliance. It may be necessary to adapt the bottom
cover by removing the easy break sections.
Page 43
Adapting the boiler to the heating installation
11 Adapting the boiler to the heating
installation
You can find all setting options in the diagnostic codes in the installer level (¬ section 9.2).
11.1 Diagnosis codes – Overview
You can use the parameters that are marked as adjustable in ¬ table 11.1 to adapt the boiler to the heating installation and the needs of the customer:
You can enter your settings in the last column
after setting the system-specific parameters.
i
> Switch to the installer level (¬ section 9.2) and select
the diagnostic codes.
> Press the minus button
to switch between the displayed diagnosis
codes.
With modifiable parameters:
> Press the right-hand selection button
select the parameter to make a change.
> Press the minus button
to change the current setting.
> Press the right-hand selection button
firm the change.
The change is saved.
or the plus button
to
or the plus button
to con-
11
Installation and maintenance instructions ecoTEC 0020173113_01 43
Page 44
Adapting the boiler to the heating installation
11
Code Parameters Adjustable values
D.000 Heating partial load Adjustable heating partial load in kW
D.001 Overrun time of internal pump for
heating mode
D.002 Max. burner anti-cycling time heating
at 20 °C flow temperature
D.003 Outlet temp. actual value in °C Not adjusta-
D.004 Measured value of hot water sensor Not relevant Not adjusta-
D.005 Flow temperature target value (or
return target value)
D.006 Hot water temperature target value
(VUW boilers only)
D.007 Warm start temperature target value
(only with VUW boilers) Cylinder temperature target value (only with VU boilers)
D.008 Room thermostat at terminal RT Room thermostat open (no heat requirement)
D.009 Target value from external eBus con-
troller
D.010 Status of internal pump 1 = on, 0 = off Not adjusta-
D.011 Status of external heating pump 1 to 100 = on, 0 = off Not adjusta-
D.012 Status of cylinder charge pump Not relevant Not adjusta-
D.013 Status of hot water circulation pump Not relevant Not adjusta-
D.014 Target pump speed (high-efficiency
pump)
D.015 Actual pump speed (high-efficiency
pump)
D.016 Room thermostat 24 V DC open/
closed
D.017 Heating flow/return regulation
changeover
D.018 Pump operating mode setting 1 = Comfort (continuously operating pump)
D.019 Operating mode of 2-stage pump Not relevant Not adjusta-
D.020 Max. setting for cylinder target value Not relevant Not adjusta-
D.022 Hot water demand via C1/C2, internal
hot water control system
D.023 Summer/winter operating mode (heat-
ing on/off)
D.025 Hot water generation enabled by eBUS
controller
D.026 Auxiliary relay control Not relevant Not adjusta-
11.1 Diagnosis codes
Auto: Boiler automatically adjusts max. partial load to cur­rent system demand
1 - 60 min 5 min
2 - 60 min 20 min
In °C, max. of the value set in d.71, limited by an eBUS con­troller if connected)
35 to 65 °C Not adjusta-
40 to 65 °C 15 °C frost protection, then 40 to 70 °C; (max. temperature can be adjusted under D.020)
Room thermostat closed (heat requirement) in °C Not adjusta-
Not relevant Not adjusta-
Not relevant Not adjusta-
0 = Room thermostat open (no heating mode) 1 = Room thermostat closed (heating mode)
0 = Flow, 1 = Return 0
3 = Eco (intermittently operating pump)
Not relevant Not adjusta-
1 = Heating on, 0 = Heating off (summer mode) Not adjusta-
1 = Yes, 0 = No Not adjusta-
Factory setting
Auto
3
Your own setting
ble
ble Not adjusta-
ble
ble Not adjusta-
ble
Not adjusta­ble
ble
ble
ble
ble
ble
ble
ble Not adjusta-
ble
ble
ble
ble
ble
ble
ble
Page 45
Adapting the boiler to the heating installation
11
Code Parameters Adjustable values
D.027 Switching of relay 1 on the
"2 in 7" multi-functional module VR 40
D.028 Switching of relay 2 on the
"2 in 7" multi-functional module VR 40
D.033 Fan speed target value In rpm Not adjustable
D.034 Fan speed actual value In rpm Not adjustable
D.035 Position of the diverter valve 0 = Heating; 100 = Hot water; 40 = Mid-position Not adjustable
D.036 Hot water flow quantity
(impeller sensor)
D.039 Solar feed temperature Actual value in °C Not adjustable
1 = Circulation pump 2 = External pump 3 = Cylinder charging pump 4 = Extractor hood 5 = External solenoid valve 6 = External fault message 7 = Solar pump (not active) 8 = Remote control eBUS (not active) 9 = Legionella protection pump (not active) 10 = Collective solar valve (not active)
1 = Circulation pump 2 = External pump 3 = Cylinder charging pump 4 = Extractor hood 5 = External solenoid valve 6 = External fault message 7 = Solar pump (not active) 8 = Remote control eBUS (not active) 9 = Legionella protection pump (not active) 10 = Collective solar valve (not active)
In l/min Not adjustable
Factory setting
2
2
Your own setting
D.040 Flow temperature Actual value in °C Not adjustable
D.041 Return temperature Actual value in °C Not adjustable
D.044 Digitised ionisation value Display range 0 to 1020,
D.046 Pump type Not relevant Not adjustable
D.047 Outside temperature (with weather-
controlled Vaillant controller)
D.050 Offset for minimum speed In rpm, setting range: 0 to 3000 Nominal value
D.051 Offset for maximum speed In rpm, setting range: -990 to 0 Nominal value
D.058 Activation of solar post-heating for VUW
boilers; Switch hot water mode
D.060 Number of temperature limiter shut-
downs
D.061 Number of ignition device cutoffs Number of unsuccessful ignitions in the last attempt Not adjustable
D.064 Average ignition time In seconds Not adjustable
D.065 Maximum ignition time In seconds Not adjustable
11.1 Diagnosis codes (continued)
> 800 no flame < 400 good flame
Actual value in °C Not adjustable
set in factory
set in factory
0: Solar post heat mode deactivated 3: DHW activation target value minimum 60 °C
Number of shutdowns Not adjustable
0
Not adjustable
Installation and maintenance instructions ecoTEC 0020173113_01 45
Page 46
Adapting the boiler to the heating installation
11
Code Parameters Adjustable values
D.067 Remaining burner anti-cycling time In minutes Not adjustable
D.068 Unsuccessful ignitions at 1st attempt Number of unsuccessful ignitions Not adjustable
D.069 Unsuccessful ignitions at 2nd attempt Number of unsuccessful ignitions Not adjustable
D.070 Setting diverter valve position 0 = Normal mode
D.071 Target value maximum heating flow tem-
perature
D.072 Internal pump overrun after cylinder
charging
D.073 Warm start target offset Adjustable from -15 K to 5 K 0
D.075 Max. charging time for domestic hot
water cylinder without independent con­trol system
D.076 Device specific number 16 = VU 22
D.077 Limit on cylinder charging output
in kW
D.078 Limit on cylinder charging temperature
in °C
D.080 Operating hours, heating In hours (h) Not adjustable
1 = Mid-position (parallel mode) 2 = Permanent heating setting
40 to 80 °C 75 °C
Not relevant Not adjustable
Not relevant Not adjustable
16 = VUW 26 Not relevant Not adjustable
Not relevant Not adjustable
Factory setting
0
Your own setting
Not adjustable
D.081 Operating hours, hot water generation In hours (h) Not adjustable
D.082 Number of burner start-ups in heating
mode
D.083 Number of burner start-ups in hot water
mode
D.084 Maintenance indicator: Number of hours
until the next maintenance
D.088 Start delay for hot water draw-off detec-
tion via impeller (VUW boilers only)
D.090 Status of digital controller 1 = Recognised, 0 = Not recognised Not adjustable
D.091 Status DCF with external sensor con-
nected
D.092 actoSTOR module recognition Not relevant Not adjustable
D.093 Invalid device specific number (DSN) Setting range: 0 to 99
D.094 Delete fault history Delete fault list
D.095 Software version of PeBUS components PCB (BMU)
D.096 Factory setting Reset all adjustable parameters to default setting
11.1 Diagnosis codes (continued)
Number of burner start-ups Not adjustable
Number of burner start-ups Not adjustable
Setting range: 0 to 3000 hrs and "---" for deactivated "---"
0 = 1.5 l/min and no delay, 1 = 3.7 l/min and 2 sec. delay
0 = No reception, 1 = Reception, 2 = Synchronised, 3 = Valid
Display (AI)
0
Not adjustable
Not adjustable
Page 47
Adapting the boiler to the heating installation
11
11.1.1 Setting the heating partial load
The heating partial load of the Vaillant ecoTEC boiler is fac­tory-set to "auto". This means that the boiler independently determines the optimum heating output depending on the current heat demand of the system. A setting is normally no longer required. If you still want to set a fixed maximum heating partial load, you can set a value under diagnostic code "D.000", which equates to the boiler output in kW.
11.1.2 Setting pump overrun time and pump operating mode
The pump overrun time for the heating mode is set at the factory to a value of 5 minutes. You can set the pump over­run time under diagnosis code "D.001" within the range of 1 minute to 60 minutes. You can set a different pump oper­ating mode under diagnosis code "D.018". Here you have the choice between 3 = Eco and 1 = Comfort.
Comfort (continuously operating pump)
The internal pump is switched on when the heating flow temperature is not at "Heating off"(¬ Operating instruc- tions) and the heating requirement is enabled via an exter­nal controller.
Eco (intermittently operating pump)
Pump operating mode Eco is the factory setting. This pump operating mode is useful for removing residual heat after hot water generation when the heat demand is extremely low and large temperature spreads exist between the hot water generation and heating mode target values. This pre­vents living rooms from being under-supplied. If there is a heat demand, the pump is switched on every 25 minutes for 5 minutes once the overrun time has elapsed.
11.1.5 Burner anti-cycling time
Setting the burner anti-cycling time
To prevent frequent switching on and off of the burner and therefore energy loss, an electronic restart lockout is acti­vated for a specific period each time the burner is switched off. You can adjust the burner anti-cycling time to the con­ditions of the heating installation. The burner anti-cycling time is only activated for the heat­ing mode. Hot water handling during a burner anti-cycling time does not affect the timer. You can set the maximum burner anti-cycling time at installer level under diagnosis code "D.002" within the range 2 minutes to 60 minutes (factory setting: 20 min). The effective burner anti-cycling time depends on the cur­rent target flow temperature and the maximum burner anti­cycling time set.
The effective burner anti-cycling times with respect to the target flow temperature and the maximum set burner anti­cycling time can be found in the following table.
The remaining burner anti-cycling time following
a regular shutdown in heating mode can be
i
called up under diagnosis code "d.067".
Reset remaining burner anti-cycling time
> Press the fault clearance key (¬ Operating instruc-
tions).
11.1.3 Setting the maximum flow temperature
The maximum flow temperature for the heating is set at the factory to 75 °C. This can be set to a value in the range of 40 °C to 80 °C under diagnosis code "D.071".
11.1.4 Setting the return flow temperature control
If the boiler is connected to an underfloor heating system, the temperature control can be changed from flow temper­ature regulation (default setting) to return flow temperature control under diagnosis code "D.017".
Installation and maintenance instructions ecoTEC 0020173113_01 47
Page 48
Adapting the boiler to the heating installation
11
T
(target)
Feed
[°C]
20 2.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0 60.0 25 2.0 4.5 9.2 14.0 18.5 23.0 27.5 32.0 36.5 41.0 45.0 50.0 54.5 30 2.0 4.0 8.5 12.5 16.5 20.5 25.0 29.0 33.0 37.0 41.0 45.0 49.5 35 2.0 4.0 7.5 11.0 15.0 18.5 22.0 25.5 29.5 33.0 36.5 40.5 44.0 40 2.0 3.5 6.5 10.0 13.0 16.5 19.5 22.5 26.0 29.0 32.0 35.5 38.5 45 2.0 3.0 6.0 8.5 11.5 14.0 17.0 19.5 22.5 25.0 27.5 30.5 33.0 50 2.0 3.0 5.0 7.5 9.5 12.0 14.0 16.5 18.5 21.0 23.5 25.5 28.0 55 2.0 2.5 4.5 6.0 8.0 10.0 11.5 13.5 15.0 17.0 19.0 20.5 22.5 60 2.0 2.0 3.5 5.0 6.0 7.5 9.0 10.5 11.5 13.0 14.5 15.5 17.0 65 2.0 1.5 2.5 3.5 4.5 5.5 6.5 7.0 8.0 9.0 10.0 11.0 11.5 70 2.0 1.5 2.0 2.5 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 75 2.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
11.2 Effective burner anti-cycling times
11.1.6 Setting the maintenance interval
Set maximum burner anti-cycling time [min]
1 5 10 15 20 25 30 35 40 45 50 55 60
On completion of the set operating hours, you
must set the maintenance interval again in diag-
You can define maintenance intervals for the ecoTEC. After
i
nosis mode. the set burner operating hours have elapsed, in addition to the current flow temperature, the maintenance symbol (open-end spanner) appears in the display and this shows
11.1.7 Setting the by-pass valve
that the boiler must be serviced. The display on the eBUS controller (accessory) shows the information "Maintenance" "MAIN".
The boilers have a by-pass valve. The pressure is adjustable in the range between 17.0 MPa (170 mbar) and 35.0 MPa (350 mbar). Approx. 25.0 MPa
Heat demand
5.0 kW
10.0 kW
15.0 kW
20.0 kW
25.0 kW
> 27.0 kW
11.3 Guideline values for operating hours
Number of persons
1 - 2 2 - 3
1 - 2 2 - 3
2 - 3 3 - 4
3 - 4 4 - 5
3 - 4 4 - 6
3 - 4 4 - 6
Burner operating hours until the next inspection/service (depending on the system type)
1,050 h 1,150 h
1,500 h 1,600 h
1,800 h 1,900 h
2,600 h 2,700 h
2,800 h 2,900 h
3,000 h 3,000 h
(250 mbar) is pre-set (mid-position). The pressure changes by approx. 1.0 MPa (10 mbar) each time the adjusting screw is rotated. By turning right, the pressure increases and turn­ing left decreases it.
1
> Set the operating hours until the next service using diag-
nosis code "d.084".
Guideline values for the setting can be found in ¬ table 11.3. The values stated correspond to an average boiler operating time of one year. You can set the operating hours in increments of ten from 0 to 3,000 h.
If you do not enter a figure under diagnosis code "D.084" but instead enter the symbol "–", then the "Maintenance display" function is not active.
11.1 Setting the by-pass valve
Page 49
Adapting the boiler to the heating installation
11
> Regulate the pressure using the setting screw (1).
Position of the setting screw
Right-hand stop (turned all the way down)
Mid-position (5 turns to the left)
5 further turns to the left from the mid-posi­tion
11.4 Setting value for the by-pass valve (feed head)
Pressure in MPa (mbar)
35.0 (350)
25.0 (250) Factory setting
17.0 (170)
Notes/application
If the radiators do not get properly hot in the default setting. Note: In this case, you must set the pump to the maximum stage.
If noises in the radiators or radiator valves are produced
11.2 Handing over the boiler to the operator
Danger!
Risk of poisoning and burns caused by
a
escaping hot flue gas!
Hot flue gas can escape and cause poison­ing and burns if the boiler is operated with an incompletely mounted or open air/flue gas duct or if the boiler is operated with internal leaks with the front casing open.
> Operate the boiler
- for commissioning
- for testing purposes
- in continuous operation only when the front casing is fitted and closed and the air/flue gas duct is com­pletely fitted.
> Exclusively for test purposes such as gas
working pressure testing the boiler may be operated with the front casing removed for short durations ONLY but must have a completely mounted air/flue gas duct.
If this boiler is not installed and commissioned in accord­ance with the manufacturer's instructions, this may void the guarantee (Note: Your legal rights remain unaffected
by this.) > Handover the boiler to the operator. > Explain the basic operation of the heating installation to
the operator. > Provide the operator with all relevant instructions and
boiler documentation. > Go through the operating instructions with the operator > Reply to his questions if necessary. > Make the operator aware of the need to keep the instruc-
tions in a handy location near the boiler, but not in or on
the boiler. > Draw special attention to the safety instructions, which
the operator must follow. > Instruct the operator that no changes or adaptations
must be made to the flue system or combustion air sup-
ply. These must both terminate outside of the building
and be constructed only from approved components. > Explain to the operator how he should monitor the water
level/filling pressure of the system. > Explain to the operator which measures are required to
top up and purge the heating installation if required. > Explain to the operator how to correctly set the tempera-
tures, the controllers and the thermostatic radiator
valves (economically). > Complete and sign off the Benchmark commissioning
check list. > Complete and sign off the guarantee documentation.
> After completing the installation, stick the 835593
sticker in the user's language to the front of the boiler.
The sticker is delivered with the boiler. You must brief the operator of the boiler on the handling and function of the ecoTEC.
> Explain the importance of regular maintenance by a
competent skilled trade company to the operator.
It is strongly recommended that a maintenance contract
be taken out to ensure regular maintenance. Important
information is available from Vaillant Service Solutions
(0870 6060 777).
> Complete the benchmark Benchmark gas boiler commis-
sioning checklist which is found at the end of these
instructions.
Installation and maintenance instructions ecoTEC 0020173113_01 49
Page 50
Inspection and maintenance
12
12 Inspection and maintenance
After servicing, complete the relevant Service Record sec­tion of the Benchmark Checklist located on the inside back pages of this document.
12.1 Inspection and maintenance intervals
Danger!
Risk of injury and risk of damage to prop-
a
a
All service work must be carried out by a competent person in accordance with the Gas safety, installation and use regu­lations. In the UK this is considered to be a person approved at the time by the Health and Safety Executive.
In addition BS 6798: 2009 "Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net" advises that:
– The person carrying out a combustion measurement
must be assessed as competent in the use of a flue gas
analyser and the interpretation of the results.
– The flue gas analyser used must be one meeting the
requirements of BS 7927 or BS-EN50379-3 and be cali-
brated in accordance with the analyser manufacturers’
requirements.
– Competence can be demonstrated by satisfactory com-
pletion of the relevant ACS standard assessment, which
covers the use of electronic portable flue gas analysers’
in accordance with BS 7967, parts 1 to 4.
– The flue gas analyser is set to the correct fuel setting.
erty due to neglected inspection and maintenance!
Neglected inspection and maintenance works or not observing the stated inspec­tion and maintenance intervals can inter­fere with the operational safety of the boiler and can result in damage to property and to persons.
> Point out to the operator that he must
observe the demanded inspection and maintenance intervals as a minimum.
> Carry out proper regular inspections
once a year.
> Carry out regular maintenance as dic-
tated by findings during the inspection process.
Danger!
Danger of life and limb due to improper inspection/maintenance!
Inspections/Maintenance work carried out improperly can result in leakages and explo­sion.
> The boiler may only be inspected/main-
tained by a competent person.
We recommend the conclusion of an inspection and mainte­nance contract with an approved company or installer. The inspection serves to determine the actual condition of the respective boiler and compare it with the specified con­dition. This is done by measuring, checking and observing. Maintenance is required in order to eliminate any deviations of the actual condition from the specified condition.
This normally is done by cleaning, adjustment and, if neces­sary, replacing individual components that are subject to wea r.
You must carry out an annual inspection of the Vaillant ecoTEC. The annual inspection can be effectively performed without removing components by requesting data from the DIA sys­tem, carrying out the simple visual checks indicated in ¬ table 12.2 and performing a flue gas measurement. The maintenance intervals and their scope are determined by the heating engineer based on the condition of the boiler found during the inspection. All inspection and maintenance work should be performed in the order specified in ¬ table 12.2.
Danger!
Risk of poisoning and burning caused by
a
12.1.1 General inspection and maintenance
To ensure the faultless operation, long term availability of all functions and long working life of your Vaillant boiler and to prevent modifications to the approved series status only genuine Vaillant spare parts must be used when carry­ing out inspection, maintenance and repair work.
escaping hot flue gas!
Hot flue gas can escape and cause poison­ing and burning if the boiler is operated with an incompletely mounted or open air/ flue gas duct or if the boiler is operated with internal leaks with the front casing open.
> Operate the boiler
- for commissioning
- for testing purposes
- in continuous operation only when the front casing is fitted and closed and the air/flue gas duct is com­pletely mounted.
> Exclusively for test purposes such as gas
working pressure testing you can operate the boiler may be operated with the front casing removed for short durations ONLY but must have a completely mounted air/ flue gas duct.
instructions
Page 51
Inspection and maintenance
12
For an overview of the available original Vaillant spare parts, contact the Vaillant sales office on 0870 6060 777. During any inspection and maintenance or after change of parts of the combustion circuit, the following must be checked:
– The boiler has been installed in accordance with the rele-
vant installation instructions.
– The integrity of the flue gas installation and flue seals is
in accordance with the relevant flue installation instruc-
tions enclosed.
– Visual, the integrity of the boiler combustion circuit and
relevant seals (paying particular attention to the burner
door seal).
– The gas inlet working pressure at maximum rate as
described in ¬ section 10.10.
– The gas flow rates as described in ¬ section 10.12. – Correctness of electrical, water and gas connections. – Correctness of the water pressure. – The condition of the whole system, in particular the con-
dition of radiator valves, evidence of leakage from the
heating system and dripping taps.
> Correct any faults before proceeding.
12.1.2 Safety instructions
> When removing any water carrying components ensure
that water is kept away from all electrical components.
Always perform the following steps after performing any inspection or maintenance work:
> Always use new seals and O-rings when parts are
replaced. > Open the service valves in the heating flow and return. > Open the cold water stop valve if necessary. > Reconnect the boiler to the power mains. > Switch on the boiler using the on/off switch. > Fill the heating circuit of the boiler to a pressure of
between 0,1 and 0,2 MPa (1,0 and 2,0 bar) if required. > If you have topped up with water, purge the heating
installation using test program P.00 (¬ section 10.5.2). > Open the gas isolation valve. > Check the boiler for gas and water leaks. > Replace the front casing to the boiler (¬ section 4.7). > Carry out a functional check of the boiler (¬ sec-
tion 10.13). > Always check earth continuity, polarity and resistance to
earth with a multimeter after any service work and after
replacing any electrical component. > If necessary, refill and re-purge the heating installation. > Complete the benchmark gas boiler commissioning serv-
ice record on the back pages of these instructions.
Danger!
Danger of life and limb by electric shock!
a
i
Always perform the following steps prior to inspection or maintenance work:
> Switch off the main switch. > Disconnect the boiler from the power mains by
> Further check for electrical isolation of the appliance by
use of a test meter. > Close the gas isolation valve. > Close the service valves in the heating flow and return. > Remove the front casing from the boiler.
The supply terminals of the boiler are under mains voltage even if the boiler main switch is off.
> Don’t touch the supply terminals. > Protect the electronic box from any
water or spray.
> Before working on the boiler, turn off the
power and secure against restart.
If it is necessary to keep the electricity to the
boiler switched on for certain inspection and maintenance, this is indicated in the description of the maintenance task.
– disconnecting the mains plug or – de-energising the boiler via an isolating device with a
contact opening of at least 3 mm (e. g. fuses or power switches).
12.1.3 Checking the CO/CO2 ratio and the CO2 concentration
Danger!
Danger of explosion, fire or poisoning
a
i
caused by incorrect flue gas value adjustment.
Safe combustion can only be verified by measuring CO/CO
> Make sure that the CO/CO
exceed the value shown in
Checking/adjustment of the CO2 concentration
is required in the following instances:
- replacement of gas valve,
- conversion to or from Natural Gas/LPG
- or if an incorrect combustion is suspected.
ratio.
2
ratio does not
2
¬table12.1.
Installation and maintenance instructions ecoTEC 0020173113_01 51
Page 52
Inspection and maintenance
12
1
12.1 Measuring the CO2 concentration
The boiler is fitted with a flue gas analysis point
(1). A suitable flue gas analyser can be con-
i
> Remove the front casing (¬ section 4.7). > Start the testing program P.01 (¬ section 10.2). > Wait at least 5 minutes until the boiler reaches its oper-
ating temperature.
> Measure the CO
point (1). Compare the measured value with the corre- sponding value in ¬ table 12.1.
> If all these points are as required, proceed as described
in ¬ section 12.2.
> If one of the flue gas values is greater than the accepta-
ble values in ¬ table 12.1, then proceed as described in the following ¬ section 12.1.4.
12.1.4 Adjusting the CO2 concentration (or the air
a
nected to this point to establish the combustion performance of the boiler.
concentration at the flue gas analysis
2
ratio)
Danger!
Increased risk of poisoning due to incor­rect settings!
If one of the flue gas values is greater than the acceptable values in ¬ table 12.1 then:
> Check the integrity of the complete flue
gas installation.
> Check the integrity of the combustion
circuit seals. > Check the gas inlet working pressure. > Check the gas flow rate.
1
2
12.2 Removing the covering cap for the air ratio setting adjust­ing screw (gas setting) and making the air ratio setting
If the flue gas value needs to be adjusted, proceed as follows. The adjusting screw for making the air ratio setting is located beneath a blue covering cap (1), which is easy to remove.
> Remove the yellow sticker. > Remove the covering cap. > Set the relevant CO
casing ¬ table 12.1) by turning the screw (2). Use a
2.5 mm Allen key for this. – Turn to the left: higher CO – Turn to the right: lower CO
Channel islands gas: Only perform the adjust-
ment in very small increments (approximately
i
> Press the "Cancel" selection button once the settings
have been adjusted.
> When the adjusting work is complete, put the covering
cap back on again.
> Put the front casing back on (¬ section 4.7).
1/16 turns), and wait approximately 1 minute after each adjustment until the value stabilises.
value (value with removed front
2
concentration,
2
concentration.
2
Page 53
Gas used on the
Settings
after 5 minutes full load mode
CO
2
with boiler front casing fitted
CO2 after 5 minutes full load mode with boiler front casing removed
Set for Wobbe index Ws kWh/m CO value with full load ppm < 250 CO/CO
2
12.1 Target values for the gas ratio setting
Unit
Vol.–%
Vol.–%
Channel Islands
10.4 +/- 0.
10.2 +/- 0.
3
< 0.0026
Danger!
Risk to life due to poisoning!
a
CO is an extremely toxic gas. Risk to life due to excessive CO concentrations.
> If you are not able to adjust the boiler
correctly and the flue gas values remain higher than allowed in ¬ table 12.1, call the Vaillant Service Solutions (0870 6060 777).
> Do not start up the boiler!
6.6
Inspection and maintenance
3
3
12
Installation and maintenance instructions ecoTEC 0020173113_01 53
Page 54
Inspection and maintenance
12
12.2 Inspection and maintenance work steps
Column 1
Inspection must
No. Activity
Check the air flue gas installation for leaks and for proper fixation and ensure it is not
1
blocked or damaged and is fitted correctly, complying with the relevant installation instruc­tions.
2 Carry out a general inspection of the boiler for dirt and dust and clean as necessary. x x
Visually inspect the complete heat engine for its general condition and for signs of corrosion,
3
sooting or other forms of damage (paying particular attention to the burner door seal). If damage is evident proceed to column 2.
Measure the gas flow rate during operation with maximum load (¬ section 10.12). If the gas
4
flow rate complies to the ¬ table 10.4 continue with column 1, if not proceed to column 2. Check the gas inlet working pressure (¬ section 10.10) operation with maximum load. If the
5
gas inlet working pressure complies to the ¬ table 10.2 continue with column 1, if not proceed to column 2.
Check combustion by measuring CO, CO tolerances of ¬ table 10.2 proceed to maintenance column 2. You must not proceed with the
6
maintenance if a new burner door seal kit is not available. Isolate the boiler from the power mains. Check whether the electrical plug connections and
7
the other electrical connections are fitted tightly and correct them if necessary.
8 Close the gas isolation valve and the service valves. x
Drain the pressure in the boiler on the water side (observe pressure gauge) and check the
9
charge pressure of the expansion vessel. Top up if necessary.
10 Remove the compact thermal module. x
Check the integrity of all combustion circuit seals, especially the burner door seal. Ensure any
11
damage found is repaired before proceeding.
12 Clean the heat exchanger (¬ section 12.3.2). x 13 Check whether the burner is dirty and clean it if necessary. x
Check the condensate trap in the boiler, clean and fill. Flush through all discharge pipe work
14
(ensure route and termination are correct and it is unlikely to freeze up in severe weather).
15 Install the compact thermal module. Caution: Use new seals and nuts! x
For VUW boilers: Replace the hot water heat exchanger if the volume of water is insufficient
16
or the output temperature is not reached For VUW boilers: Clean the filter in the cold water inlet. If the contamination can no longer be
removed or the filter is damaged, replace the filter. In this case, also check the impeller sen-
17
sor for dirt and damage, clean the sensor (do not use compressed air for this) and replace the sensor if it is damaged.
18 Service the domestic hot water cylinder (see note below).* x x
Open the gas isolation valve, reconnect the boiler with the power mains and switch on the
19
boiler. Open the service valves and fill up the boiler/appliance to approximately 0,1 - 0,2 MPa (1,0 -
20
2,0 bar) (depending on the static height of the system). Start the purging program P.00. Perform a test operation of the boiler and heating installation, including hot water generation
21
and purge again if necessary.
22 Check visually the ignition and burner performance. x x
Check the boiler for leaks of any kind (gas, flue gas, water, condensate) and rectify as neces-
23
sary. If you had problems with the CO, CO
them again now ( ¬ table 12.1). If they are outside of the tolerances of ¬ table 12.1 make an
24
adjustment, see ¬ section 12.1.4. Complete the Benchmark gas boiler commission service record on the back pages of this
25
manual.
12.2 Inspection and maintenance steps
and CO/CO2. If the values are outside the
2
, CO/CO2-values in Step 6 before the maintenance, check
2
be carried out
each year
xx
xx
xx
xx
x
xx
xx
xx
xx
xx
xx
Column 2
Maintenance
must be car-
ried out at reg-
ular intervals
x
x
x
x
x
x
* Additional checks and procedures will be required where the
boiler is used with a cylinder or solar thermal system. These are not covered in this manual.
Page 55
Inspection and maintenance
12
12.2.1 Filling the boiler and the heating installation
A description of how to fill the boiler and the heating instal­lation is provided in ¬ section 10.5.
12.2.2 Draining the boiler
> Close the service valves of the boiler. > Start test program P.06 (diverter valve mid-position)
(¬ section 10.5).
> Open the drain valves on the service valves. > Make sure that the cap of the automatic air vent on the
internal pump is open so that the boiler can be drained fully.
12.2.3 Draining the entire heating installation
> Attach a hose to the draining device on the system. > Bring the open end of the hose to an appropriate drain
point.
> Start test program P.06 (diverter valve mid-position)
(¬ section 10.5).
> Make sure that the service valves on the boiler and the
cap of the automatic air vent on the internal pump is
open. > Open the drain cock. > Open the purging valves on the radiators.
Start from the highest radiator and then work from the
top to the bottom. > Once the water has drained off, close the purging valves
of the radiators and the drain cock.
The compact thermal module consists of five main compo­nents:
1. Speed-regulated fan
2. Gas/air mixture fitting
3. Gas supply (mixture pipe) to the premix burner
4. Burner door
5. Premix burner
> Switch off the boiler using the on/off switch. > Close the gas isolator cock on the boiler. > Close the service valves on the boiler. > Remove the front casing from the boiler (¬ section 4.7). > Fold the electronics box forwards (¬ section 8.2).
1
2
3
4
12.3 Remove the air intake pipe
> Unscrew the retaining screw (2, ¬ fig. 12.3) and detach
12.3 Carrying out maintenance work
12.3.1 Removing the compact thermal module
the air intake pipe (1, ¬ fig. 12.3) from the intake stub.
> Unscrew either the cap nut (3, ¬ fig. 12.3) from the gas
valve or the cap nut (4, ¬ fig. 12.3) between the gas pipes.
> Secure the gas pipe against twisting by holding the pipe
against the spanner flat when undoing the cap nut.
Danger!
Risk of being burned or scalded by hot
a
components!
There is danger of being burned or scalded at the compact thermal module and at all water-carrying components.
> Only carry out work on these compo-
nents if they have cooled down.
Installation and maintenance instructions ecoTEC 0020173113_01 55
Page 56
Inspection and maintenance
12
> Remove the compact thermal module (¬ section 12.3.1).
1
7
6
5
4
12.4 Removing the compact thermal module
The plug on the fan motor has a latching lug
with which it engages in the slot. You have to
i
> Remove the plug of the ignition line (5, ¬ fig. 12.4) and
the ground connection (6, ¬ fig. 12.4) from the ignition
electrode. > Remove the plug (3, ¬ fig. 12.4) from the fan motor. > Remove the plug from the gas valve (4, ¬ fig. 12.4). > Unscrew the four nuts (7, ¬ fig. 12.4). > Remove the entire compact thermal module (2,
¬ fig. 12.4) from the heat exchanger (1, ¬ fig. 12.4). > Once removed, check the burner and the heat exchanger
for damage and dirt. > If necessary, clean the components according to the fol-
lowing sections. > Check the burner flange insulation on the module. If
signs of damage, other than small cracks, are apparent
you must replaced it (article number 193 595).
release the latching lug by pushing it in to pull off the plug.
2
3
1
12.5 Cleaning the heat exchanger
Caution.
Risk of damage to the heat exchanger.
b
> Clean the heating coil (3) of the heat exchanger (4)
using water or if required commercially-available white vinegar.
> Allow the vinegar to act on the heat exchanger for
20 minutes.
> Rinse away any loose dirt with a sharp jet of water or
use a plastic brush.
> Do not point the water jet directly at the insulating sur-
face (2) on the back of the heat exchanger.
The water flows out of the heat exchanger through the con­densate trap.
12.3.3 Checking the burner
> You should neither loosen nor tighten
the four screws (1).
2
3
4
1
12.3.2 Cleaning the heat exchanger
Caution.
Risk of damage from water spray.
b
If you fail to protect the electronics box adequately, water can penetrate the box during cleaning and may damage the elec­tronics.
> Protect the folded down electronics box
against sprayed water.
12.6 Checking the burner
Page 57
As the burner (1) is maintenance-free, it does not require cleaning.
> Check the surface of the burner for damage. > If necessary, replace the burner.
12.3.4 Cleaning the condensate trap
Inspection and maintenance
12
a
Danger!
Risk of death caused by improper main­tenance.
If you operate the boiler with an empty condensate trap, flue gas can escape into the room air.
> Top up the condensate trap after each
cleaning session.
1
1
12.8 Removing the filter from the cold water inlet
> Close the cold water stop valve. > Drain the hot water from the boiler. > Undo the nut (1, ¬ fig. 12.8) of the cold water supply line
from the casing of the boiler.
1
12.7 Cleaning the condensate trap
> Remove the lower part (1) of the condensate trap by
turning the bayonet fitting anti-clockwise. > Clean the bottom of the condensate trap by flushing it
out with water. > Fill the lower part of the condensate trap with water up
to about 10 mm below the upper edge. > Re-fit the lower part of the condensate trap. > Flush through all discharge pipe work (ensure route and
termination are correct and it is unlikely to freeze up in
severe weather).
12.3.5 Cleaning the filter in the cold water inlet (VUW boilers only)
There is a filter in the cold water inlet of the boiler which must be cleaned during maintenance work.
Installation and maintenance instructions ecoTEC 0020173113_01 57
2
12.9 Removing the pipe with the cold water filter
> Fold the electronics box forwards (¬ section 8.2). > Remove the clamp (1, ¬ fig. 12.9) from the flow sensor. > Pull off the cold water pipe from the flow sensor. > Remove the pipe (2, ¬ fig. 12.9) from the boiler. > Rinse the filter under a jet of water holding against the
direction of flow. > Refit the pipe with the cleaned filter in the reverse order. > Always use new seals.
Page 58
Inspection and maintenance
12
12.3.6 Installing the compact thermal module
Danger!
Risk of death and risk of damage caused
a
by hot flue gas!
If you do not renew the seal and the self­locking nuts on the burner door, hot flue gases may escape and cause personal injury and material damage.
> Replace the seal each time you open the
burner door.
> Replace the self-securing nuts each time
you open the burner door.
> If the burner flange insulation on the
module shows signs of damage other than small cracks it must be replaced (article number 193 595).
10
9
12.11 Secure the gas pipe against twisting
> Tighten either the cap nut (6, ¬ fig. 12.10) on the gas
valve or the cap nut (7, ¬ fig. 12.10) between the gas
pipes. Use a new seal for this. > Secure the gas pipe against twisting (¬ fig. 12.11) by
holding the pipe against the spanner flat when tighten-
ing the cap nut. > Open the gas isolator cock on the boiler and ensure
there are no leaks. > Check that the sealing ring in the air intake pipe is posi-
1
2
3
4
tioned correctly in the seal seat. > Insert the air intake pipe (1, ¬ fig. 12.3) back into the
intake stub. > Attach the air intake pipe using the retaining screw (2,
¬ fig. 12.3).
8
7
12.10 Installing the compact thermal module
> Attach the compact thermal module (4, ¬ fig. 12.10) to
the heat exchanger (1, ¬ fig. 12.10).
> Tighten the four nuts (3, ¬ fig. 12.10) crosswise until the
burner door fits closely and uniformly onto the mating surfaces (If a torque spanner is available, set at 6Nm).
> Attach the plug of the ignition line (10, ¬ fig. 12.10) and
the ground connection (9, ¬ fig. 12.10) to the ignition electrode.
> Attach the plug (5, ¬ fig. 12.10) to the fan motor. > Attach the plug (8, ¬ fig. 12.10) to the gas valve.
12.3.7 Checking the charge pressure of the
5
6
12.12 Checking the charge pressure of the expansion vessel
The service valves of the boiler must be closed.
expansion vessel
> Measure the charge pressure of the expansion vessel at
the testing nozzle (1) of the vessel with the boiler depres-
surised. > Top up the expansion vessel at a pressure of less than
0.75 bar in accordance with the static height of the heat-
1
Page 59
ing installation, ideally with nitrogen, otherwise with air. Ensure drain valve on boiler is open during topping up.
> If water escapes from the measuring stub pipes (1) of the
expansion vessel, you must replace the expansion vessel.
12.4 Checking the gas flow pressure
> Check the gas flow pressure (¬ section 10.10).
12.4.1 Checking CO2 content
> Check the CO2 content (¬ section 12.1.3).
Inspection and maintenance
12
Installation and maintenance instructions ecoTEC 0020173113_01 59
Page 60
Troubleshooting
13
13 Troubleshooting
13.1 Contact Vaillant Service Solutions (0870 6060 777)
> If you contact Vaillant Service Solutions (0870 6060
777) or your Vaillant service partner, if possible, please mention
– the fault code displayed (F.xx), – the boiler status that is displayed (S.xx) in the "Live
monitor" (¬ section 13.2.1).
13.2 Performing diagnostics
13.2.1 Calling up Live Monitor (status codes)
You can call up the boiler status codes in the display which provide information on the current operating status of the boiler.
> Press the left-hand
buttons
("i") at the same time
and right-hand selection
S.04
13.1 Status code display view
13.2.2 Status codes – Overview
Display Meaning
Heating mode S.00 Heating, no heat demand S.01 Heating mode fan start-up S.02 Heating mode pump flow S.03 Heating mode, ignition S.04 Heating mode, burner on
S.05 Heating mode, pump/fan overrun S.06 Heating mode, fan overrun S.07 Heating mode, pump overrun S.08 Heating mode, burner anti-cycling time
13.1 Status codes
13.2.3 Status codes – Overview
Display Meaning
DHW mode (VUW boiler) S.10 Hot water demand via impeller sensor S.11 DHW mode, fan start-up S.13 DHW mode, ignition S.14 DHW mode, burner on S.15 DHW mode, pump/fan overrun S.16 DHW mode, fan overrun S.17 DHW mode, pump overrun DHW mode, (VU boiler with cylinder or VUW comfort mode warm
start) S.20 DHW demand
S.21 DHW mode, fan start-up S.22 DHW mode, pump running S.23 DHW mode, ignition S.24 DHW mode, burner on S.25 DHW mode, pump/fan overrun S.26 DHW mode, fan overrun S.27 DHW mode, pump overrun S.28 Hot water burner anti-cycling time Special cases S.30 Room thermostat (RT) is blocking heating mode S.31 Summer mode active or no heat requirement from eBUS
controller
S.32 Waiting period because of fan speed deviation S.34 Frost protection mode active S.39 "Burner off contact" has triggered (e.g. contact thermo-
stat or condensate pump)
S.40 Comfort safety mode is active: Boiler is running with lim-
ited heating comfort (¬ section 13.2.4)
S.41 Water pressure > 2.8 bar S.42 Flue non-return flap return signal blocks burner opera-
tion (only in connection with VR40 accessory) or con-
densate pump faulty, heat requirement is blocked S.46 Comfort safety mode, flame loss at minimum load S.53 Boiler is in waiting period of modulation block/operation
block function due to water shortage (supply-return
spread too large) S.54 Boiler is in waiting period of operation blocking function
as a result of water shortage (temperature gradient) S.76 System pressure too low; top up water
S.96 Return temperature sensor test running, heating
demands are blocked S.97 Water pressure sensor test running, heating demands
are blocked S.98 Flow/return temperature sensor test running, heating
demands are blocked
13.1 Status codes (continuation)
Page 61
Troubleshooting
13
13.2.4 Service messages
If the "open-end spanner" maintenance symbol appears on the display, a service message is present. The mainte­nance symbol appears if you have set a maintenance inter­val, for example, (¬ section 11.1.6) and it has elapsed. The boiler is not in fault mode but continues to operate.
To obtain more information about the service message:
> Call up the "Live monitor" (¬ section 13.2.1).
13.2.5 Calling up diagnosis levels
You can use the diagnostic codes to view parameters and modify certain parameters (¬ section 9.2) An overview of the diagnostic codes can be found in ¬ table 11.1.
13.2.6 Reading off the fault codes
If a fault develops in the boiler, the display shows a fault code F.xx.
Fault codes have priority over all other displays. If a fault occurs, the display no longer shows the current heating flow temperature of the heating installation. If multiple faults occur at the same time, the display shows the corresponding fault codes for two seconds each in sequence.
13.2.8 Resetting the fault memory
You can delete the entire fault list.
> Call up the installer level (¬ section 9.2). > Set the diagnostic code "D.094" to 1 (¬ section 11.1).
> Remedy the fault. > To restart the boiler, press the fault clearance key
(¬ Operating instructions).
> If you are unable to remedy the fault and the fault reoc-
curs despite having carried out several resets, contact Vaillant Service Solutions (0870 6060 777).
13.2.7 Querying the fault memory
The boiler has a fault memory. ¬ section 9.2 describes how you can call up the fault memory. Here you can query the last ten faults that occurred in chronological order.
The display shows:
– the number of faults that have occurred – the fault currently selected with fault number F.xx.
> You can display the last 10 faults that occurred using the
minus button
or the plus button .
Installation and maintenance instructions ecoTEC 0020173113_01 61
Page 62
Troubleshooting
13
13.2.9 Overview of fault codes
Code Meaning Cause
F.00 Flow temperature sensor interruption NTC plug not plugged in or has come loose, multiple plug on the PCB
F.01 Return temperature sensor interruption NTC plug not plugged in or has come loose, multiple plug on the PCB
F.10 Flow NTC short circuit NTC defective, short circuit in cable harness, cable/casing
F.11 Return NTC short circuit NTC defective, short circuit in cable harness, cable/casing
not plugged in correctly, interruption in cable harness, NTC defective
not plugged in correctly, interruption in cable harness, NTC defective
F.20 Safety switch-off: temperature limiter Incorrect earth connection between cable harness and boiler, flow or
F.22 Safety switch-off: low water pressure No water pressure, or water pressure is too low in the boiler, water pres-
F.23 Safety switch-off: Temperature difference too great Pump blocked, insufficient pump output, air in boiler, flow and return
F.24 Safety switch-off: Temperature rise too fast Pump blocked, poor pump performance, air in boiler, system pressure
F.25 Safety switch-off: Flue gas temperature too high Break in plug connection for optional flue gas safety thermostat (STB),
F.26 Fault: Gas valve without function Gas valve stepper motor not connected, multiple plug on the PCB not
F.27 Safety switch-off: Flame simulation Moisture on the electronics, electronics (flame monitor) defective, gas
F.28 Failure during start-up: ignition unsuccessful Gas meter defective or gas pressure regulator has triggered, air in gas,
F.29 Failure during operation: Re-ignition unsuccessful Gas supply temporarily stopped, flue gas recirculation, condensate duct
F.32 Fan fault Plug at fan not correctly plugged in, multiple plug on PCB not correctly
F.49 eBUS fault Short circuit on eBUS, eBUS overload or two power supplies with differ-
F.61 Fault: Gas valve regulation - Short circuit/short to earth in cable harness for the gas valve
F.62 Fault: Gas valve switch-off delay - Delayed shutdown of gas valve
return NTC defective (loose connection), black discharge via ignition cable, ignition plug or ignition electrode
sure sensor defective, cable to pump or water pressure sensor loose/not connected/defective
NTC interchanged
too low, non-return valve blocks/incorrectly installed
break in cable harness
plugged in correctly, interruption in cable harness, gas valve stepper motor defective, electronics defective
solenoid valve leaking
gas flow pressure too low, thermal isolator device (TAE) has triggered, condensate duct blocked, incorrect gas restrictor, incorrect ET gas valve, fault on the gas valve, multiple plug on PCB incorrectly plugged in, break in cable harness, ignition system (ignition transformer, ignition cable, ignition plug, ignition electrode) defective, ionisation current interrupted (cable, electrode), incorrect earthing of boiler, electronics defective
blocked, faulty earthing of boiler, ignition transformer has spark failure
plugged in, break in cable harness, fan blocked, Hall sensor defective, electronics defective
ent polarities on the eBUS
- Gas valve defective (coils shorted to earth)
- Electronics defective
- Delayed extinguishing of flame signal
- Gas valve leaking
- Electronics defective
F.63 EEPROM error Electronics defective F.64 Electronics/NTC fault Supply or return NTC short circuited, electronics defective F.65 Electronic temperature fault Electronics overheating due to external influences, electronics defective F.67 Electronics/flame fault Implausible flame signal, electronics defective
13.2 Fault codes
Page 63
Troubleshooting
Code Meaning Cause
F.68 Unstable flame signal fault Air in gas, gas flow pressure too low, wrong air ratio, condensate route
F.70 Invalid device specific number (DSN) Spare part case: Display and PCB changed at the same time and appliance
F.71 Flow NTC fault Flow temperature sensor signalling constant value:
F.72 Flow/return NTC fault Flow/return NTC temperature difference too great -> flow and/or return
F.73 Water pressure sensor signal in the wrong range
(too low)
F.74 Water pressure sensor signal outside correct
range (too high)
F.75 Fault, no pressure change detection when start-
ing pump
F.76 Overheating protection on primary heat
exchanger has responded
F.77 Flue non-return flap/condensate pump fault No response from flue non-return flap or condensate pump defective F.78 Interruption to DHW outlet sensor at external
controller
F.83 Flow and/or return temperature sensor tempera-
ture change fault
blocked, wrong gas restrictor, ionisation flow interruption (cables, elec­trodes), flue gas recirculation, condensate route
code not reset
- Flow temperature sensor incorrectly positioned at supply pipe.
- Flow temperature sensor defective.
temperature sensor defective Interruption/short circuit of water pressure sensor, interruption/short cir-
cuit to GND in supply line to water pressure sensor or water pressure sen­sor defective
Cable to water pressure sensor has short-circuited at 5 V/24 V or internal fault in water pressure sensor
Water pressure sensor and/or pump defective, air in heating installation, too low water pressure in boiler; check adjustable bypass, connect external expansion vessel to return
Cable or cable connections for safety fuse in primary heat exchanger or primary heat exchanger defective
UK link box is connected, but hot water NTC not bridged
When the burner starts, the temperature change registered at flow and/or return temperature sensor is non-existent or too small.
- Not enough water in the boiler
- Flow and/return temperature sensor not in correct position at pipe.
13
F.84 Fault: Flow/return temperature sensor tempera-
F.85 Fault: Flow and return temperature sensors incor-
connec­tion
13.2 Fault codes (continued)
ture difference implausible
rectly fitted No communication with the PCB Communication fault between display and PCB in the electronics box
Flow and return temperature sensors returning implausible values.
- Flow and return temperature sensors have been inverted.
- Flow and return temperature sensors have not been correctly fitted. Flow and/or return temperature sensors
have been fitted to the same pipe/wrong pipe.
13.3 Running test programs
By activating various test programs, you can trigger special functions on the boiler (¬ table. 10.1). The display shows which test program you have chosen.
> Read how to start the test programs in ¬ section 10.2.
13.4 Resetting parameters to factory settings
As well as the option to manually reset individual parame­ters to the default settings specified in ¬ table 11.1, you can also reset all parameters at once.
> Set the value of the diagnosis code parameter D.096 to
"1" (¬ section 11.1).
You have now reset all parameters to factory settings.
Installation and maintenance instructions ecoTEC 0020173113_01 63
Page 64
Replacing components
14
14 Replacing components
The work described in this section must only be carried out by a competent person.
> Only use genuine Vaillant spare parts for repairs . For an overview of the available original Vaillant spare parts, contact the Vaillant sales office on 0870 6060 777.
14.1 Preparing for and completing replacement
work
14.1.1 Preparing for replacement work
Danger!
Risk of death from electric shock!
e
Mains connection terminals L and N remain live even if the continuous voltage on/off switch is turned off.
> Before carrying out maintenance work
on the boiler, switch the boiler off using the on/off button.
> Disconnect the boiler from the power
mains by disconnecting the mains plug or by de-energising the boiler via a parti­tion with a contact opening of at least 3 mm (e. g. fuses or power switches).
14.2 Replacing the burner
> Remove the compact thermal module (¬ section 12.3.1).
1
14.1 Replacing the burner
> Undo the four screws (1) on the burner. > Remove the burner. > Fit the new burner with a new seal. Make sure that the
nose on the burner window grips the seal inside the recess in the burner.
> Reinstall the compact thermal module.
(¬ Section 12.3.6).
When carrying out any repair to the boiler, make
sure that you observe the following instructions
i
> Switch off the boiler.
> Disconnect the boiler from the power mains (¬ sec-
tion 11.3).
> Remove the front casing (¬ section 4.7).
> Close the gas isolator cock.
> Close the service valves in the heating flow and in the
heating return. > Close the service valve in the cold water pipe. > Drain the boiler if you want to replace components that
carry water (¬ section 11.3.2). > Make sure that water does not drip on live components
(e.g. the electronics box). > Use only new seals and O-rings.
14.1.2 Completing replacement work
> Check the boiler for gas leaks. > Reattach the front casing (¬ section 4.7). > Perform a function check (¬ section 10.13).
for your own safety and to avoid material dam­age to the boiler.
14.3 Replacing the fan or the gas valve
1
2
3
4
5
6
7
8
14.2 Removing/refitting the fan/gas valve unit
> Remove the air intake pipe (¬ section 12.3.1).
Page 65
> Remove the plug from the gas valve (7, ¬ fig. 14.2).
The plug on the fan motor has a latching lug
with which it engages in the slot. You have to
i
> Remove the plug (6, ¬ fig. 14.2) from the fan motor. > Unscrew either the cap nut (2, ¬ fig. 14.3) from the gas
valve or the cap nut (8, ¬ fig. 14.2) between the gas
pipes. > Secure the gas pipe against twisting by holding the pipe
against the spanner flat when undoing the cap nut. > Unscrew the three screws (2-4, ¬ fig. 14.2) between the
mixture pipe (1, ¬ fig. 14.2) and the fan flange.
release the latching lug by pushing it in to pull off the plug.
Replacing components
14.4 Secure the gas pipe against twisting
> Tighten the cap nut (2, ¬ fig. 14.3) on the gas valve and
the cap nut (8, ¬ fig. 14.2) between the gas pipes. Use new seals.
> Secure the gas pipe against twisting (¬ fig. 14.4) by
holding the pipe against the spanner flat when tighten­ing the cap nut.
> After completing the work, perform a gas-tightness
check and function check (¬ section 10.13).
> If you have fitted a new gas valve, adjust the gas setting
(¬ section 10.10).
14
1
2
14.3 Removing the gas valve from the fan
> Remove the entire fan/gas valve unit from the boiler. > If you want to replace the gas valve, unscrew the cap nut
(2, ¬ fig. 14.3) if the gas pipe is still secured to the gas
valve. > Unscrew the two fixing screws (1, ¬ fig. 14.3) from the
gas valve and remove the fan from the gas valve. > Replace the defective fan or the defective gas valve. > Fit the gas valve and the fan in the same position as
before. Use new seals. > Screw the fan to the gas valve. > If you had replaced the gas valve, screw the cap nut of
the gas pipe (2, ¬ fig. 14.3) only loosely to the gas valve.
Only tighten the cap nut on the gas valve after complet-
ing the installation work. > Refit the entire fan/gas valve unit in reverse order. You
must use a new seal for this (5, ¬ fig. 14.2). > Pay attention to the order in which the three screws
between the fan and the mixture pipe are screwed in, as
per the numbering 3, 2 and 4 (¬ fig. 14.2).
14.4 Replacing the expansion vessel
> Drain the boiler (¬ section 12.2.2).
1
2
3
4
14.5 Replacing the expansion vessel
> Loosen the screw connection (4) at the water connec-
tion on the underside of the expansion vessel.
> Remove both screws (1) on the support plate (2). > Remove the support plate (2). > Pull out the expansion vessel (3) from the front. > Insert the new expansion vessel into the boiler. > Screw the new expansion vessel to the water connection.
Use a new seal for this.
> Attach the support plate using both screws (1). > If necessary, adjust the pressure to the static height of
the heating installation (¬ section 12.3.7).
Installation and maintenance instructions ecoTEC 0020173113_01 65
Page 66
Replacing components
14
> Fill and purge the boiler and, if necessary, the system
after installing the new expansion vessel (¬ sec-
tion 10.5). > On completion of the work, check for water leaks.
1
2
14.5 Replacing the heat exchanger
Caution.
Risk of damage to the heat exchanger.
b
> Drain the boiler (¬ section 12.2.2). > Remove the compact thermal module (¬ section 12.3.1). > Detach the condensate discharge hose from the heat
exchanger.
1
2
3
14.6 Replacing the heat exchanger
> Detach the clamps (2, ¬ fig. 14.6) and (3, ¬ fig. 14.6)
from the flow connection and the return connection. > Detach the flow connection from the heat exchanger. > Detach the return connection from the heat exchanger. > Remove two screws (1, ¬ fig. 14.6) from each of the two
brackets of the heat exchanger.
> You can neither loosen nor tighten the
four screws (¬ fig. 14.7, pos. 1).
3
1
14.7 Heat exchanger brackets
> Disconnect the plug connection (2, ¬ fig. 14.7) of the
thermal fuse in the heat exchanger.
> Remove the bottom three screws (3, ¬ fig. 14.7) from
the rear part of the heat exchanger bracket.
> Swivel the bracket around the top screw (1, ¬ fig. 14.7)
to one side.
> Pull the heat exchanger downwards and to the right, and
remove it from the boiler.
Caution.
Risk of damage to the boiler.
b
> Install the new heat exchanger in the reverse order. > Replace the seals. > Insert the flow and return connections into the heat
exchanger as far as they will go.
Mineral oil-based lubricants may damage the seals. The seals should therefore not be lubricated.
> Only use water or commercially available
soft soap, if necessary, to assist with installation.
Make sure that the brackets are seated correctly
on the flow and return connections.
i
> Reinstall the compact thermal module.
(¬ section 12.3.6).
> Fill and purge the boiler and, if necessary, the heating
installation (¬ section 10.5).
Page 67
Replacing components
14
14.6 Replacing the PCB and/or the display
Danger!
Risk of death from electric shock!
e
b
Mains connection terminals L and N remain live even if the continuous voltage on/off switch is turned off.
> Before carrying out repair work on the
boiler, switch the boiler off using the on/ off button.
> Disconnect the boiler from the power
mains by disconnecting the mains plug or by de-energising the boiler via a parti­tion with a contact opening of at least 3 mm (e. g. fuses or power switches).
Caution.
Risk of material damage caused by incor­rect repairs.
Using an incorrect spare part display can cause damage to the electronics.
> Before replacing, check that the correct
spare part display is available.
> ONLY fit the correct spare part display.
The electronics are now set to the appliance type and the parameters of all adjustable diagnosis codes are set to default settings.
> Make the system-specific settings (¬ section 11).
Comply with the assembly and installation
instructions provided with the spare parts.
i
14.6.1 Replacing either the display or the PCB
> Replace the PCB or display according to the assembly
and installation instructions supplied.
If you are replacing only one of the two components (PCB or display), the parametrisation functions automatically. By switching on the boiler, the new component takes over the previously set parameters from the unreplaced component.
14.6.2 Replacing the PCB and the display at the same time
Setting the appliance type
> Set the correct value for the appliance type in accord-
ance with ¬ table 14.1 for diagnostic code D.093.
After confirmation, the display restarts itself automatically.
ecoTEC
22 (VU GB 226/5-3) 16 26 (VUW GB 266/5-3) 16
14.1 Device specific numbers for the appliance types
Device specific
number (DSN)
Installation and maintenance instructions ecoTEC 0020173113_01 67
Page 68
Decommissioning
15
15 Decommissioning
15.1 Temporarily shutting down the boiler
Caution.
Risk of frost damage due to incorrect
b
shutdown.
If you switch off the boiler using the on/off switch or disconnect it from the power mains, this can cause frost damage to the heating installation.
> Only shutdown the boiler fully if the
heating installation is otherwise pro­tected from frost.
> Drain the heating installation fully.
2
50
The boiler and its accessories must not be disposed of with household waste.
> Make sure that the boiler and any existing accessories
are disposed of properly.
16 Guarantee and customer service
16.1 Factory guarantee
One year guarantee for ecoTEC appliances
Vaillant undertakes to rectify any manufacturing defect that occurs within twelve months of the installation date.
Registering with us
Registration is simple. Just complete the Guarantee Regis­tration Card and return to Vaillant within 30 days of instal­lation. Your details will then be automatically registered within the Vaillant scheme. Note: No receipt will be issued.
Immediate help
If your Vaillant boiler develops a fault your first action should be to contact your installer, as his professional assessment is needed under the terms of our Guarantee. If you are unable to contact your installer, phone Vaillant Ser­vice Solutions: 0870 6060 777
1
15.1 Switching off the boiler
> Close the gas isolator cock. > Close the cold water stop valve. > Drain the heating installation fully
(¬ section 12.2.2).
> Press the on/off switch (1).
The display (2) goes off.
15.2 Taking the boiler permanently out of service
> Close the gas isolator cock. > Close the cold water stop valve. > Drain the heating installation fully
(¬ section 12.2.2).
> Press the on/off switch (1).
The display (2) goes off.
> Isolate the boiler from the power mains. > Dispose of the boiler correctly (¬ section 15.3).
15.3 Disposing of the boiler
The Vaillant ecoTEC boiler consists primarily of materials that can be recycled.
16.2 Vaillant Service
To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details.
Page 69
Technical data
17 Technical data
ecoTEC Unit 22 (VU GB 226/5-3) 26 (VUW GB 266/5-3)
Nominal heat output range P at 50/30 °C kW 7.1 - 23.8 Nominal heat output range P at 80/60 °C kW 6.4 - 22.4 Maximum heat output for hot water generation kW 27.2 Maximum heat input for hot water generation kW 27. 8 Maximum heat input at the heating side kW 22.9 Minimum heat input kW 6.8 Heating setting range kW 6 - 22
Heating
Max. flow temperature °C 85 Max. flow temperature setting range(factory setting: 75 °C) °C 30 - 80 Min. pressure for full operation MPa/bar 0.08/0.8 Permissible total over-pressure MPa/bar 0.3/3.0 Expansion vessel capacity l 8 Circulation water quantity (with reference to DT = 20 K) Condensate rate approx. (pH value 3.5 – 4.0)
in heating mode 50 °C supply/30 °C return Remaining feed head of pump (at nominal circulation water
volume)
DHW mode
Lowest water volume l/min - 2 Water volume (at DT = 30 K) Permitted overpressure MPa/bar - 1.0/10.0 Required connection pressure MPa/bar - 0.035/0.35 Hot water output temperature range °C - 35 - 65
General
Boiler-side gas connection mm 15 Flow/return heating connections, boiler side mm 22 Connecting the hot and cold water, boiler side Inches - G 3/4 Connector expansion relief valve (minimum) mm 15 Condensate discharge pipework (minimum) mm 19 Flue gas spigot mm 60/100 (concentric), optional 80/125 (concentric) Gas connection pressure (gas inlet working pressure)
Gas used on the Channel Islands Gas flow rate at 15 °C and 1013 mbar
(based on hot water generation if applicable) Gas used on the Channel Islands
Flue gas mass flow min./max. g/s 4.08/15.70 Flue gas temperature min./max. °C 40/80 Certificated flue gas connections C13, C33, C43, C53, C83, C93, B33(P), B53(P) 30% efficiency 108 NOx class 5 Boiler dimensions (H x W x D) mm 720 x 440 x 372 Mounting weight approx. kg 36.9 38.6 Electrical connection V/Hz 230/50 Built-in fuse 2 A, slow-blow Electrical power consumption min./max. W 35/80 Standby electrical consumption W <2 Level of protection IP X4 D Certification number CE-0085CM0321
17.1 Technical data
l/h 963
l/h 2.3
MPa/bar 0.025/0.25
l/min - 13
kPa/mbar 0.13/13
3
m
/h 4.2
17
Installation and maintenance instructions ecoTEC 0020173113_01 69
Page 70
Glossary
18
18 Glossary
Air/flue gas duct
An air/flue gas duct is a line system with two separate flow channels. The flue gas is routed into separate chambers at the same time as the required combustion air is pumped to the boiler. The air/flue gas duct can be designed as a con­centric or adjacent double flue gas pipe (the flue gas chan­nel is sealed from the air channel). Floor-standing boilers and gas-fired wall-hung boilers can be operated as room­sealed through the air/flue gas duct. As a result, boilers can be installed in new buildings that do not offer sufficient combustion air for open-flued heaters due to their airtight construction.
Burner anti-cycling time
The burner is electronically locked for a specific time after each time it is switched off ("restart interlock") to avoid fre­quent switching on and off of the burner (energy losses) and to extend the working life of the boiler. The burner anti-cycling time is only activated for the heat­ing mode. Hot water handling is not affected if burner anti-cycling time is running.
Calorific value
Unlike the heating value, the calorific value of a fuel describes the total useable heat during combustion, based on the quantity of fuel used, including the condensation heat in the steam. The energy contained in steam can also be used if the steam liquefies on cooling.
Digital information and Analysis system (DIA)
The Vaillant ecoTEC boiler is fitted with a digital informa­tion and analysis system (DIA). If additional settings are required, which have not been configured using the installa­tion assistant, you can view and modify further parameters using the DIA.
eBUS
eBUS is an abbreviation for energyBUS. The eBUS is a spe­cial bus used in heating technology, which assists the com­munication between intelligent components in the heating technology. In a Vaillant system, up to eight different heat­ers can be connected via the eBUS. The eBUS communications protocol simplifies the control­related linking of different system components within a heating installation. It provides particular flexibility for ret­rofitting and expanding the system. This simplifies the installation of boiler cascades or the subsequent addition of components such as solar hot water generation. The eBUS provides extended facilities for connecting con­trollers.
Multi-functional module
The multi-functional module is an accessory that controls additional functions or components in combination with Vaillant boilers with eBUS electronics. It also allows you to select and control 2 in 7, e. g. circulation pump, external heating pump, external solenoid valve or response from the flue non-return flap.
Compact thermal module
The compact thermal module is an assembly of Vaillant condensing units that consists of the following four main components in the ecoTEC: speed-regulated fan, gas-air mixture fitting, gas supply (mixture pipe) for the premix burner and premix burner
Condensing technology
Technology which maximises the use of the calorific value of the fuel. The flue gas is cooled until the water vapour that it contains condenses. The condensation heat that this releases can also be used. In particular, the flue gas losses are greatly reduced. The losses from conduction of heat and radiation are also reduced by the lower system temperatures. The entire heat­ing installation should therefore be designed for low system temperatures (flow/return temperature) for the effective use of the calorific value. The level of efficiency attainable for boilers is always given based on the heating value of the gas. Due to the additional condensation heat used, the cal­culated values can exceed 100 %.
Page 71
19 Appendix
Installation,
Commissioning and
Appendix
19
Service Record
Installation and maintenance instructions ecoTEC 0020173113_01 71
Page 72
Appendix
20
Please affix the label from the
rear cover of the control box
over this area.
Page 73
0020008345-06
SERVICE INTERVAL RECORD
21
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below .
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service
as described in the boiler manufacturer ’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.
SERVICE 1 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 3 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 5 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
SERVICE 2 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 4 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 6 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 7 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 9 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Installation and maintenance instructions ecoTEC 0020173113_01 73
Signature
Yes No
Signature
SERVICE 8 Date
Energy Efficiency Checklist completed? Yes No
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
SERVICE 10 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
Engineer ID Number
Comments
Signature
Yes No
Page 74
Index
Index
A
Accessories.................................................................................... 12
Air/flue gas duct .................................................................. 25, 70
Air/flue system ............................................................................ 25
Article numbers ............................................................................ 4
B
Burner ............................................................................................ 56
Burner anti-cycling time ............................................. 47, 60, 70
C
Calorific value .............................................................................. 70
Checking
Burner ...................................................................................... 56
Expansion vessel charge pressure .................................... 58
Function of boiler ................................................................... 41
Gas flow rate ............................................................................ 41
Heating mode ......................................................................... 42
Leaks ......................................................................................... 41
Scope of delivery .................................................................... 12
Circulation pump................................................................... 31, 44
Commissioning ............................................................................ 35
Compact thermal module .................................................. 55, 70
Condensate discharge pipework ............................................. 23
Condensate trap ................................................................... 38, 57
Condensing technology ............................................................. 70
Connecting
Cold and hot water ................................................................ 22
Condensate discharge pipework ........................................ 23
Controller................................................................................. 30
Flow and return ...................................................................... 22
Gas line .................................................................................... 20
Multi-functional module ........................................................ 31
Connection diagram ................................................................... 32
Connection measurements ....................................................... 17
Customer service ........................................................................ 68
E
eBUS .............................................................................................. 70
F
Fault codes ............................................................................. 61, 62
Fault memory ................................................................................ 61
Filling
Condensate trap .................................................................... 38
Heating installation ............................................................... 36
Hot water system ................................................................... 37
Filling pressure ............................................................................ 36
Fitting
Boiler ......................................................................................... 18
Controllers ............................................................................... 30
Front casing ............................................................................. 18
Side panel ................................................................................. 19
Flue gas system ........................................................................... 25
Frost protection ............................................................................ 10
G
Gas flow rate ................................................................................. 41
H
Heating mode .............................................................................. 42
Heating water
Preparation ............................................................................... 9
I
Installation clearance .................................................................. 15
Installation site ........................................................................ 8, 15
Installation template ................................................................... 15
Installer level ................................................................................ 34
D
Diagnosis codes..................................................... 43, 44, 45, 46
DIA system.................................................................................... 70
Disposal
Boiler ........................................................................................ 68
Packaging ................................................................................. 13
Domestic hot water cylinder ............................................. 46, 54
Draining
Boiler ........................................................................................ 55
Heating installation ............................................................... 55
L
Low loss header .......................................................................... 23
M
Mains connection ........................................................................ 29
Manufacturer’s guarantee ........................................................ 68
Minimum clearance ..................................................................... 15
Multi-functional module ............................................................ 70
Page 75
Index
O
Overview
Inspection and maintenance work .................................... 54
Parameters ............................................................... 44, 45, 46
Read-off and setting options .............................................. 34
Status codes ........................................................................... 60
P
Preparing
Electrical installation ............................................................ 29
Gas installation ...................................................................... 20
Hydraulic installation ............................................................. 21
Pump operating mode ........................................................ 44, 47
Pump overrun .............................................................................. 47
Purge
Heating installation ................................................................ 37
R
Removing
Burner ...................................................................................... 64
Compact thermal module .................................................... 55
Display ...................................................................................... 67
Fan ............................................................................................. 64
Front casing ............................................................................. 18
Heat exchanger ...................................................................... 66
PCB ........................................................................................... 67
Side panel ................................................................................. 19
Repair ............................................................................................ 64
Replacement parts ..................................................................... 64
Reset ............................................................................................... 61
T
Test programs .............................................................................. 35
Type overview ................................................................................. 5
W
Water pressure ...................................................................... 37, 60
Water pressure sensor ................................................. 37, 60, 62
Wiring diagram ............................................................................ 32
S
Setting
Burner anti-cycling time ...................................................... 47
By-pass valve .......................................................................... 48
Heating partial load .............................................................. 47
Maintenance interval ............................................................ 48
Maximum flow temperature ................................................ 47
Pump operating mode .......................................................... 47
Pump overrun ......................................................................... 47
Return flow temperature control....................................... 47
Unit type .................................................................................. 67
Status codes................................................................................. 60
75Installation and maintenance instructions ecoTEC 0020173113_01
Page 76
Supplier
Manufacturer
0020173113_01 Channel Islands 082013 – Subject to change
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