How it Works
Vaillant
Loading...
E
F
G
H
I
M
Loading...
Loading...
ecoTEC VU 466/4

Vaillant ecoTEC VU 466/4 Installation And Maintenance Instructions Manual

For the heating engineer
Installation and maintenance instructions
ecoTEC
Gas fired wall hung high efficiency boiler
VU 466/4
GB
Contents
Contents
1 Notes on the documentation ........................... 3
1.1 Storage of documents ............................................. 3
1.2 Safety instructions and symbols ........................... 3
1.3 Validity of the instruction manual ........................ 3
2 Description of the boiler .................................. 4
2.1 Design .......................................................................... 4
2.2 Type summary ........................................................... 5
2.3 CE label ........................................................................ 5
2.4 Intended use ............................................................... 5
2.5 Identification plate .................................................... 5
3 Safety instructions and regulations .............. 5
3.1 Safety instructions ................................................... 5
3.1.1 Installation and setting ............................................ 5
3.1.2 Gas odour .................................................................... 5
3.1.3 Changes to the surroundings of the boiler ........ 6
3.1.4 Important information regarding
propane-fired appliances ........................................ 6
3.2 General requirements .............................................. 6
3.2.1 Related documents ................................................... 6
3.2.2 Installation site .......................................................... 6
3.3 Air/flue gas duct ....................................................... 7
3.3.1 Standard 125 mm air/flue gas duct ...................... 7
3.3.2 Flue termination ........................................................ 7
3.4 Air supply .................................................................... 9
3.5 Compartment ventilation ........................................ 9
3.6 Electrical supply ........................................................ 9
4 Assembly ........................................................... 10
4.1 Scope of delivery ...................................................... 10
4.2 Accessories ................................................................. 10
4.3 Installation site .......................................................... 10
4.4 Dimension drawing and connection
dimensions .................................................................. 11
4.5 Required minimum gaps/installation
clearances ................................................................... 12
4.6 Using the installation template ............................. 12
4.7 Mounting the boiler .................................................. 12
4.8 Removing/attaching the front casing .................. 13
5 Installation ......................................................... 13
5.2 Cylinder charging mode .......................................... 15
5.3 Heating mode and cylinder charging mode ....... 16
5.4 Gas connection .......................................................... 17
5.5 Heating connection .................................................. 17
5.6 Expansion relief valve (safety group),
heating installation ................................................... 18
5.7 Condensate drainage pipework ............................. 18
5.8.1 Mains connection ...................................................... 19
5.8.3 Connecting a low loss header sensor .................. 21
5.8.4 Additional relay (grey plug on the PCB)
and VR40 - "2 in 7“ multifunctional module ..... 21
5.8.5 Wiring diagrams......................................................... 22
6 Start-up .............................................................. 24
6.1 Water circulation system ........................................ 24
6.2 Filling the system ...................................................... 24
6.2.1 Preparation of heating water ................................ 24
6.2.2 Filling and bleeding from the heating side ......... 24
6.3 Checking the gas setting ......................................... 26
6.3.1 Checking for tightness of the flue gas
installation and flue gas recirculation ................. 26
6.3.2 Checking the gas flow rate ..................................... 27
6.3.3 Checking the gas inlet working pressure ............ 27
6.4 Checking the appliance function ........................... 28
6.4.1 Heating ........................................................................ 28
6.4.2 Cylinder charging ...................................................... 29
6.5 Handing over the boiler to the operator ............ 29
6.6 Vaillant warranty....................................................... 29
7 Adapting the boiler to the
heating installation ........................................... 30
7.1 Selection and setting of parameters ................... 30
7.2 Overview of adjustable system parameters ...... 30
7.2.1 Setting the heating partial load ............................ 32
7.2.2 Setting of pump overrun and pump
operating mode ......................................................... 32
7.2.3 Setting of maximum flow temperature ............... 32
7.2.4 Setting of burner anti-cycling time ...................... 32
7.2.5 Determination of maintenance
interval/maintenance display ................................ 33
8 Inspection and maintenance ........................... 34
8.1 Inspection and maintenance intervals ................. 34
8.1.1 General inspection and maintenance
instructions ................................................................. 34
8.1.2 Safety instructions ................................................... 35
8.1.3 Checking the CO
8.1.4 Adjusting the CO
concentration ........................... 35
2
concentration
2
(or the air ratio)......................................................... 36
.8.1.5 Inspection and maintenance work steps............. 37
8.2 Filling/draining the boiler and
heating installation ................................................... 38
8.2.1 Filling the boiler and the heating installation .... 38
8.2.2 Draining of the boiler ............................................... 38
8.2.3 Draining the entire system ..................................... 38
Installation and maintenance instructions ecoTEC 0020029172_032
Contents
Notes on the documentation 1
8.3 Maintenance of the compact thermal module .. 38
8.3.1 Dismounting the compact thermal module ........ 38
8.3.2 Cleaning the heat exchanger ................................. 39
8.3.3 Checking the burner ................................................. 39
8.3.4 Installing the compact thermal module .............. 40
8.4 Cleaning the condensate siphon ........................... 40
8.6 Cleaning the air separation system ..................... 41
8.6.2 Cleaning the air separator ...................................... 41
8.7 Checking the charge pressure of the external ex-
pansion vessel ............................................................ 41
8.8 Checking gas connection pressure (gas inlet
working pressure) ..................................................... 42
8.9 Checking the CO
8.10 Test operation............................................................ 42
9 Troubleshooting ................................................ 42
9.1 Diagnostics ................................................................. 42
9.1.1 Status codes ............................................................... 42
9.1.3 Fault messages .......................................................... 46
9.2 Check programs ........................................................ 48
9.3 Resetting parameters to factory settings .......... 48
10 Replacing components ..................................... 49
10.1 Safety instructions ................................................... 49
10.2 Replacing the burner ............................................... 49
10.3 Replacing the fan or the gas valve...................... 49
10.4 Replacing the heat exchanger ............................... 50
10.5 Replacing PCB and display ..................................... 51
concentration .......................... 42
2
Other applicable documents and service auxiliaries
• Always observe all installation instructions for
structural parts and components of the system when installing the ecoTEC VU. 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.
Auxiliary service equipment:
The following test and measuring equipment is required for inspection and maintenance:
measuring instrument
– CO
2
– U tube manometer or digital
The manuals for any accessories and controllers used also apply.
1.1 Storage of documents
Please pass on these installation and maintenance instructions and all other applicable documents to the operator of the installation who is responsible for keeping these documents for future reference when required.
1.2 Safety instructions and symbols
Please observe the safety instructions in this manual for the installation of the appliance! The symbols used in the manual are explained below:
Danger!
d
Immediate risk of serious injury or death!
11 Vaillant Service ................................................. 51
12 Recycling and disposal ..................................... 51
12.1 Boiler ............................................................................ 51
12.2 Packaging .................................................................... 51
13 Technical data ................................................... 52
Benchmark gas boiler commissioning checklist ......54
1 Notes on the documentation
The following instructions are intended to help you throughout the entire documentation. Further documents apply in combination with this installation and maintenance manual. We accept no liability for any damage caused by non-observe these instructions.
Danger!
e
Danger of death by electric shock!
Danger!
H
Danger of burning or scalding!
Caution!
a
Potentially dangerous situation for the product and environment!
Note!
h
Useful information and instructions.
• Symbol for a necessary task
1.3 Validity of the instruction manual
These installation instructions apply exclusively to the boiler with the following part number:
Type designation Article number
ecoTEC VU GB 466/4-5 H 00 1000 4139
Table 1.1 Type designation and article number
The article number of the boiler can be found on the identification plate.
3Installation and maintenance instructions ecoTEC 0020029172_03
2 Description of the boiler
2 Description of the boiler
2.1 Design
15
1
2
14
13
12
11
10
9
3
4
5
6
7
8
Fig. 2.1 Functional components
Legend:
1 Connection for the air/flue gas duct 2 Heat exchanger 3 Compact thermal module 4 Flow rate sensor 5 Fan 6 Water pressure sensor 7 Pump 8 Connection for expansion vessel 9 Connection for expansion relief valve 10 Electronic box 11 Air separation system 12 Automatic air vent 13 Gas valve 14 Ignition electrode 15 Air intake pipe
Note!
h
When using accessories observe the minimum gaps/mounting clearances (see Chapter 4.5).
Installation and maintenance instructions ecoTEC 0020029172_034
2.2 Type summary
Description of the boiler 2
Safety instructions and regulations 3
Boiler type Designated country
ecoTEC VU GB 466/4-5 H GB (Great Britain)
Table 2.1 Type summary
2.3 CE label
CE labelling shows that the appliances comply with the basic requirements of the following directives: – Gas appliances directive (90/396/EEC) – Electromagnetic compatibility directive (Guideline
89/336/EEC of the council) – Low voltage directive (Council Directive 73/23/EEC) – Effectivity guideline (Council Directive 92/42/EEC) as
condensing boiler.
Note!
h
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 handing-over to the operator of the installation.
(designation in accord­ance with ISO 3166)
IE (Eire)
Category of permit Type of gas Nominal heat output range P
II
2H3P
(kW)
Natural gas H - G 20 - 20 mbar Propane - G 31 - 37 mbar
Intended use also includes observance of the operating and installation manual and the inspection/maintenance conditions.
Caution!
a
Any form of misuse is prohibited.
2.5 Identification plate
The data badge of the Valliant ecoTEC is attached at the factory to the bottom of the boiler.
12.3 – 44.1 (80/60 °C)
12.5 – 45.0 (60/40 °C)
12.9 – 46.4 (50/30 °C)
13.3 – 47.7 (40/30 °C)
3 Safety instructions and regulations
3.1 Safety instructions
3.1.1 Installation and setting
Installation, adjustments and maintenance and repairs to the boiler may only be carried out by a recognised skilled trade company.
2.4 Intended use
The Vaillant ecoTEC boiler has been constructed using state-of-the-art technology in accordance with recognised safety 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 intended for use by persons (including children) having limited physical, sensory or mental capacities or who have inadequate experience and/or knowledge, unless supervised by a person responsible for their safety or who has been given instructions from them as to how to operate the boiler. Children must be watched to ensure that they do not play with the boiler. The boiler is intended for use as a heater in closed hot water central heating installations. Any other or additional use is considered to be improper. The manufacturer/supplier will not be held liable for claims resulting from improper use. The operator alone bears the risk.
Caution!
a
To tighten or loosen screw connections, only use suitable open-ended spanners (do not use pipe spanners, extensions, etc.). Improper use or unsuitable tools can cause damage, such as gas or water leaks.
3.1.2 Gas odour
If you smell gas, the following safety instructions must be observed:
• Open doors and windows wide, provide for ventilation, stay out of rooms where smell of gas is present!
• Avoid naked flames, do not smoke, do not use pocket lighters!
• Do not use electric switches, plugs, doorbells, telephones and other communication systems in the building!
• Close gas meter isolator device or main isolator device!
• Warn other building residents, but do not ring doorbells!
• Vacate the building!
• If a gas leak is audible, immediately leave the building, prevent others from entering the building, notify the police and fire brigade from outside the building!
• Notify the gas supply company or National Grid Transco 0800 111999 by telephone from outside the building!
5Installation and maintenance instructions ecoTEC 0020029172_03
3 Safety instructions and regulations
3.1.3 Changes to the surroundings of the boiler
Changes may not be made to the following equipment: – the heating appliance, – gas, supply air, water and power lines– flue gas
removal system, – drain line and expansion relief valve for heating water, – constructional conditions that could affect the
operational reliability of the boiler.
3.1.4 Important information regarding
propane-fired appliances
Bleeding the liquid gas tank when installing the system: before installing the appliance, make sure that the gas tank has been bled. The liquid gas supplier is responsible for proper ventilation of the tank. Ignition problems can result if the tank is not bled properly. In such cases, first contact the person in charge of filling the tank.
Note!
h
Also observe the information on conversion to liquid gas in Chapter 6.3 of this manual.
Caution!
a
If the incorrect type of gas is used this cause ignition and combustion noise and fault shutdowns! Only use propane gas G 31.
3.2 General requirements
3.2.1 Related documents
The installation of the boiler must be in accordance with the relevant requirements of Gas Safety (Installation and Use) Regulations 1998, Health and Safety Document No. 635 (The Electricity at Work Regulations 1989), BS7671 (IEE Wiring Regulations) and the Water Supply (Water Fitting) Regulations 1999, or The Water Bylaws 2000 (Scotland). It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, The Building Regulations (Scotland). The Building Regulations (Northern Ireland) and the relevant recommendations of the following British Standards: BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired
boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises (2
BS 7593: Treatment of water in domestic hot water
central heating installations.
Institute of Gas Engineers Publication IGE/UP/7/1998: „Guide for gas installations in timber framed housing” BS. 5482 Pt. 1 Domestic butane and propane gas
burning installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
nd
family gas).
IGE/UP2 Gas installation pipework, boosters and
compressors on industrial and commercial premises. IGE/UP10 Installation of gas appliances in industrial and commercial premises.
BS. 6644 Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW
nd
and 3rd family gases).
(2
BS. 5449 Forced circulation hot water central heating
installations for domestic premises. Note: only up to 45 kW.
BS. 6880 Low temperature hot water heating
installations of output greater than 45 kW. Part 1 Fundamental and design considerations. Part 2 Selection of equipment. Part 3 Installation, commissioning and maintenance.
BS. 4814 Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating installations.
BS. 5440 Installation and maintenance of flues and
ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2 family gases). Part 2 Specification for installation of flues. Part 3 Specification for installation and maintenance of ventilation for gas appliances.
3.2.2 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. 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.
Note!
h
Where a room sealed boiler is installed in a room containing a bath or shower, any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be touched by a person using the 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.
nd
and 3rd
Installation and maintenance instructions ecoTEC 0020029172_036
Safety instructions and regulations 3
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.
Note!
h
If the boiler is to be installed in a timber framed building, it should be fitted in accordance with "IGE/UP/7 Edition 2 Gas installations in timber framed and light steel framed buildings".
3.2.3 Gas supply
The gas supplier should ensure the availability of sufficient gas flow rate. A gas meter may only be connected to the service pipe by the supplier of gas or their contractor. An existing meter should be checked to ensure that it is capable of passing the rate of gas supply required. Installation pipes should be fitted in accordance with BS 6891, in IE 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 for lacks of tighness and bled as described in BS 6891.
3.3 Air/flue gas duct
Danger!
d
Vaillant appliances are only system-certified if genuine Vaillant air/flue gas ducts are used. Only use genuine Vaillant air/flue gas ducts. Malfunctions can occur if you use other accessories. These may result in damage and injury. You will find a list of genuine air/flue gas ducts in the Vaillant installation manual for air/flue gas ducts. The CE mark is valid only if the appliance is operated with Vaillant air/flue gas ducts.
Only for commercial appliances: For installations in cascade arrangement using the appliance type B23p a common non-Vaillant flue system serving more than one appliance shall be used. The requirements of the flue installation instructions must be met.
1103
15
70
70
Fig. 3.1 Item No. 303 209
1530
880
70
Fig. 3.2 Item No. 303 200
3.3.2 Flue termination
The following details refer to both flue systems. a. The terminal must be positioned such that the
products 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).
Note!
h
Vertical flues must not terminate within 600 mm of an openable window, air vent or any other ventilation terminal.
3.3.1 Standard 125 mm air/flue gas duct
A concentric air/flue gas duct which has an outside diameter of 125 mm and can be extended up to a length of 21 m is available. You can also get a vertical system. For more information refer to the installation manual for the air/flue gas duct.
7Installation and maintenance instructions ecoTEC 0020029172_03
7
3 Safety instructions and regulations
P
I
F
J
Fig. 3.3 Termination of the air/flue gas duct
L
G
Q
B
Q
D, E
C
A
I
I
The flue system shall be so placed or shielded as to prevent ignition or damage to any part of the building.
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
C
window, etc. Below temperature-sensitive building compo-
D
nents 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, win­L
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 N/A P From a vertical structure on the roof N/A Q Above intersection with roof 300 mm
Table 3.1 Position of the termination in a fan-assisted air/flue
gas duct
Minimum dimensions
300 mm
300 mm
75 mm
1200 mm
Q
O
H
H
N
MM
N
K
Note!
h
In addition, the terminal should not be nearer than 300 mm to an opening in the building fabric formed for the purpose of accommodating a built–in element such as a window.
BS 5440–1 It is recommended that the fanned flue terminal should be positioned as follows: a) at least 2 m from an opening in the building directly
opposite, and
b) so that the products of combustion are not straightly
directed to discharge across a boundary.
1) Dimensions D, E and F: These clearances may be reduced to 25 mm without affecting the performance of the boiler. In order to ensure that the condensate plume does not affect adjacent surfaces the terminal should be extended as shown in Fig. 3.3.
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.
Installation and maintenance instructions ecoTEC 0020029172_038
Balcony/eaves
Gutter
Safety instructions and regulations 3
Flue pipe adequately fixed
Fig. 3.4 Termination of air/flue gas duct under balcony or
eaves
Flue pipe must project beyond every overhang
3.4 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.
3.5 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.
3.6 Electrical supply
A 230 V, ~ 50 Hz single phase electricity supply fused to 3 Amp. must be provided in accordance with the latest edition of BS7671 (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.
Danger!
Risk of fatal electric shock! The boiler must be earthed.
9Installation and maintenance instructions ecoTEC 0020029172_03
4 Assembly
4 Assembly
Caution!
a
Flush the heating installation thoroughly before installing the boiler to remove foreign substances such as solder and flux residue, leftover sealant or dirt.
4.1 Scope of delivery
The Vaillant ecoTEC is delivered pre-mounted in a package unit. Check that all parts have been delivered and are intact (see Fig. 4.1 and Table 4.1).
Installation instructions
ecoTEC
Installation instructions
8
7
6
ecoTEC
Installation instructions
ecoTEC
1
2
3
4.2 Accessories
Optional accessories for use in conjunction with the installation and operation of the boiler are available.
4.3 Installation site
Please note the safety instructions below before choosing where to install the boiler:
Caution!
a
Do not install the boiler in rooms prone to frost. In rooms with aggressive steam or dust, the boiler must be operated room sealed!
When choosing the installation site and while operating the boiler, make sure that the combustion air is technically free of chemical substances containing fluorine, chlorine, sulphur etc. Sprays, solvents and cleaning agents, paints, adhesives etc. contain these kinds of substances, which may lead in the worst case to corrosion, also in the flue system, during open flued operation of the boiler. Using an old chimney of an oil fired boiler may also cause this problems. The boiler must be operated room sealed, particularly in hairdressing salons, carpenter‘s shops, or paint shops and cleaning companies. Otherwise, a separate installation room is required to guarantee that the combustion air supply is technically free of the substances mentioned above.
5
Fig. 4.1 Scope of delivery
Position Number Name
1 1 Hanging bracket
2 1 Boiler
Connection accessories:
3 4 5
6 1 Condensate drainage pipework
71
81
Table 4.1 Scope of delivery
- Gas isolation valve
1
- Drain valves
2
- Expansion relief valve
1
- Seals (without Fig.)
Bag containing hardware (assembly kit):
- 2 wood screws
- 2 wall plugs 10 x 60 mm
- 2 washers
- 1 seal
- 1 crimp connection Bag with printed documents: – Installation and maintenance instructions – Operating manual – Installation instructions, air/flue gas duct
system
- Installation template
- Changeover sign for liquid gas
- Miscellaneous stickers
2 x
Select boiler position
4
Refer to Chapter ‘Installation site’ for information regarding the siting of the boiler. In general the boiler must be positioned such that:
• There is sufficient space around the boiler for service and maintenance.
• The boiler can be correctly flued, i.e. the flue terminal position is sited in accordance with these instructions and the air/flue duct can be installed in accordance with the flue installation instructions supplied.
• All necessary pipework can be connected, including the expansion relief valve and condensate drain.
Installation and maintenance instructions ecoTEC 0020029172_0310
4.4 Dimension drawing and connection dimensions
Assembly 4
800
480
Ø 80/125
1
A
49
2
450
190
Ø20, R1
30
8 7
Fig. 4.2 Connection dimensions in mm
Legend:
1 Flue gas connection, 80/125 mm
diameter, dimension A (hanging bracket – centre of air/flue gas
pipe) with 87° elbow: 253 mm 2 Hanging bracket 3 gas pipe, 20 mm diameter, gas connection R1“ 4 Connection for condensate drainage pipework 5 Connection for expansion vessel 6 Connection for heating return 7 Connection for heating flow 8 Connection for expansion relief valve 9 Filling device (combined filling and emptying valve)
Rp 1 Rp 1 G 11/
2
R 1/
2
100 100
152 152
G 1
R 1
3
4
5
1
/
2
6
48
100
9
5, 8
Note!
h
When using accessories observe the minimum gaps/mounting clearances (see Chapter 4.5).
11Installation and maintenance instructions ecoTEC 0020029172_03
3
75
175
270
25
44
1
2
4 Assembly
4.5 Required minimum gaps/ installation clearances
For the installation/assembly of the boiler as well as for carrying out future maintenance tasks, you need the minimum gaps and installation clearances given below:
350
250
4.7 Mounting the boiler
Caution!
a
When assembling the boiler make sure that the fixing point has a sufficient load-bearing capacity. Also take the condition/nature of the wall into account.
Fig. 4.3 Required minimum gaps/installation clearances
It is not necessary to ensure a particular clearance between the boiler and combustible materials or components as the temperature of the boiler will always
Fig. 4.4 Mounting the boiler
be less than the maximum permissible temperature of 85 °C at its rated heating output. You need a minimum of 600 mm clearance in front of the boiler to enable easy access for servicing. This may be provided by an openable door.
• Mount the hanging bracket (1) on the wall using the wall plugs and screws (2) provided with the boiler.
• Hang the boiler (3) on the hanging bracket from above using the suspension bracket.
4.6 Using the installation template
Only use the assembly template provided to mount the boiler.
• Align the installation template vertically and fix it to the wall.
• Mark the positions of the drill holes for the hanging bracket and also the position of the wall opening for the air/flue gas duct on the wall.
• Remove the assembly template from the wall.
• Drill 2 holes for the hanging bracket in the wall, each with a diameter of 8 mm.
• If necessary cut the aperture in the wall for the air/ flue gas duct.
Installation and maintenance instructions ecoTEC 0020029172_0312
Assembly 4
Installation 5
4.8 Removing/attaching the front casing
2
1
Fig. 4.5 Removing the front casing
To dismount the front casing of the boiler, proceed as follows:
• Unfasten the screw (1) on the bottom of the boiler.
• Push in both retaining clips (2) on the bottom of the
boiler so that the front casing is released.
• Pull the casing forwards by its bottom edge and lift the casing up and off.
To mount the front casing of the boiler, proceed as follows:
• Place the casing thus on the upper boiler edge that casing and boiler edges engage.
• Push the casing onto the boiler so that both retaining clips (2) engage with the casing.
• Fix the casing by tightening the screw (1) on the bottom of the boiler.
5 Installation
Danger!
d
Danger of injury to persons and/or material damage due to improper installation! The Vaillant ecoTEC boiler may only be installed by a recognised skilled trade company. who also assumes the responsibility for proper installing and initial start-up of the boiler.
Caution!
a
The ecoTEC VU 466 must be used with a suitably sized low loss header.
Selection of the low loss header
The low loss header uncouples the boiler from the heating installation. A sufficiently large water volume is constantly supplied through the boiler via the low loss header in conjunction with the boiler circulation pump. It acts as a neutral point in the system and has minimal hydraulic resistance, therefore the boiler circulation pump does not affect the circuit pumps and vice-versa.
A suitable WH type low loss header can be chosen from Table 5.1.
Temperature spread of
heating installation
Output of heating installation
Stand-alone boiler WH 95 WH 40 WH 40 Two cascade
arrangement Three cascade
arrangement Four cascade
arrangement
Table 5.1 Selection of the low loss header
Note!
h
We strongly recommend the installation of a suitably sized quality dirt filter in the return pipe work to the low loss header (not to the boiler!) particularly in the case of old systems. This will help to prevent any system water contamination from entering and blocking the boiler and producing an additional high pressure loss.
10 K 15 K 20 K
WH 160 WH 95 WH 95
WH 280 WH 160 WH 160
WH 280 WH 160 WH 160
No electrical accessories are required in order to use a low loss header. Simple systems can be connected directly inside the electronic box.
13Installation and maintenance instructions ecoTEC 0020029172_03
5 Installation
Model Article
number
WH 40 306720 1
WH 95 306721 2" BSP (f) 155 155 750 155/155 470 540 n/a 8
WH 160 306726 DN65 520* 120 1350 220/220 900 900 300 12
WH 280 306725 DN80 600* 160 1390 260/260 930 930 300 21.5
Table 5.2 Low loss headers dimensions
All dimensions in mm * = distance between flanges
Connection
Sizes
1
1
/4" BSP (f) 115 115 500 115/115 280 340 n/a 3.5
Header
width
A
Header
depth
B
Total
height
C
Insulation
dimensions
To boilerDTo heating
circuit
E
Height from
floor
F
Safety devices
• The outlet of the expansion relief valve must be suitably terminated in accordance with BS 6798 or BS 6644.
• The boiler is suitable for connection to plastic centralheating pipes. In this connection preferably
1.5 m copper pipes should be used prior to the transition to the plastic pipes for the connection to the boiler.
• Should a system be found to include non-oxygen barrier pipe then it is essential that a plate heat exchanger be installed in between the boiler and the non-oxygen barrier pipe, thus preventing corrosion. It is essential that the boiler and the system have provision for water make up and expansion.
For more detailed information on examples of systems and system equipment contact your Vaillant sales support point.
Maximum
volume
flow m3/hr
Fig. 5.1 Low loss header
Caution!
a
The following system diagrams are schematic representations. They cannot be regarded as a substitute for professional planning! The system diagrams do not include the isolator and safety devices that are required to carry out a professional installation. Observe the applicable standards and guidelines.
The boiler can be installed in three different configurations:
• heat only,
• cylinder only, and
• heating and cylinder.
5.1 Heating mode
In case of only one heating circuit to be operated downstream of the low loss header, this one can directly be controlled by the ecoTEC. A suitable pump can be selected and installed downstream of the low loss header. You can select a pump that fits to your system (4 m or 6 m pump or electronically controlled pump). In case of systems with multiple circuits please pay additional attention to the control system accessories.
Installation and maintenance instructions ecoTEC 0020029172_0314
Installation 5
Hydraulic schematic drawing: Heating circuit connection using low loss header
4
1
3
2
Fig. 5.2 Heating circuit connection using low loss header
Legend:
1 Boiler with internal pump 2 Low loss header 3 External heating pump 4 Consumer (e.g. heating circuit)
The charging circuit connection downstream of the low loss header enables the choice of an individual cylinder size and of a charging pump.
Note!
h
Observe that non-return valves or mixer circuits may be required in order to eliminate cross-flow to other circuits or the effects of high temperatures from the charging circuit.
Hydraulic schematic drawing: Cylinder priority switching via low loss header
4
1
2
3
98
X14
X6
Fig. 5.3 Electrical connection for heating pump downstream of
the low loss header
X18
543NL
X11
X13
1
The settings for the internal pump are made at the factory. The pump output does not require adjustment. Use the grey ProE plug to establish the electrical connection with the external heating pump. To assign the "external heating pump" function to the plug (1) (additional relay) diagnosis point "d.26" in the
nd
diagnosis level must be set to the value "2", see
2 Chapter 9.1.2. The low loss header ensures, in conjunction with the boiler circulation pump, that a sufficiently high minimum quantity of water is always circulating through the boiler.
5.2 Cylinder charging mode
The electronics of the ecoTEC are designed in such a way that one cylinder charging circuit and one heating circuit can be connected directly without the need for accessories.
Fig. 5.4 Cylinder priority switching via low loss header
Legend:
1 Boiler with internal pump 2 Low loss header 3 External heating pump 4 Consumer (e.g. charging circuit)
98
X14
X6
Fig. 5.5 Electrical connection for cylinder charging pump
1
X18
543NL
X11
X13
Use the mounted ProE plug (1) to establish the electrical connection for the cylinder charging pump.
The pink plug-in location X6 (1) on the PCB is reserved for the cylinder charging pump. It is not necessary to do settings at any diagnosis point.
15Installation and maintenance instructions ecoTEC 0020029172_03
5 Installation
The low loss header ensures, in conjunction with the boiler circulation pump, that a sufficiently high minimum quantity of water is always circulating through the boiler.
5.3 Heating mode and cylinder charging mode
Note!
h
Also observe Chapters 5.1 and 5.2 of this manual.
The combination of heating mode and cylinder charging mode of the boiler can not be equated with either heating mode or cylinder charging mode. Other hydraulic relationships must be taken into account in order to ensure faultless operation. The boiler is uncoupled from the consumer circuits by the low loss header. This means that the circuits downstream of the low loss header can be designed according to individual requirements (pump dimension, cylinder position).
Hydraulic schematic drawing: Cylinder priority switching and heating circuit via low loss header
One direct heating circuit and one hot water cylinder (including charging pump and non-return valve) can be connected downstream of the low loss header to the ecoTEC boiler without additional equipment. If additional heating circuits are required this can be achieved with the use of optional controllers and hydraulic accessories (e.g. VRC630). The available pump head from the boiler circulation pump is sufficient to pump water around the boiler circuit between the boiler and low loss header. All heating circuits and hot water cylinder configurations can be connected downstream of the low loss header.
Note!
h
Observe that non-return valves or mixer circuits may be required in order to eliminate cross-flow to other circuits or the effects of high temperatures from the charging circuit.
X14
98
1
X18
543NL
X13
2
4
1
3
2
Fig. 5.6 Cylinder priority switching and heating circuit via low
loss header
Legend:
1 Boiler with internal pump 2 Low loss header 3 External heating pump 4 Consumer (e.g. heating circuit) 5 External cylinder charging pump 6 Cylinder
5
6
X11
X6
Fig. 5.7 Electrical connection for cylinder charging pump and
external heating pump
Legend:
1 Plug-in location for cylinder charging pump 2 Plug-in location for external heating pump
Use the relevant mounted ProE plug to perform the electrical connection.
The pink plug-in location X6 (1) on the PCB is reserved for the cylinder charging pump. It is not necessary to do settings at any diagnosis point.
To assign the "external heating pump" function to the grey plug (2) (additional relay) the value "2" must be specified at diagnosis point "d.26" in the 2
nd
diagnosis
level, see Chapter 9.1.2.
Installation and maintenance instructions ecoTEC 0020029172_0316
Installation 5
5.4 Gas connection
Danger!
d
Danger of injury to persons and/or material damage due to improper installation! The Vaillant ecoTEC boiler may only be installed by a recognised skilled trade company who also assumes the responsibility for proper installation and initial start-up of the boiler. The legal directives and the local regulations for gas supply companies must be observed.
Caution!
a
Ensure strainless assembly of the gas pipes to avoid leakages!
Note!
h
Maintain the same gas pipe dimension all the way to the boiler and avoid reducing the dimen­sion downstream of the gas meter.
Caution!
a
The gas valve may be damaged if the test pressure or operating pressure is exceeded! You must check the tightness of the gas valve only using a maximum pressure of 110 mbar!
5.5 Heating connection
Caution!
a
Ensure strainless assembly of the supply lines to avoid leakages in the heating installation!
The boiler is connected to the heating flow and return via service valves.
1
2
1
Fig. 5.8 Fitting the gas connection
The boiler must be connected to your gas pipe via a gas isolation valve.
• Screw the boiler‘s gas supply pipe (1) gas-tight with the gas isolation valve (5, see Fig. 5.9). To do this, use the R3/4 crimp connection supplied with the boiler. This is also suitable for the connection of a R3/4 gas isolation valve.
• Inspect the gas connection for leakage.
5
Fig. 5.9 Heating connection
• Fit the flow, return and gas isolation valves (3, 4, 5)
including the seals onto the flow, return and gas pipes. Do not overtighten and ensure the joints are checked for leaks after fitting.
Caution!
a
It is essential to use the combined filling and emptying valve (3, Fig. 5.10) in the return for filling the boiler without fail, as otherwise the bleeding of the boiler cannot be ensured.
Note!
h
We recommend the use of seals made of a fibre­based material similar to cardboard instead of materials similar to rubber as the latter can plastically deform and cause pressure losses.
4
3
17Installation and maintenance instructions ecoTEC 0020029172_03
Loading...
+ 39 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use