Installation and maintenance instructions
For the competent person
Installation and maintenance instructions
ecoTEC
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 Benchmark .................................................................. 5
2.5 Intended use ............................................................... 5
2.6 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
3.2.3 Gas supply ................................................................... 7
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
5.1 Heating mode ............................................................. 14
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 Electrical connection ................................................ 19
5.8.1 Mains connection ...................................................... 19
5.8.2 Connecting controllers ............................................. 20
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 ......... 25
6.2.3 Filling the condensate siphon ................................ 26
6.3 Checking the gas setting ......................................... 26
6.3.1 Checking for tightness of the flue gas
installation and flue gas recirculation.................. 27
6.3.2 Checking the gas flow rate ..................................... 27
6.3.3 Checking the gas inlet working pressure ............ 28
6.4 Checking the appliance function ........................... 28
6.4.1 Heating ........................................................................ 29
6.4.2 Cylinder charging ...................................................... 29
6.5 Handing over the boiler to the operator ............. 29
7 Adapting the boiler to the heating
installation ......................................................... 31
7.1 Selection and setting of parameters .................... 31
7.2 Overview of adjustable system parameters ....... 31
7.2.1 Setting the heating partial load............................. 33
7.2.2 Setting of pump overrun and pump operating
mode ............................................................................. 33
7.2.3 Setting of maximum flow temperature ................ 33
7.2.4 Setting of burner anti-cycling time ....................... 33
7.2.5 Determination of maintenance
interval/maintenance display ................................. 34
8 Inspection and maintenance............................ 35
8.1 Inspection and maintenance intervals ................. 35
8.1.1 General inspection and maintenance
instructions ................................................................. 35
8.1.2 Safety instructions .................................................... 36
8.1.3 Checking the CO
8.1.4 Adjusting the CO
concentration ........................... 36
2
concentration (or the air
2
ratio) ............................................................................. 37
.8.1.5 Inspection and maintenance work steps ............. 38
8.2 Filling/draining the boiler and heating
installation .................................................................. 39
8.2.1 Filling the boiler and the heating installation .... 39
8.2.2 Draining of the boiler ............................................... 39
8.2.3 Draining the entire system...................................... 39
8.3 Maintenance of the compact thermal module ... 39
8.3.1 Dismounting the compact thermal module ........ 39
8.3.2 Cleaning the heat exchanger ................................. 40
8.3.3 Checking the burner ................................................. 40
8.3.4 Installing the compact thermal module ............... 41
8.4 Cleaning the condensate siphon ........................... 41
8.5 Cleaning the condensate ducts ............................. 42
8.6 Cleaning the air separation system ...................... 42
8.6.1 Cleaning the filter ..................................................... 42
8.6.2 Cleaning the air separator ...................................... 42
Installation and maintenance instructions ecoTEC 0020029172_042
Contents
Notes on the documentation 1
8.7 Checking the charge pressure of the external
expansion vessel ........................................................ 42
8.8 Checking gas connection pressure
(gas inlet working pressure) ................................... 43
8.9 Checking the CO
8.10 Test operation ............................................................ 43
9 Troubleshooting ................................................. 43
9.1 Diagnostics .................................................................. 43
9.1.1 Status codes ............................................................... 43
9.1.2 Diagnosis codes ......................................................... 44
9.1.3 Fault messages........................................................... 47
9.1.4 Fault memory ............................................................. 47
9.2 Check programs ......................................................... 49
9.3 Resetting parameters to factory settings ........... 49
10 Replacing components ..................................... 50
10.1 Safety instructions .................................................... 50
10.2 Replacing the burner ................................................ 50
10.3 Replacing the fan or the gas valve ...................... 50
10.4 Replacing the heat exchanger ............................... 51
10.5 Replacing PCB and display ..................................... 52
11 Vaillant Service ................................................. 52
12 Recycling and disposal ..................................... 52
12.1 Boiler ............................................................................ 52
12.2 Packaging .................................................................... 52
13 Technical data ................................................... 53
Benchmark Commissioning and Servicing Section . 54
concentration .......................... 43
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!
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_04
2 Description of the boiler
2 Description of the boiler
2.1 Design
15
1
2
14
13
12
10
3
4
5
6
11
7
9
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_044
8
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
The CE label shows that the products comply with the basic requirements of all applicable directives as stated on the identification plate.
The declaration of conformity can be viewed at the manufacturer's site.
2.4 Benchmark
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
The use of the product 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 (known as "fixed installation").
Any other use that is not specified in these instructions,
or use beyond that specified in this document, shall be
considered improper use. Any direct commercial or
industrial use is also deemed to be improper.
The manufacturer/supplier is not liable for any claims or
damage resulting from improper use. The user alone
bears the risk.
Caution!
a
Improper use of any kind is prohibited.
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)
2.5 Intended use
There is a risk of injury or death to the user or others, or
of damage to the product and other property in the
event of improper use or use for which it is not intended.
The product is intended as a heat generator for closed
hot water central heating installations and for hot water
generation. The products referred to in this manual must
only be installed and operated in conjunction with the
accessories listed in the associated flue pipe installation
manual.
Intended use includes the following:
- observance of accompanying operating, installation
and servicing instructions for Vaillant products as well
as for other parts and components of the system
- installing and fitting the product in accordance with
the product and system approval
- compliance with all inspection and maintenance condi-
tions listed in the instructions.
2.6 Identification plate
The data badge of the Valliant ecoTEC is attached at the
factory to the bottom of the boiler.
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.
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!
5Installation and maintenance instructions ecoTEC 0020029172_04
3 Safety instructions and regulations
• 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!
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.
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.
nd
family gas).
nd
and 3rd
Installation and maintenance instructions ecoTEC 0020029172_046
Safety instructions and regulations 3
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.
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".
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.
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.
1103
15
70
70
Fig. 3.1 Item No. 303 209
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.
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).
7Installation and maintenance instructions ecoTEC 0020029172_04
7
3 Safety instructions and regulations
Note!
h
Vertical flues must not terminate within
600 mm of an openable window, air vent or any
other ventilation terminal.
P
I
F
J
Fig. 3.3 Termination of the air/flue gas duct
L
Q
B
G
Q
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
D, E
O
H
H
MM
N
Q
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_048
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_04
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_0410
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
1
/
G 1
2
R 1/
2
100
152 152
100
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_04
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_0412
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_04
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
To ta l
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.
Maximum
volume
flow m3/hr
Fig. 5.1 Low loss header
For more detailed information on examples of systems
and system equipment contact your Vaillant sales
support point.
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_0414
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
2
diagnosis level must be set to the value "2", see
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_04
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_0416
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
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.
1
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
2
3
17Installation and maintenance instructions ecoTEC 0020029172_04
5 Installation
5.6 Expansion relief valve (safety group), heating
installation
bar
1 2 3 4
Fig. 5.10 Fitting the expansion relief valve
The ecoTEC is equipped ex factory with connections for
a safety group:
• Expansion relief valve (1)
• Pressure gauge (2)
• Filling device (combined filling and emptying valve) (3)
• Connection for expansion vessel (4)
As an accessory the expansion relief valve for the
heating installation is delivered with the boiler.
• Install the expansion relief valve (1).
• Fit a sufficiently sized expansion vessel (to be
provided on site) at the designated connection (4).
Danger!
H
Danger of burning and scalding!
The expansion relief valve (1) must be
noticeable! Terminate the line in such a way
that escaping water or steam cannot cause
injury to persons.
Please note that the end of the line must be
visible.
5.7 Condensate drainage pipework
1
2
4
a
3
Fig. 5.11 Condensate drainage pipework
Legend:
a Internal stackpipe
b Internal drainage system
c Gully
d Soakaway
b
3
c
6
5
d
7
The ecoTEC boilers are equipped with a usual
condensate collector from which the condensate is
continuously removed via the drain pipe.
• Connect the condensate discharge (1) of the boiler to
a condensate drainage pipework (2) which has a
minimum internal diameter of 19 mm (22 mm outside
diameter for all external pipes) and should be made
from an acid-resistant material (e.g. plastic overflow
pipe).
Note!
h
The condensate drainage pipework connected to
the condensate discharge of the boiler must
have a fall throughout its entire length (45 mm
per metre) and should be installed and
connected within the building to prevent
freezing.
Caution!
a
Risk of damage!
The line should be terminated in such a way
that cables or other electrical components
cannot be damaged.
The condensate drainage pipework must terminate in a
suitable location, e.g.:
a) Preferably the condensate drainage pipework should
run and terminate internally to the house soil and
vent stack (at least 450 mm above the invert of the
stack). A siphon giving a water seal of at least 75 mm
(3) (built into the boiler) should be incorporated into
the pipe run, and there must be an air break (4) in the
condensate drainage pipework upstream of the
siphon.
Installation and maintenance instructions ecoTEC 0020029172_0418
Installation 5
The connection to the stack should not be made in a
way that could cause cross flow into any other branch
pipe, or from that branch pipe into the condensate
drainage pipework. This can be achieved by
maintaining an offset between branch pipes of at least
110 mm on a 100 mm diameter stack and 250 mm on a
150 mm diameter stack.
b)connecting into the internal drainage branch (e.g. sink
waste) with an external termination, the condensate
drainage pipework should have a minimum diameter
of 22 mm with no length restriction and should
incorporate a siphon with a 75 mm (3) (built into the
boiler) seal. The connection should preferably be
made down stream of the sink waste siphon. If the
connection is only possible upstream, then an air
break is needed between the two siphons. This is
normally provided by the sink waste.
c)in a gully (5) below grid level (6) and above the water
level. The external pipe length should be kept as short
as possible to minimise the risk of freezing and should
not be more than 3 m.
d)at a soakaway (condensate absorption point) (7). The
external pipe length should not be more than 3 m.
Further information can be obtained from "BS 6798
Specification for installation of gas–fired boilers of rated
input not exceeding 70 kW net“.
Danger!
d
Risk of poisoning due to escaping flue gas!
The condensate drainage pipework must be
linked to the waste water piping by an open
transition as otherwise the internal siphon
could be sucked dry. Before the boiler is
switched on the siphon must have been filled
with water to prevent flue gas from leaking via
the siphon (see Chapter 6.2.3).
5.8 Electrical connection
Danger!
e
Risk of fatal electric shock through contact
with live connections!
The electrical installation may only be carried
out by a recognised skilled trade company.
Always switch off the power supply first and
ensure that it cannot be switched back on
unintentionally. Only after this can the
installation be undertaken. Mains connection
terminals L and N remain live even if the boiler
main switch is turned off!
5.8.1 Mains connection
All electrical work shall be carried out by a heating
engineer and shall comply with BS 7671 (IEE
Regulations).
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, ~ 50 Hz
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 3 core flexible cord according to
BS 6500 tables 6, 8 or 16 (3 x 0.75 to 3 x 1.5 mm
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.
2
)
19Installation and maintenance instructions ecoTEC 0020029172_04
987+-
543NL
BUS
5 Installation
4
• Dismantle the supply line over a length of
approximately 2 - 3 cm and strip the insulation off the
wires.
Caution!
a
1
Supplying power to the wrong plug terminals of
the Pro E system can destroy the electronics.
Only connect a 230 Vac live supply to boiler
terminal connections marked LNE.
• Connect the cores to the plug-in locations in the
electronics (L, N and Earth), see Fig. 5.13, using the
2
corresponding ProE plug.
• Close the rear cover of the electronic box until it
3
audibly engages.
• Lift the electronic box up and press the two clips on
the left and right of the box against the side casing of
the boiler until they audibly engage.
• Mount the front casing (see Chapter 4.8).
Fig. 5.12 Opening back wall of the electronic box
987+-
BUS
Fig. 5.13 Example for cable routing
543NL
• Remove the front casing of the boiler (see
Chapter 4.8) and tilt the electronic box (3) forwards
(see Fig. 5.12).
• Unclip the rear cover (2) of the electronic box at the
fastening points (1) and fold it up.
• Use a commercially available mains connection cable.
• Guide the mains connection cable through a cable
duct (4). Use the grommet to seal the opening.
• Then feed the mains connection cable into the
electronic box and cut the line to the correct length.
5.8.2 Connecting controllers
Mount the controllers in accordance with the
corresponding operating and installation manuals.
The required connections to the electronic system of
the boiler (e.g. for external controllers, external sensors
etc.) should be performed as follows:
• Remove the front casing of the boiler (see
Chapter 4.8) and tilt the electronic box (3) forwards
(see Fig. 5.12).
• Unclip the rear cover (2) of the electronic box at the
fastening points (1) and lift it up (see Fig. 5.12)
• Guide the supply lines of the relevant components to
be connected through the cable ducts (4) on the
bottom of the boiler on the left (see Fig. 5.12)
• Then feed the supply lines into the electronic box and
cut the lines to the correct length.
• Dismantle the supply line over a length of
approximately 2 - 3 cm and strip the insulation off the
wires.
• Connect the cores to the corresponding ProE plugs or
plug-in locations of the electronics, as shown in
Fig. 5.13.
Caution!
a
Danger of destroying the electronics!
Do not connect a mains voltage supply to the
following terminals: 7, 8, 9, eBUS (+,-)!
Note!
h
Make sure that the cores are securely fastened
to the screw terminals of the ProE plug.
• If a roomthermostat/timer is not connected, you must
insert a bridge between terminals 3 and 4, if not
already installed. Remove the bridge if you connect a
corresponding room/thermostat timer to terminals
3 and 4.
• If a weather-compensated or room temperature
control system is connected (continuous control
Installation and maintenance instructions ecoTEC 0020029172_0420
connection terminals 7, 8, 9) the bridge between
terminal 3 and 4 must remain inserted.
• Close the rear cover of the electronic box until it
audibly engages.
• Lift the electronic box up and press the two clips on
the left and right of the box against the side casing of
the boiler until they audibly engage.
• Mount the front casing (see Chapter 4.8).
• To choose pump operating mode 1 (running on of
pump) for multi-circuit controllers, change the setting
at diagnosis point "d.18" (pump operating mode) from
3 "intermittent" to 1 "run on" (see Chapter 7.2.2).
Observe that the bridge at the ProE plug must be
removed when connecting a maximum thermostat
(contact thermostat) for underfloor heating.
5.8.3 Connecting a low loss header sensor
The low loss header sensor must either be connected to
the X41/RF according to the connection diagram
(Fig. 5.15) or to the selected controller (see
corresponding operating manual).
Installation 5
5.8.4 Additional relay (grey plug on the PCB) and
VR40 - "2 in 7“ multifunctional module
Additional relay (grey plug on the PCB)
With the ecoTEC it is possible to actuate one additional
component via the additional relay. You can select the
installed components via diagnosis point "d.26" at
diagnosis level 2 (see Chapter 9.1.2).
VR40 - "2 in 7“ multifunctional module
If you wish to connect additional components this can
be done using the Vaillant VR40 - "2 in 7"
multifunctional module.
Note!
h
Please observe the separate manual attached
to the VR40 - "2 in 7" multifunctional module.
Carry out the installation in accordance with the
corresponding operating and installation manual.
To actuate relay 1 at the multifunctional module select
diagnosis point "d.27" at diagnosis level 2, and to
actuate relay 2 select diagnosis point "d.28"
(see Chapter 9.1.2). You can select the following
components here:
1 = circulation pump
2 = external pump
3 = charging pump
4 = vapour extraction hood
5 = external solenoid valve
6 = external fault message
7 = not active
8 = remote control eBUS (not active)
9 = legionella pump (not active)
21Installation and maintenance instructions ecoTEC 0020029172_04
5 Installation
5.8.5 Wiring diagrams
X 11
14
10
4
2
5
9
11
12
X 2
13
1
17
3
4
16
5
7
8
Low-voltage plug
12
13
X20
14
brown
black
orange
violet
black
green
black
blue
black
grau
red
red
black
blue
black
black
black
red
green
red
natural
black
Cylinder thermostat (connection)
“C1-C2”
Cylinder
1)
1
2
P
Water pressure sensor
4
+
Signal
-
Flow rate sensor
Earth
Hall signal
1
2
PWM signal
3
4
+24V
5
NTC sensor
Fan
Flow temperature sensor
Return temperature sensor
1)
Mains
18
blue
red
9
Igniter
X14
Fig. 5.14 Connection diagram of ecoTEC
(continued on next page)
1) You must not use both the C1/C2 and the cylinder sensor connections!
green/yellow
+
Gas valve
Ignition electrode
Appliance earth
Installation and maintenance instructions ecoTEC 0020029172_0422
Fan
230V~
N
L
blue
X11
Cylinder
charging pump
X13
X18
5
4
3
N
L
grey
N
green
L
Installation 5
Additional relay (e.g. external heating pump)
(adjustable in d.26, see table 9.3)
Internal pump
Boiler enable connection (factory link fitted)
N
Mains voltageLow voltage
L
N
L
pink
X6
X1
X41
X22
Fig. 5.15 Connection diagram of ecoTEC (continued)
turqoise violetwhiteredblue
9
8
7
+
-
2
1
0
1
0
DCF
RF
AF
6
FB
Edge connector
230 volt mains input
Optional ext. controller/room thermostat 7-8-9
(continuous, analogue)
Bus connection for optional accesories
Safety circuit connection
Earth
Earth
DCF connection
Low loss header sensor
External sensor
Remote control, circulation pump
24 V 230 V~
Connector for controller accessories
VRC 430
PWM signal, internal pump
Fan
23Installation and maintenance instructions ecoTEC 0020029172_04
6 Start-up
6 Start-up
Caution!
a
The boiler may only be permanently operated
with its casing properly closed!
Otherwise, under unfavourable conditions, it can
result in material damage or even injury or
death.
Note!
h
When starting up particularly take the following
into consideration:
Before the heating circuit or charging circuit is
filled you must open the cap on the automatic
air vent which must remain open during
subsequent operation.
Use the bleeding program to bleed the heating
circuit or charging circuit (see Chapter 9.2).
6.1 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.
6.2 Filling the system
6.2.1 Preparation of heating water
Caution!
a
If anti-freeze inhibitors are to be used it has
been found that Sentinel X500 and Fernox
Alphi-11 have no known incompatibility issues
with our boilers. Vaillant cannot guarantee the
compatibility and effectiveness of these
products in the rest of the heating installation
and accepts no liability or responsibility for
damage caused by use on non-recommended
anti-freeze inhibitor products.
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 instructions 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
Caution!
a
To prevent deposition and severe damage to the
boiler and heating installation the cleaning
agent must be applied carefully and
subsequently removed from the heating
installation by draining it completely. Cleaning
agents should not remain in the heating
installation longer than 24 hours.
This cleaning process must take place before a new
boiler is fitted in accordance with BS 7593.
Recommendations on the use of system cleaning agents
can be obtained from Sentinel, Betz Dearborn Ltd.
Widnes, Cheshire, WA8 8UD, Tel. 0151 420 9595, or
Fernox, Cookson Electronics, Forsyth Road, Sheerwater,
Woking, Surrey GU21 5RZ, Tel. 01483 793200.
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.
Installation and maintenance instructions ecoTEC 0020029172_0424
Start-up 6
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 quanti-
ty 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 ob-
served.
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 filling 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 table6.1 were exceeded
(softening, desalination, hardness stabilisation or desludging).
Table 6.1 Guideline values for heating water: water hardness
Overall hardness at smallest boiler heating
20 l/kW
3
mol/m
(mg/l CaCO3)
No require-
ment or
1)
< 3
< (300)
2
(200)
1.5
(150)
0.02
(2.0)
(mg/l CaCO3)
1)
2)
surface
> 20 l/kW
< 50 l/kW
3
mol/m
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)
3
Caution!
a
Only fill the system via the boilers' built-in
combined filling and emptying valve as
otherwise problems may occur with bleeding
the system.
Note!
h
The ecoTEC is equipped with a pressure gauge
(1) and a digital pressure indicator. You can
display the precise filling pressure when the
boiler is switched on by pushing the "-" button
(2). You can also switch between the continuous
display of temperature or pressure by keeping
the "-" button pushed for about 5 seconds.
For the heating installation to work properly the
indicator on the pressure gauge (1) must be in the upper
half of the dark grey area when the system is cold (see
Fig. 6.1). This corresponds to a filling pressure between
1.0 and 2.0 bar.
If the heating installation serves several floors, the
values for the water pressure in the system may need
to be higher (to avoid the ingress of air).
• Flush through the heating installation throroughly
before actually filling it.
1
6.2.2 Filling and bleeding from the heating side
2
Fig. 6.1 Check the filling pressure of the heating installation
Fig. 6.2 Automatic air vent
• Unfasten the cap on the automatic air vent (1) by one
or two turns (the appliance is bled automatically while
continuously operated via the automatic air vent).
• Open all thermostatic radiator valves in the
installation.
• Connect the system's combined filling and emptying
valve to a cold water draw-off valve in accordance
with the standards.
Note!
h
1
To avoid damaging the appliance through
operation with insufficient water pressure, the
boiler is equipped with a pressure sensor.
This sensor records a lack of pressure if the
pressure value falls below 0.6 bar and the
detected pressure value flashes in the display.
If the pressure falls below 0.3 bar the boiler
switches off. Fault message F.22 ("water lack")
25Installation and maintenance instructions ecoTEC 0020029172_04
6 Start-up
appears in the display. Fill the system up with
water before you start up the boiler again. This
message also appears if you switch the boiler
on when it is empty and disappears
automatically when it is filled.
Caution!
a
Risk of damage from leaking water!
If the pressure drops frequently the reason for
the loss of heating water must be identified and
eliminated.
• Open the combined filling and emptying valve and the
draw-off valve slowly and add water until the required
system pressure is shown on the pressure
gauge/display.
• Close the draw-off valve.
Note!
h
Use the check program P.0 to bleed the heating
installation: The boiler does not start up. The
internal pump runs intermittently and bleeds
the appliance circuit. The pressure is displayed
digitally. Ensure that the system pressure does
not fall below 0.8 bar when bleeding is in progress. Otherwise the bleeding will not be carried
out properly. The bleeding program takes about
6.5 minutes to complete.
• Bleed all the radiators.
• Check the system pressure again.
6.2.3 Filling the condensate siphon
Fig. 6.3 Filling the condensate siphon
Danger!
d
If the boiler is operated with an empty
condensate siphon, there is danger of poisoning
through escaping flue gases. Therefore it is
mandatory to fill the siphon as described below
before start-up.
1
Caution!
a
If too much air is still in the system after the
bleeding program is finished it must be started
again! Once the filling procedure is complete
the system pressure should be at least 0.2 bar
above the back-pressure from the expansion
vessel (P
• Check all connections for leaks.
Note!
h
When the boiler starts operating a maintenance
or fault message may occur due to falling
system pressure. The message disappears
automatically when the boiler is refilled.
system
P
+ 0.2 bar).
ADG
• Screw off the bottom (1) of the condensate siphon.
• Fill the bottom about 3/4 with water.
• Screw the bottom back on the condensate siphon.
6.3 Checking the gas setting
Caution!
Malfunctions or reduction in working life of the
boiler!
If the boiler version does not correspond to the
local gas family, there will be malfunctions or
you have to change components of the boiler
ahead of schedule, e. g. do not use a LPG boiler
on natural gas.
• Before starting up the boiler compare the
details of the type of gas specified on the
identification plate with the type of gas
supplied at the installation site.
If the boiler version corresponds to the local gas family:
• Proceed as described below.
If the boiler version does not correspond to the local
gas family:
• Perform the gas conversion in accordance with the
gas conversion kit 0020010641.
Installation and maintenance instructions ecoTEC 0020029172_0426
Start-up 6
• Adjust the gas setting as described below
(see sections 6.3.1 to 6.3.3).
The combustion of this boiler has been checked,
adjusted and preset at the factory for operation on the
type of gas defined on the identification plate. No
measurement of the combustion is necessary to set up
the boiler.
• Do not adjust the multifunctional automatic gas valve.
• Ensure
- that the boiler has been installed in accordance with
these instructions,
- the integrity of the flue system and the flue seals,
as described in the flue installation instructions
enclosed with this boiler, and as described below,
- a visual check is carried out on the boiler
combustion circuit and the relevant seals,
- that any defects have been corrected at this stage.
To further validate the integrity of the flue system and
confirm correct operation of the boiler it is possible to
conduct flue gas and air measurements on this
boiler - for details see section 6.3.1.
Proceed to put the boiler into operation as follows:
• Check the maximum gas flow rate as detailed in
section 6.3.2.
• Check the gas inlet working pressure as detailed in
section 6.3.3.
• Note that you must re-measure the gas flow rate or
the gas inlet working pressure, if changes were
required to correct any issues found.
6.3.1 Checking for tightness of the flue gas
installation and flue gas recirculation
• Check the integrity off the flue gas installation
according to TB 200.
• Should the flue gas installation be longer than 2 m we
strongly recommend to check the system for flue gas
recirculation as described below.
1
• For checking the system for recirculation use the air
measure point (2).
• Use the flue gas analyser.
• If you detect any CO or CO2 in the fresh air, search
for 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.
6.3.2 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.1 as
described in section 9.2.
• In addition, ensure that maximum heat can be
dissipated into the heating system by turning up the
room thermostat.
• 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 6.2.
Appliance ecoTEC VU 466
Maximum net heat input in kW 45
Gas flow rate nom. + 5 % – 10 %
Natural gas in m3/h 4,76 5,00 4,29
Propane in kg/h 3,50 3,67 3,15
Table 6.2 Gas flow rates
• If the measured gas flow rate lies outside the
tolerance limits specified in Table 6.2, do not operate
the boiler and inform the Vaillant Service Solutions
(0870 6060 777).
Fig. 6.4 Flue gas and air measure points
Legend:
1 Flue gas measure point
2 Air measure point
If the measured gas flow rate is within the tolerance
limits shown in Table 6.2, then proceed as follows:
• Take the boiler out of operation by
2
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
• Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
27Installation and maintenance instructions ecoTEC 0020029172_04
6 Start-up
6.3.3 Checking the gas inlet working pressure
• Ensure that the gas inlet working pressure can be
obtained with all other gas appliances in the property
working.
• Remove the front casing from the boiler.
• Close the gas isolation valve of the boiler.
1
2
Fig. 6.5 Measuring the gas inlet working pressure
• Loosen the sealing screw marked “in” (1) on the gas
valve.
• Connect a digital pressure gauge or U-tube
manometer (2).
• Open the gas isolation valve of the boiler.
• Start the boiler by activating the test program P.1 as
described in section 9.2.
• In addition, ensure that maximum heat can be
dissipated into the heating system by turning up the
room thermostat.
• 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 6.3.
Natural gas (G20) LPG (G31)
Minimum
pressure at
reference test
point in mbar
17 25 25 45
Table 6.3 Gas inlet working pressure at the reference test point
Maximum
pressure at
reference test
point in mbar
Minimum
pressure at
reference test
point in mbar
Maximum
pressure at
reference test
point in mbar
• Should the pressure recorded at the reference test
point in the boiler be lower than indicated (Table 6.3)
check if there is any blockage in the pipework or if the
pipework is undersized.
• 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 team and
proceed as follows:
• Take the boiler out of operation by
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
• Close the gas isolation valve of the boiler.
• Remove the pressure gauge and re-tighten the sealing
screw (1).
• 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:
• Take the boiler out of operation by
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
• Close the gas isolation valve of the boiler.
• Remove the pressure gauge and re-tighten the sealing
screw (1).
• Open the gas isolation valve of the boiler.
• Make sure that there is no leakage at the sealing
screw.
• Put the front casing back on.
• Reset boiler controls for normal operation.
• Record the appliance gas inlet working pressure
(mbar) in the Benchmark gas boiler commissioning
checklist.
6.4 Checking the appliance function
If the installation is complete and the gas setting has
been checked, perform a function check before starting
up the boiler and handing it over to the operator.
• Commission the boiler in accordance with the
instructions in the relevant operating manual.
• Check the tightness of the gas supply line, flue gas
installation, heating installation and hot water pipes.
• Check the air/flue gas duct for proper installation.
• Make absolutely sure that the front casing is properly
closed.
• Check the function of the heating (see Chapter 6.4.1)
and hot water generation (see Chapter 6.4.2)
• Hand over the boiler to the operator.
The Vaillant ecoTEC displays status codes to indicate
the operating condition of the boiler. You can perform a
function check based on these status codes by pressing
the "i" button.
Installation and maintenance instructions ecoTEC 0020029172_0428
Fig. 6.6 Tightness check
Start-up 6
boiler is running properly in normal operation and
"S. 24" appears in the display.
Note!
h
If you connect your controller to a dual-cable
eBUS line, specify the highest possible hot
water temperature using the corresponding rotary knob. Specify the set target temperature
for your cylinder at the controller.
6.4.1 Heating
• Switch on the boiler.
• Make sure that a heat requirement is applied.
• Push "i" to activate the status indicator.
As soon as there is a heat requirement, the boiler goes
through the status displays "S. 1" to "S. 3", until the
boiler is running properly in normal operation and
"S. 4" appears in the display.
Fig. 6.7 Display during heating mode
6.4.2 Cylinder charging
• Switch on the boiler and the connected hot water
cylinder.
• Make sure that the cylinder thermostat is requesting
heat.
• Push the "i" button.
If the cylinder is correctly charged the boiler runs
through the status displays "S. 20" to "S. 23", until the
Fig. 6.8 Display in cylinder charging mode
6.5 Handing over the boiler to the operator
Note!
h
Once the installation is complete, please affix
the enclosed sticker (Item No. 835 593)
containing the language used by the operator to
the boiler front.
The operator must be instructed in handling and
functions of the ecoTEC boiler.
• Hand over any instruction manuals intended for the
operator, as well as the appliance documents for safe
keeping.
• Read through the operating manual with the operator
and answer any questions.
• Draw special attention to the safety instructions which
the operator must follow.
• Make the operator aware of the need for regular
inspection and maintenance of the system.
• Make the operator aware of the need to keep the
manuals in a handy location near the ecoTEC, but not
in or on the boiler.
• Instruct the operator about measures taken to ensure
the supply of combustion air and flue gas guiding.
Point out that these measures, particularly, must not
be altered.
• Explain to the operator how to check the water level/
filling pressure of the system and show the operator
how to refill and bleed the heating installation when
the need arises.
29Installation and maintenance instructions ecoTEC 0020029172_04
6 Start-up
• Show the operator the correct (economical)
temperature, controller and thermostat valve settings.
Caution!
a
The boiler may only be permanently operated
with its casing properly closed! Otherwise,
under unfavourable conditions, it can result in
material damage or even injury or death.
Installation and maintenance instructions ecoTEC 0020029172_0430
Adapting the boiler to the heating installation 7
7 Adapting the boiler to the heating
installation
The ecoTEC boilers are equipped with a Digital
Information and Analysis system (DIA system).
7.1 Selection and setting of parameters
In the diagnosis mode, you can change various
parameters to match the boiler to the heating
installation.
+
Table 7.1 shows only those diagnosis points where
modifications are possible. All the other diagnosis points
are only required for diagnostics and fault repair
(see Chapter 9).
Using the following description you can select the
relevant parameters:
• Push the "i“ and "+“ buttons simultaneously.
The display shows "d. 0“.
• Scroll to the desired diagnosis code with the "+" or "–"
buttons.
• Push the "i" button.
The display shows the respective diagnosis information.
• If necessary, use the "+" or "–" keys to change the
value (display flashes).
• Save the new value by holding the "i" button pressed
for about 5 seconds until the display stops flashing.
You can finish the diagnosis mode as follows:
• Push the "i“ and "+“ buttons simultaneously or avoid
pressing any buttons for about 4 minutes.
The current heating flow temperature, or installation
pressure (if option is selected), reappears in the display.
7.2 Overview of adjustable system parameters
The following parameters can be set to match the boiler
to the heating installation and to suit the customers
requirements:
Note!
h
You can enter your settings in the last column
after setting the appliance-specific parameters.
Note!
The diagnosis points d.14, d.17, d.18, d.20, d.26,
d.27, d.28, d.50, d.51, d.70, d.71, d.72, d.75,
d.77, d.78, d.84, d.93 and d.96 can be found at
diagnosis level 2, see Chapter 9.1.2.
+
Fig. 7.1. Setting the parameters
31Installation and maintenance instructions ecoTEC 0020029172_04
7 Adapting the boiler to the heating installation
Display Meaning Adjustable parameters
d. 0 Heating partial load 12.5 - 45 kW 35 kW
d. 1 Overrun time of internal pump for heat-
d. 2 Maximum burner anti-cycling time heat-
d.14 Pump speed target value Target value of internal pump in %:
d.17 Heating flow/return regulation changeo-
d.18 Specification of the pump operating
d.20 Maximum setting for cylinder target
d.26 Additional relay control ecoTEC 1 = circulation pump
d.27 Switch of relay 1 on the
d.28 Switch of relay 2 on the
d.50 Offset for minimum speed in rpm/10, adjustment range: 0 to 300 30
d.51 Offset for maximum speed in rpm/10, adjustment range: -99 to 0 -45
d.70 not relevant not relevant
d.71 Target value maximum heating flow tem-
d.72 Pump overrun time after cylinder charg-
d.75 maximum charging time for hot water
d.77 Limitation of cylinder charging output
d.78 Limitation of cylinder charging tempera-
d.84 Maintenance indicator: Number of hours
d.93 DSN appliance variant setting Setting range: 0 to 99 46 = VU 466
d.96 Factory setting 1 = Resetting adjustable parameters to factory set-
d.97 Activation of the 2
ing mode
ing at 20°C flow temperature
ver
mode
value
multifunctional module 2 in 7
multifunctional module 2 in 7
perature
ing
cylinder without independent control system
in kW
ture in °C
until the next maintenance
nd
diagnosis level Code: 17 for level 2
2 - 60 min 5 mins
2 - 60 min 20 min
0 = auto, 1 = 53, 2 = 60, 3 = 70, 4 = 85,
5 = 100
0 = flow, 1 = return 0 do not adjust
0 = overrun, 1 = run on,
2 = winter, 3 = intermittent
40 to 70 °C 65 °C
2 = ext. Pump
3 = charging pump
4 = vapour extraction hood
5 = ext. solenoid valve
6 = ext. fault message
7 = not active
8 = remote control, eBUS (not yet supported)
9 = legionella pump (not active)
1 = circulation pump
2 = ext. Pump
3 = charging pump
4 = vapour extraction hood
5 = ext. solenoid valve
6 = ext. fault message
7 = not active
8 = remote control, eBUS (not yet supported)
9 = legionella pump (not active)
1 = circulation pump
2 = ext. Pump
3 = charging pump
4 = vapour extraction hood
5 = ext. solenoid valve
6 = ext. fault message
7 = not active
8 = remote control, eBUS (not yet supported)
9 = legionella pump (not active)
40 to 85 °C 75 °C
0 - 600 s 80 s
20 - 90 min 45 mins
such as heating partial load 35 kW
55 - 85 °C 80 °C
0 to 3000 h and "-"
(300 corresponds to 3000 h, "-" = deactivated)
ting
Factory
setting
5
3
2
1
2
„-“
Boiler-specific
setting
Table 7.1 Adjustable parameters, levels 1 and 2
Installation and maintenance instructions ecoTEC 0020029172_0432
Adapting the boiler to the heating installation 7
7.2.1 Setting the heating partial load
The output of the boilers is set at 35 kW in the factory.
You can specify a value that corresponds to the kW
output of the boiler under diagnosis point "d. 0“.
7.2.2 Setting of pump overrun and pump operating
mode
The pump overrun time for the heating operation is set
at the factory to a value of 5 minutes. It can be adjusted
through a range of 2 – 60 minutes under diagnosis point
"d. 1“. Under diagnosis point "d.18“, you can set the
overrun behaviour of the pump to a different mode.
Overrun: Once the heating requirement has ended, the
pump runs on for the time specified under "d. 1“.
Run on: The pump is switched on if the rotary knob for
setting the heating flow temperature is not at the
left-hand stop and the heat requirement is enabled by
an external controller.
Intermittent: This pump operating mode is useful for
removing residual heat after charging when the heat
demand is extremely low and large temperature spreads
exist between the charging and heating mode target
values. This avoids underheating of the living spaces. In
the event of a heat demand the pump is switched on
every 25 minutes for 5 minutes once the overrun time
has elapsed
7.2.3 Setting of maximum flow temperature
The maximum flow temperature for the heating is set at
the factory to 75 °C. Under diagnosis point "d.71“ it can
be set to between 40 and 85 °C.
7.2.4 Setting of burner anti-cycling time
To prevent frequent switching on and off of the burner
(energy loss), an electronic restart lockout is activated
for a specific period each time the burner is switched
off. The burner anti-cycling time can be modified to suit
the conditions of the heating installation.
The burner anti-cycling time is only activated for the
heating operation.
Hot water operation during a burner anti-cycling time
does not affect the timer. The maximum burner
anti-cycling time can be set to a value of between 2 and
60 min under diagnosis point d.2 (factory setting:
20 min). The individual effective anti-cycling time is
calculated from the current target flow temperature and
the set maximum burner anti-cycling time.
The timer can be reset or cancelled by pressing the fault
clearance key and also by activating summer mode for a
short time (by briefly turning the nominal flow
potentiometer to the left-hand stop then back to the
starting position). The remaining burner anti-cycling
time following a regular shutdown in heating mode can
be called up under diagnosis point "d.67".
33Installation and maintenance instructions ecoTEC 0020029172_04
7 Adapting the boiler to the heating installation
T
(target)
Flow
[°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
Table 7.2 Effective burner anti-cycling times
The effective burner anti-cycling times for each case
depending on the set target flow temperature and the
maximum specified burner anti-cycling time can be
taken from Table 7.2.
Set maximum burner anti-cycling time [min]
1 5 10 15 20 25 30 35 40 45 50 55 60
Note!
h
After the set number of hours has elapsed, the
service interval must be entered in the
diagnosis mode again.
7.2.5 Determination of maintenance
interval/maintenance display
The ecoTEC electronics incorporate a feature that
enables you to determine the maintenance intervals for
the boiler. This function serves to provide a signal after
a specific, adjustable number of burner operating hours
that the boiler needs to be maintained.
The service signal SEr and the current flow temperature
are shown alternately in the display of the ecoTEC once
the specified number of burner operating hours has
elapsed. The "maintenance" message appears in the
display of the eBUS controller (accessories).
Heat demand
5 kW
10 kW
15 kW
20 kW
25 kW
> 27 kW
Table 7.3 Guide 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 to the next
inspection/maintenance
(dependent upon the system type)
1.650 h
1.650 h
2.300 h
2.300 h
1.800 h
1.800 h
2.500 h
2.500 h
2.600 h
2.600 h
3.000 h
3.000 h
The number of operating hours up to the next
maintenance can be set under the diagnosis point
"d.84". Guide values can be taken from table 7.3; these
values comply with an approximate operating time of
one year for the appliance.
The operating hours can be set in steps of ten from 0 to
3000 h.
If the symbol "–" is entered at diagnosis point "d.84"
instead of a numerical value, the "maintenance display"
function is deactivated.
Installation and maintenance instructions ecoTEC 0020029172_0434
Inspection and maintenance 8
8 Inspection and maintenance
8.1 Inspection and maintenance intervals
Danger!
Risk of injury and risk of damage to property
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 dictated by
findings during the inspection process.
The frequency of maintenance must not be
longer than every 5 years.
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/maintained
by a competent person.
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.
This normally is done by cleaning, adjustment and, if
neces-sary, replacing individual components that are subject
to wear.
You must carry out an annual inspection of the
Vaillant ecoTEC.
It is possible to perform a quick, accurate inspection
without removing components by requesting data from
the DIA system, carrying out the simple visual checks
indicated in Table 8.2 and performing a flue gas
measurement.
The maintenance intervals (at least once every 5 years)
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 8.2.
Danger!
d
Possible poisoning and burning by escaping hot
flue gases!
It is possible that hot flue gases escape and
could result in poisoning or burning, if the boiler
is operated
- without a completely installed air/flue gas
duct
- with an opened air/flue gas duct
- with internal leakages and an opened front
casing.
• Operate the boiler
- for commissioning
- for testing purposes
- in continuous mode
only with closed front casing and completely
mounted and closed air/flue gas duct.
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 BS7927 or BS-EN50379-3 and be
calibrated in accordance with the analyser
manufacturers’ requirements.
- Competence can be demonstrated by satisfactory
completion 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.
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.
8.1.1 General inspection and maintenance
instructions
The original components of the product were also certified as part of the CE declaration of conformity. If you
do not use certified Vaillant original spare parts for
maintenance or repair work, this voids the CE conformity of the product. We therefore strongly recommend
that you fit Vaillant genuine spare parts. You can find
information about the available Vaillant original spare
parts on the back page of these instructions, below the
contact address.
> If you require spare parts for maintenance or repair
work, use only Vaillant genuine spare parts .
During any inspection and maintenance or after change
of parts of the combustion circuit, the following must be
checked:
- The appliance has been installed in accordance with
the relevant installation instructions.
- The integrity of the flue gas installation and flue seals
is in accordance with the relevant flue installation
instructions enclosed.
35Installation and maintenance instructions ecoTEC 0020029172_04
8 Inspection and maintenance
- Visual, the integrity of the boiler combustion circuit
and relevant seals.
- The gas inlet working pressure at maximum rate as
described in section 6.3.3.
- The gas flow rates as described in section 6.3.2.
- Correctness of electrical, water and gas connections.
- Correctness of the water pressure.
- The condition of the whole system, in particular the
condition of radiator valves, evidence of leakage from
the heating system and dripping taps.
• Correct any faults before proceeding.
8.1.2 Safety instructions
Danger!
Danger of life and limb by electric shock!
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.
Note
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.
• Fill the heating circuit of the boiler to a pressure of between 1.0 and 2.0 bar if required.
• Bleeding the heating installation (see section 6.2,
Filling the system).
• Open the gas isolation valve.
• Check the boiler for gas and water leaks.
• If necessary, refill and re-bleed the heating
installation.
• Replace the front casing to the boiler.
• Carry out a functional check of the boiler
(see section 6.4).
• Always check earth continuity, polarity and resistance
to earth with a multimeter after any service work and
after replacing any electrical component.
8.1.3 Checking the CO
concentration
2
Note
Checking/adjustment of the CO
concentration
2
is required in the following instances:
- replacement of gas valve,
- conversion to or from Natural Gas/LPG
- or if an incorrect combustion is suspected.
1
2
3
Always perform the following steps prior to inspection
or maintenance work:
• Switch off the main switch.
• Disconnect the boiler from the power mains by
- 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).
• 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.
• 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.
• Reconnect the boiler to the power mains.
• Switch the main switch on.
4
Fig. 8.1 Measuring the CO2 concentration, specifying the air
ratio (gas setting)
Legend:
1 Flue gas analysis point
2 Screw
3 Air intake pipe
4 Main throttle
Note
The boiler is fitted with a flue gas analysis
point (1). A suitable flue gas analyser can be
connected to this point to establish the
combustion performance of the boiler.
Installation and maintenance instructions ecoTEC 0020029172_0436
Inspection and maintenance 8
• Remove the front casing.
• Start the testing program P.1.
• Wait at least 5 minutes until the boiler reaches its
operating temperature.
• Measure the CO
concentration at the flue gas
2
analysis point (1). Compare the measured value with
the corresponding value in Table 8.1.
• If all these points are as required, proceed as
described in section 8.1.5.
• If one of the flue gas values is greater than the
acceptable values in Table 8.1, then proceed as
described in the following section 8.1.4.
8.1.4 Adjusting the CO
concentration (or the air
2
ratio)
Danger!
d
Increased risk of poisoning due to incorrect
settings!
Incorrect setting may increase the risk of
poisoning.
• If one of the flue gas values is greater than
the acceptable values in Table 8.1 then check
- the integrity of the complete flue gas
installation
- the integrity of the combustion circuit seals
- the gas inlet working pressure
- the gas flow rate.
If the flue gas value needs to be adjusted,
• unfasten the screw (Fig. 8.1, 2) and
• fold the air intake pipe (Fig. 8.1, 3) forwards through
90°. Do not remove the air intake pipe.
• Specify the required flue gas value if necessary (value
with front casing of boiler removed, see Table 8.1) by
turning the screw of the main throttle (Fig. 8.1, 4)
• Push the „i“ button to deactivate the full load mode.
The full load mode is also deactivated if no button is
pushed for 15 minutes.
• The adjusting screw shall be sealed after the adjustment.
• Re-secure the air intake pipe with the screw (2).
• Put the front casing back on.
Settings
after 5 minutes full
CO
2
load mode with
boiler front casing closed
CO
after 5 minutes full
2
load mode with boiler
front casing removed
Set for Wobbe index W
CO value with full load < 250 < 250 ppm
CO/CO
2
Table 8.1 Factory gas setting
Natural gas
(H) Tolerance
s
9.0 1.0 10.0 0.5 Vol.–%
8.8 1.0 9.8 0.5 Vol.–%
15 22.5 kWh/m3
‹ 0,0031 < 0,0026
Propane
Tolerance
Unit
Danger!
d
Risk to life due to poisoning!
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 8.1, call the
Vaillant Service Solutions.
• Do not start up the boiler!
Note
h
Use a 4 mm hexagon socket spanner to turn
the screw.
• Turn to the left: higher CO
• Turn to the right: lower CO
concentration,
2
concentration.
2
Note
h
Natural gas: Only perform the adjustment in
increments of 1/8 turn and wait approximately
1 minute after each adjustment until the value
stabilises.
Liquid gas: Only perform the adjustment in very
small increments (approximately 1/16 turns),
and wait approximately 1 minute after each
adjustment until the value stabilises.
• After performing the adjustments, fold the air intake
pipe back up.
• Check the CO
concentration once again.
2
• If necessary, repeat the setting process.
37Installation and maintenance instructions ecoTEC 0020029172_04
8 Inspection and maintenance
.8.1.5 Inspection and maintenance work steps
Column 1
No. Activity
Inspection must
be carried out
each year
Check the air flue gas installation for leaks and for proper fixation and ensure it is not blocked
1
or damaged and is fitted correctly, complying with the relevant installation instructions.
xx
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. If damage is evident proceed to column 2.
Measure the gas flow rate during operation with maximum load (section 6.3.2). If the gas flow
4
rate complies to the Table 6.1 continue with column 1, if not proceed to column 2.
xx
xx
Check the gas inlet working pressure (section 6.3.3) operation with maximum load. If the gas
5
inlet working pressure complies to the Table 6.2 continue with column 1, if not proceed to
xx
column 2.
Check combustion by measuring CO, CO
tole rances of Table 8.1 proceed to maintenance column 2. You must not proceed with the
6
and CO/CO2. If the values are outside the
2
x
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.
xx
Maintenance
must be carried
out at regular
intervals – but
no longer than
Column 2
5 years
Close the gas isolation valve and the service valves. x
8
Dump 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.
Remove the compact thermal module. x
10
Check the integrity of all combustion circuit seals, especially the burner door seal. If there are
11
any damages repair them before proceeding.
12 Clean the heat exchanger. x
13 Check whether the burner is dirty and clean it if necessary. x
14 Check the condensate siphon in the boiler, clean and fill if necessary. x x
15 Check the condensate ducts in the boiler and clean if necessary. x x
16 Clean the air separation system. x
17 Install the compact thermal module. Caution: Use new seals and nuts! x
Open the service valves and fill up the boiler/appliance to approximately 1.0 - 2.0 bar
18
(depending on the static height of the system). Start the bleeding program P.0.
Open the gas is
19
boiler.
erform a test operation of the boiler and heating installation, including water heating and
P
20
bleed again if necessary.
olation valve, reconnect the boiler with the power mains and switch on the
xx
xx
21 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
22
necessary.
If you had problems with the CO, CO
them again now (see Table 8.1). If they are outside of the tolerances of Table 8.1 make an
23
, CO/CO2-values in Step 6 before the maintenance, check
2
xx
adjustment, see section 8.1.4.
x
x
x
x
24 Complete the gas commission checklist (benchmark book). x x
Table 8.2 Inspection and maintenance steps
Installation and maintenance instructions ecoTEC 0020029172_0438
8.2 Filling/draining the boiler and heating
installation
Inspection and maintenance 8
8.2.1 Filling the boiler and the heating installation
A description of how to fill the boiler and heating
installation is provided in Chapter 6.2.
8.2.2 Draining of the boiler
• Close the service valves of the boiler.
• Open the drain valves on the service valves.
• Open the automatic air vent on the air separator to
allow the boiler to drain completely.
8.2.3 Draining the entire system
• Attach a hose to the draining device on the system.
• Bring the open end of the hose to an appropriate
drain point.
• Make sure that the service valves of the boiler are
open.
• Open the drain valve.
• Open the bleeding valves of the radiators.
Start from the highest radiator and then work from
the top to the bottom.
• Once the water has drained off, close the bleeding
valves of the radiators and the drain valve.
8.3 Maintenance of the compact thermal module
8.3.1 Dismounting the compact thermal module
The compact thermal module consists of the speed
ontrolled fan, the gas/air combination valve, the gas
c
feed (mixture pipe) to the fan premix burner and the
premix burner itself. These four individual parts form the
compact thermal module component.
1
2
3
Fig. 8.2 Removing air intake pipe
• Remove the screw (2) and remove the air intake pipe
(1) from the intake stub.
• Disconnect the gas supply line (3) at the gas valve. To
prevent the corrugated gas pipe from twisting when
loosening the cap nut, hold up the pipe at the spanner
flat.
Danger!
H
Danger of burning or scalding!
There is danger of being burned or scalded at
the compact thermal module and at all watercarrying components. Only carry out work on
these components once they have cooled down.
To dismount the compact thermal module proceed as
follows:
• Turn off the boiler by the main switch.
• Isolate the boiler from the electrical mains.
• Cut off the gas supply to the boiler.
• Remove the front casing of the boiler.
• Swing off the electronic box.
39Installation and maintenance instructions ecoTEC 0020029172_04
8 Inspection and maintenance
Caution!
a
Damage to gas supply!
Under no circumstance may the compact
thermal module dangle on the flexible
corrugated gas pipe.
1
2
7
6
5
4
Fig. 8.3 Dismounting compact thermal module
1
2
3
• Remove the two plugs for the ignition (5) and ground
connections (6) from the ignition electrode.
• Remove the plugs (3) at the fan motor and the
cable (4) at the gas valve.
• Undo the five nuts (7).
• Pull off the entire compact thermal module (2) from
the heat exchanger (1).
• After dismounting check the burner and heat
exchanger for damage and soiling – clean the
components if necessary as described below.
• Check the insulating layer at the burner door. If signs
of damage are apparent it must be renewed (Item
No. 210734).
3
4
Fig. 8.4 Cleaning the heat exchanger
• Dismount the compact thermal module as described
under 8.3.1.
• Clean the heating coil (2) of the heat exchanger (3)
using commercially-available essence of vinegar. Flush
with water. The water flows out of the heat exchanger
through the condensate siphon. You can also clean
the condensate trap via the opening (4).
• Allow the cleaning agent to take effect for
approximately 20 minutes then rinse off the loose dirt
with a powerful water jet. Avoid pointing the water jet
directly at the insulating mat (1) at the rear of the
heat exchanger.
You can also use a plastic brush to carry out the
cleaning.
8.3.3 Checking the burner
1
8.3.2 Cleaning the heat exchanger
Caution!
a
Danger of short-circuiting and irrepairable
damage to the PCB and fan!
Protect the downfolded electronic box and also
the fan against splash water.
2
3
Fig. 8.5 Checking the burner
The burner (2) is maintenance-free and needs no
cleaning.
• Check the surface of the burner for damage, replace
the burner if necessary.
• After checking/repairing the burner install the compact thermal module as described in Chapter 8.3.4.
Installation and maintenance instructions ecoTEC 0020029172_0440
Inspection and maintenance 8
8.3.4 Installing the compact thermal module
• Renew the seals (1) and (3) in the burner door
(see Fig. 8.5).
Danger!
H
Danger of combustion and damage due to
escaping hot flue gases!
Both seals (1) and (2) and the self-locking nuts
on the burner door must be replaced each time
the burner door is opened (e.g. during
maintenance and service work). If the insulation
layer on the burner door shows signs of damage
it must also be renewed (Item No. 210734).
• Insert the compact thermal module (2, Fig. 8.3) into
the heat exchanger (1, Fig. 8.3).
• Tighten the five nuts (7, Fig. 8.3) including the
retainer for the air intake pipe crosswise until the
burner door is uniformly seated on the contact
surfaces.
• Plug on the ignition wire (5, Fig. 8.3) and the ground
connection (6, Fig. 8.3).
• Plug on the cables (3, Fig. 8.3) at the fan motor and
the cable (4, Fig. 8.3) at the gas valve.
• Connect the gas supply with a new seal to the gas
valve. Use the spanner flat at the flexible gas line to
hold up the gas valves.
8.4 Cleaning the condensate siphon
Fig. 8.7 Cleaning the condensate siphon
Danger!
d
If the boiler is operated with empty condensate
siphon, there is risk of poisoning from escaping
flue gases.
Therefore, fill up the siphon again after each
cleaning session.
1
1
Fig. 8.6 Checking for gas tightness
Caution!
a
Open the gas feed and check the gas tightness
of the boiler with leak detector spray. Check the
screwed connection (1) particularly carefully.
• Make sure the blue sealing ring in the air intake pipe is
positioned correctly in the seal face.
• Insert the air intake pipe onto the intake stubs and
fasten the pipe with the retaining screw (2, Fig. 8.2).
• Unscrew the lower section (1) of the condensate
siphon.
• Clean the bottom of the siphon by flushing it out with
water.
• Fill the lower section of the siphon about 3/4 with
water.
• Screw the lower section back to the condensate
siphon.
41Installation and maintenance instructions ecoTEC 0020029172_04
8 Inspection and maintenance
8.5 Cleaning the condensate ducts
4
2
1
Fig. 8.8 Dismounting the condensate siphon
• Completely remove the condensate siphon to clean
the condensate ducts by pulling out the clamp (1). This
allows access to the condensate discharge nozzle on
the heat exchanger.
• You can remove accumulations of dirt in the front of
the condensate discharge area via the lower cleaning
eye (2) on the heat exchanger.
• Refill the siphon with water.
8.6 Cleaning the air separation system
Danger!
H
Danger of burning or scalding!
All water-carrying components present a
danger of injury and scalding. Only carry out
work on these components if they have cooled
down.
5
6
Fig. 8.10 Cleaning the filter
8.6.1 Cleaning the filter
You can clean or replace the filter (5) in the air
separator (2) without having to remove the air
separator.
• Unscrew the brass cover (4) of the steel casing (6).
• Pull the filter (5) upwards out of the air separator.
You can either clean the filter with hot water or replace
it with a new one.
• Insert the filter into the air separator.
• Screw the brass cover onto the air separator.
8.6.2 Cleaning the air separator
If the collector tray (on the inside of the casing next to
the filter) is heavily soiled, you can completely dismount
the air separator (2), clean it with hot water then
reinsert it.
• At first unfasten the 1.5“ nut (3) on the lower outlet.
• Turn the casing on the axis of the upper connection.
• Only now unfasten the knurled nut (1) for the upper
inlet.
• Slide down the casing and pull the complete air
separator forwards out of the boiler.
• Dismount the filter as described in 8.6.1.
1
2
3
Fig. 8.9 Cleaning the air separation system
Now you can clean the air separator and filter with hot
water.
Caution!
a
All O-rings must be replaced with new ones as
otherwise leaks may occur!
• To reinstall the air separator, carry out the steps
described above in reverse.
8.7 Checking the charge pressure of the external
expansion vessel
• Measure the charge pressure of the expansion vessel
at the testing nozzle of the vessel when the boiler is
depressurised.
Installation and maintenance instructions ecoTEC 0020029172_0442
Inspection and maintenance 8
Troubleshooting 9
• Fill the expansion vessel with air at a pressure of less
than 0.75 bar according to the static head of the
heating installation.
• If water is discharged at the testing nozzle of the
expansion vessel the vessel must be replaced.
8.8 Checking gas connection pressure
(gas inlet working pressure)
To check the connection pressure proceed as described
in Chapter 6.3.3.
8.9 Checking the CO
To check the CO
described in Chapter 8.1.3.
8.10 Test operation
Always perform the following checks after completing
any maintenance task:
• Start up the appliance in accordance with the
instructions in the relevant operating manual.
concentration follow the procedure
2
concentration
2
9 Troubleshooting
Note!
h
Whenever possible, please quote the fault
message displayed (F.xx) and the status of the
boiler (S.xx) when contacting the Vaillant
customer service or your Vaillant service
partner.
If the display flashes „SEr“ this means, that
you should carry out a service in the near
future. The boiler is not in a failure mode but
works further on. Press the info-button „i“ for
addional information.
9.1 Diagnostics
9.1.1 Status codes
The status codes that you can see on the display
provides information about the current operating
condition of the boiler.
The display of the status codes can be viewed as
follows:
Fig. 8.11 Tightness check
• Check the appliance for gas and water leaks.
• Check the flue system for leaks and for proper
fixation.
• Check over-ignition and that the flame on the burner
is burning evenly.
• Check the function of the heating (see Chapter 6.4.1)
and hot water generation (see Chapter 6.4.2).
• Document the inspection/maintenance tasks carried
out in the form provided in the inspection or
maintenance contract.
Fig. 9.1 Display of status codes
• Push the "i" button.
The status code appears in the display, e.g. S.4 for
"Heating mode, burner on.".
The display of the status codes can be ended as follows:
• Push the "i" button
or
• Do not push any buttons for about 4 minutes.
Depending on the settings, the current flow
temperature or current water pressure of the heating
installation reappears in the display.
43Installation and maintenance instructions ecoTEC 0020029172_04
9 Troubleshooting
Display Meaning
Heating mode
S.0 Heating no heat demand
S.1 Heating mode fan start-up
S.2 Heating mode pump pre-run
S.3 Heating mode ignition
S.4 Heating mode burner on
S.5 Heating mode pump/fan overrun
S.6 Heating mode fan overrun
S.7 Heating mode pump overrun
S.8 Heating remaining off-period xx min
Domestic hot water mode (DHW)
S.20 DHW demand
S.21 DHW mode fan start-up
S.22 DHW mode pump pre-run
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 DHW mode burner off-period
Other:
S.30 Heating mode blocked by room thermostat
(terminal 3-4 open)
S.31 Summer mode active or no heat demand from eBUS
controller
S.32 Heat exchanger antifreeze active, as fan speed
variation is too high. Boiler is within the waiting time of
the operation block function
S.34 Antifrost mode active
S.36 Reference setting of continuous controller 7-8-9 or
e-BUS controller is < 20°C and blocks the heating mode
S.39 Contact thermostat activated
S.41 Water pressure > 2.8 bar
S.42 Exhaust flap return signal blocks burner operation (only
in connection with accessories) or condensate pump
faulty, heat demand is blocked
S.53 Boiler remains within the waiting time for the modula-
tion block/operation block function due to a water lack
(flow-return difference too large)
S.54 Boiler remains within the waiting time of the operation
block function due to a water lack (temperature
gradient)
S.59 Waiting time: minimum quantity of circulation water not
achieved
S.85 Service info: Check quantity of circulation 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 is in progress,
heating demands are blocked
SEr Carry out a service in the near future. Press the
„i“-button for further information.
9.1.2 Diagnosis codes
In the diagnosis mode, you can change certain
parameters or display more information.
The diagnosis information is divided into two diagnosis
levels. The 2
nd
diagnosis level can be reached only after
entering a password.
Caution!
a
The access to the 2
nd
diagnosis level may only
be used by a qualified heating engineer.
st
diagnosis level
1
• Push the "i“ and "+“ buttons simultaneously.
The display shows "d.0“.
• Scroll to the desired diagnosis code on the 1
st
diagnosis level with the "+" or "–" buttons (see
Table 9.2).
• Push the "i" button
The display shows the associated diagnosis information.
• If necessary, use the "+" or "–" keys to change the
value (display flashes).
• Save the new value by holding the "i" button pressed
for about 5 seconds until the display stops flashing.
You can finish the diagnosis mode as follows:
• Push the "i“ and "+“ buttons simultaneously or
• Do not push any buttons for about 4 minutes.
The current heating flow temperature or the current
water pressure of the heating installation reappears in
the display.
Table 9.1 Status codes
Installation and maintenance instructions ecoTEC 0020029172_0444
Troubleshooting 9
Display Meaning Display value/adjustable value
d.0 Heating part load Adjustable heating part load in kW (factory setting: approx. 70%
d.1 Pump overrun for heating mode 2 - 60 minutes (factory setting: 5)
d.2 Maximum burner anti-cycling time heating at 20°C flow
d.4 Measured value of cylinder sensor in °C
d.5 Set value of flow temperature (or target value of return) in °C, maximum of the value set in d.71, limited by an eBUS controller
d.7 Set value cylinder temperature 40 to 65 °C (maximum temperature can be adjusted at d.20)
d.8 Room thermostat at terminals 3-4 0 = Room thermostat open (no heat request)
d.9 Set value flow temperature at terminal 7-8-9 in °C, minimum off, target value of ext. eBus and target value of
d.10 Status internal pump 1 = on, 0 = off
d.11 Status external heating pump 1 to 100 = on, 0 = off
d.12 Status cylinder charge pump 1 to 100 = on, 0 = off
d.13 Status circulation pump 1 to 100 = on, 0 = off
d.15 Pump speed actual value Actual value internal pump in %
d.22 Hot water demand via C1/C2, internal hot water control
d.23 Summer/winter operating mode (heating on/off) 1 = heating on, 0 = heating off (summer mode)
d.24 not relevant not relevant
d.25 Hot water generation enabled by eBUS controller 1 = yes, 0 = no
d.29 Actual value circulation water quantity of flow rate
d.30 Control signal for the gas valve 1 = on, 0 = off
d.33 Fan speed target value in rpm/10
d.34 Fan speed actual value in rpm/10
d.35 not relevant Not relevant
d.40 Flow temperature actual value in °C
d.41 Return temperature actual value in °C
d.44 Digitalised ionisation voltage Display range 0 to 102, >80 no flame, <40 good flame display
d.47 Outside temperature (with weather-controlled Vaillant
d.76 Boiler variant (display): Device specific number (DSN) 46
d.90 Status digital regulator 1 = detected, 0 = not detected (eBUS Address <=10)
d.91 Status DCF with external sensor connected 0 = no reception, 1 = reception, 2 = synchronised, 3 = valid
d.97 Activation of the 2
d.98 Telephone number of heating engineer Programmable telephone number
Table 9.2 Diagnosis codes in the 1
temperature
system
sensor
controller)
nd
diagnosis level Code: 17 for level 2
st
diagnosis level
of maximum output)
2 - 60 minutes (factory setting: 20)
if connected)
1 = Room thermostat closed (heat request)
terminal 7
1 = on, 0 = off
Actual value in m
Actual value in °C
3
/h
2nd diagnosis level
• Scroll as described above in the 1
st
diagnosis level to
diagnosis code d.97
• Change the displayed value to 17 (password) and save
this value.
nd
You are now in the 2
information from the 1
diagnosis level in which all
st
(see Table 9.2) and the 2nd
(see Table 9.3) is displayed.
Scroll and change values and exit diagnosis mode as
described in the 1
st
diagnosis level.
Note!
h
If you push the buttons "i" and "+" within
4 minutes of leaving the 2
can directly access the 2
nd
diagnosis level, you
nd
diagnosis level
without re-entering the password.
45Installation and maintenance instructions ecoTEC 0020029172_04
9 Troubleshooting
Display Meaning Display value/adjustable value
d.14 Pump speed target value Target value of internal pump in % Possible settings:
d.17 Heating flow/return regulation changeover 0 = flow, 1 = return (factory setting: 0)
d.18 Specifying the pump operating mode 0 = overrun
d.20 Maximum setting for cylinder target value 40 to 70°C (factory setting: 65°C)
d.26 Additional relay control ecoTEC 1 = circulator
d.27 Switch of relay 1 on the
multifunctional module 2 in 7
d.28 Switch of relay 2 on the
multifunctional module 2 in 7
d.50 Offset for minimum speed in rpm/10, setting range: 0 to 300 (factory setting 30)
d.51 Offset for maximum speed in rpm/10, setting range: -99 to 0 (factory setting -45)
d.60 Number of safety thermostat shutdowns Number
d.61 Number of faults of the automatic combustion system Number of unsuccessful ignitions in the last attempt
d.64 Average ignition time in seconds
d.65 Maximum ignition time in seconds
d.67 Remaining burner anti-cycling time in minutes
d.68 Unsuccessful ignitions at 1
d.69 Unsuccessful ignitions at 2
st
attempt Number
nd
attempt Number
d.70 not relevant Not relevant
d.71 Target value maximum flow temperature Setting range in °C: 40 to 85 (factory setting: 75)
d.72 Pump overrun time after cylinder charging Setting range in seconds: 0, 10, 20 to 600
d.75 Maximum charging time for cylinder without an own
control system
d.77 Limitation of cylinder charging output in kW Setting range in kW: depending on boiler
d.78 Limitation of cylinder charging temperature in °C Setting range in °C: 55 to 85 (factory setting: 80)
d.80 Operating hours heating in h
0 = auto (factory setting)
1 = 53%
2 = 60%
3 = 70%
4 = 85%
5 = 100%
1 = continuous
2 = intermittent (factory setting)
2 = ext. pump (factory setting)
3 = cylinder charge pump
4 = extractor hood
5 = ext. solenoid valve
6 = ext. fault message
7 = not active
8 = remote control eBUS (not yet supported)
9 = legionella pump (not active)
1 = circulator (factory setting)
2 = ext. pump
3 = cylinder charge pump
4 = extractor hood
5 = ext. solenoid valve
6 = ext. fault message
7 = not active
8 = remote control eBUS (not yet supported)
9 = legionella pump (not active)
1 = circulator
2 = ext. pump (factory setting)
3 = cylinder charge pump
4 = extractor hood
5 = ext. solenoid valve
6 = ext. fault message
7 = not active
8 = remote control eBUS (not yet supported)
9 = legionella pump (not active)
(factory setting: 80 s)
Setting range in min: 20 - 90 (factory setting: 45 min)
(factory setting: maximum output)
Note: Chosen value must be at least 15 K or 15 °C above set cylinder
target value.
1)
Table 9.3 Diagnosis codes for diagnosis level 2 (continued on
next page)
Installation and maintenance instructions ecoTEC 0020029172_0446
Troubleshooting 9
Display Meaning Display value/adjustable value
d.81 Operating hours hot water generation in h
d.82 Burner start-ups in heating mode Number/1001) (3 equals 300)
d.83 Burner start-ups in hot water mode Number/100
d.84 Maintenance indicator: Number of hours until the next
maintenance
d.93 DSN appliance variant setting Setting range: 0 to 99
d.96 Factory setting 1 = Resetting adjustable parameters to factory setting
1) In the diagnosis codes 80 to 83 5 digit figure values are stored. When selecting e.g. d.80 only the first two digits of the figure value
are displayed (e.g.10). By pressing the "i“ key, the display switches over to the last three figures (e.g. 947). The operating hours
counter of the heating in this case would be 10947 h. Pressing the "i" again causes the display to switch back to the diagnosis point
that was called up.
Table 9.3 Diagnosis codes at diagnosis level 2 (continued)
9.1.3 Fault messages
The fault messages displace all other displays when
failures occur. Occuring failures are displayed as "F ...",
e.g. "F.10" (see Tab. 9.4).
If several failures occur simultaneously, each fault
message is displayed for approximately two seconds on
an alternating basis.
Once you have repaired the failure push the fault
clearance key to restart the boiler.
If the failure cannot be repaired and reoccurs despite
having carried out several fault clearance attempts,
please contact your factory customer service.
1)
1)
(3 equals 300)
Setting range: 0 to 3000 h and "-“ for deactivated
Factory setting: "-“ (300 corresponds to 3000 h)
9.1.4 Fault memory
The last ten failures which occurred are saved in the
fault memory of the boiler.
• Push the "i“ and „-“ buttons simultaneously.
• Scroll back in the failure memory with the "+" button.
You can exit the fault memory display as follows:
• Push the "i" button
or
• Do not push any buttons for about 4 minutes.
Depending on the settings, the current flow temperature
or current filling pressure of the heating installation
reappears in the display.
47Installation and maintenance instructions ecoTEC 0020029172_04
9 Troubleshooting
Code Meaning Cause
F. 0 Break Flow NTC NTC plug not plugged in or has come loose, multiple plug on the
F. 1 Break Return NTC NTC plug not plugged in or has come loose, multiple plug on the
F.10 Short circuit Flow NTC Short to ground/short circuit in cable harness, NTC defective
F.11 Short circuit Return NTC Short to ground/short circuit in cable harness, NTC defective
F.13 Short circuit Cylinder sensor Short to ground/short circuit in cable harness, moisture in plug,
F.20 Safety shutdown Temperature limiter Incorrect earth connection between cable harness and boiler, flow
F.22 Safety shutdown Water lack/dry combustion No or insufficient water in the boiler, cable for pump, water
F.23 Safety shutdown Over temperature-spread NTC Pump blocked, insufficient pump output, air in boiler, system
F.24 Safety shutdown Temperature rises too quickly Pump blocked, insufficient pump output, air in boiler, system
F.25 Safety shutdown Excessive flue temperature Break in plug connection for optional flue gas safety thermostat,
F.27 Safety shutdow Flame simulation Moisture on the PCB, PCB (flame monitor) defective, gas solenoid
F.28 Failure during start-up: Ignition failed Gas meter defective, gas pressure monitor has been triggered, air
F.29 Failure during operation: Re-ignition failed Gas feed interrupted from time to time, flue gas recirculation,
F.32 Failure Fan Plug at fan not correctly plugged in, multiple plug on PCB not
F.49 Failure eBUS Short-circuit on eBUS, eBUS overload or two power supplies with
F.61 Failure Activation fuel valve short circuit/short to ground in cable harness for gas valve, gas
F.62 Failure Off delay fuel valve delayed shutdown of gas valve, delayed extinguishing of flame
F.63 Failure EEPROM PCB defective
PCB not plugged in correctly, interruption in cable harness, NTC
defective
PCB not plugged in correctly, interruption in cable harness, NTC
defective
NTC defective
or return NTC defective (loose connection), black discharge via
ignition cable, ignition plug or ignition electrode
pressure sensor or flow rate sensor loose/not plugged in/defective,
pump blocked or defective, pump output too low, non-return valves
blocked/incorrectly installed, minimum quantity of circulation
water not reached
pressure too low, flow and return NTC interchanged
pressure too low, non-return valves blocked/incorrectly installed,
flow and return NTC interchanged
break in cable harness
valve leaking
in gas, gas inlet working pressure too low,
Thermal isolator device (TAE) has been triggered, condensate duct
blocked, failure at 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, PCB defective
condensate duct blocked, faulty earthing of boiler
correctly plugged in, break in cable harness, fan blocked, Hall
sensor defective, PCB defective
different polarities on the eBUS
valve defective (coils shorted to ground), PCB defective
signal, gas valve leaking, PCB defective
F.64 Failure Electronics/sensor Flow or return NTC short circuited, PCB defective, recirculation
F.65 Failure Electronics temperature PCB too hot due to external effect, PCB defective
F.67 Failure Electronics/flame Implausible flame signal, PCB defective
F.70 Invalid application ID Spare part case: Display and PCB changed at the same time and
F.71 Failure Flow NTC Flow sensor signalling constant value -> flow sensor defective
F.72 Failure Flow/return NTC Temperature spread between flow sensor and return sensor too
F.73 Failure Water pressure sensor Interruption/short-circuit of water pressure sensor, interruption/
Table 9.4 Fault messages (continued on next page)
boiler variant not re-set
large -> flow and/or return sensor defective
short-circuit to GND in supply line to water pressure sensor
Installation and maintenance instructions ecoTEC 0020029172_0448
Troubleshooting 9
Code Meaning Cause
F.74 Failure Water pressure sensor signal outside correct
range (too high)
F.75 Failure Pump/water lack Water pressure sensor and/or pump defective, air in heating
F.77 Failure Flue gas damper/condensate pump condensate pump defective, cable connection; no checkback signal
con No communication with the electronics Communication failure between display and PCB in the electronic
Table 9.4 Fault messages (continued)
Line to water pressure sensor has short-circuited at 5V/24V
or internal failure in water pressure sensor
installation, too little water in boiler; check adjustable bypass,
connect external expansion vessel to return
from flue gas damper (bridge) of "2 in 7" multifunctional module,
flue gas damper has triggered
box
9.2 Check programs
Special functions can be triggered in the boilers by
activating various check programs.
These programs are given in detail in Table 9.5.
The check programs P.0 to P.6 are started as follows:
• Push the "+" button and hold it down.
• Push the "Fault clearance key" once or switch the
main switch off and on again.
After approximately 5 seconds, P.0 appears in the
display. You can now release the "+" button.
• Push the "+" key to start counting the check
programme number upwards.
• Push the "i“ to operate the boiler now and to start the
check programme.
• Push "i“ and "+“ simultaneously to exit the check
programs. You can also exit the check programs by
not pushing any button for 15 minutes.
Display Meaning
1)
P. 0
Check Program Dearation
The heating circuit and the hot water circuit are bled
via the automatic air vent (the cap of the automatic air
vent must be released).
1 x "i" button: Start bleeding heating circuit
(display view: HP)
2 x "i" button: Start bleeding charging circuit
(display view: SP)
3 x "i" button: Exit bleeding program
9.3 Resetting parameters to factory settings
In addition to the option of manually resetting the
factory settings for the individual parameters specified
in Tables 9.2 and 9.3, you can also reset all parameters
simultaneously.
• Change the value at diagnosis point "d.96“ in
diagnosis level 2 to 1 (see Chapter 9.1.2).
The parameters of all adjustable diagnosis points now
correspond to the factory settings.
The heating pump is cyclically actuated.
Note: The check program deaeration takes about 6.5
minutes to complete.
P.1 Check Program Max. Load:
P.2 Check Program Min. Load:
P.5 Check Program Safety Overheat Cut-Off:
P.6 Check Program Diverter Valve Middle Position:
Table 9.5 Check programs
1)
Bleeding the boiler circuit:
Actuation of heating pump for 15 cycles: 15 s on, 10 s off.
The boiler is operated at full load after successful
ignition.
The boiler is operated at minimum load after
successful ignition.
The burner is switched on at maximum output and the
temperature control is switched off so that the boiler
produces heat, bypassing a regular shutdown, until the
shutdown temperature of the safety thermostat is
reached (97 °C).
(not active)
Display view: HP or SP.
49Installation and maintenance instructions ecoTEC 0020029172_04
10 Replacing components
10 Replacing components
The tasks listed below in this section may be carried out
only by a qualified heating engineer.
The original components of the product were also certified as part of the CE declaration of conformity. If you
do not use certified Vaillant original spare parts for
maintenance or repair work, this voids the CE conformity of the product. We therefore strongly recommend
that you fit Vaillant genuine spare parts. You can find
information about the available Vaillant original spare
parts on the back page of these instructions, below the
contact address.
> If you require spare parts for maintenance or repair
work, use only Vaillant genuine spare parts .
• Make sure the parts are correctly fitted and that their
original position and alignment are retained.
10.1 Safety instructions
Danger!
d
Each time components are replaced, comply
with the safety instructions below for your own
safety and to avoid damage to the boiler.
• Take the boiler out of operation.
Danger!
e
Risk of fatal electric shock through contact
with live connections!
Disconnect the boiler from the power mains by
de-energising the boiler using an isolating
device with a contact opening of at least 3 mm
(e.g. fuses or power switches).
• Close the gas isolation valve and the service valves in
the heating flow and return.
• Close the service valve in the cold water supply pipe.
• Empty the boiler if you want to replace water-bearing
components of the boiler!
• Make sure that water does not drip on live
components (e.g. the electronic box)!
• Use only new seals and O-rings!
• After completing the work, perform a tightness check
and function check (see Chapter 6.4)
10.2 Replacing the burner
Danger!
d
Before replacing the component, observe the
safety information in Chapter 10.1.
• Dismount the compact thermal module as described in
Chapter 8.3.1.
1
Fig. 10.1 Replacing the burner
• Release the four screws (1) on the burner, and remove
the burner.
• Mount the new burner with a new seal. Make sure the
seal notch for the inspection glass fits into the notch
of the burner flange.
• Re-install the compact thermal module as described in
Chapter 8.3.4.
• After completing the work, perform a gas-tightness
check and function check (see Chapter 8.10).
10.3 Replacing the fan or the gas valve
Danger!
d
Before replacing the component, observe the
safety information in Chapter 10.1.
• Disconnect the boiler from the power mains as
described in Chapter 10.1, and close the gas isolation
valve.
• Remove the air intake pipe (1, Fig. 8.2).
• Disconnect the gas supply pipe at the gas valve
(6, Fig. 10.3).
Installation and maintenance instructions ecoTEC 0020029172_0450
Replacing components 10
10.4 Replacing the heat exchanger
Danger!
d
Before replacing the component, observe the
safety information in Chapter 10.1.
1
• Disconnect the boiler from the power mains as
described in Chapter 10.1, and close the gas isolation
valve.
• Close the service valves in the heating flow and return
and drain the boiler.
• Dismount the compact thermal module as described
2
under 8.3.1.
4
Fig. 10.2 Dismantling the fan with gas valve
• Pull the plug (4) out of the gas valve.
• Pull the plugs (2) out of the fan.
• Unfasten the four screws (3) on the compact thermal
module (1).
• Remove the complete unit "gas valve/fan".
5
6
Fig. 10.3 Screwed connection gas valve/fan
• Release both fixing screws (5) on the gas valve and
remove the fan from the gas valve.
• Replace the defective component.
Caution!
a
The gas valve and fan must be returned to their
previous installation position. Use a new seal!
• Screw the fan to the gas valve. Use new seals.
• Re-install the complete "gas valve/fan" boiler in the reverse sequence.
• After completing the work, perform a gas-tightness
check and function check (see Chapter 8.10)
3
1
2
3
4
5
Fig. 10.4 Replacing the heat exchanger
• Pull out the clip (4) of the condensate siphon (5).
• Unfasten the screw connections on the condensate
siphon and pull it off the heat exchanger.
• Disconnect the flow connection (2) and the return
connection (1) on the heat exchanger.
• Slacken the white plastic nut between the siphon and
heat exchanger.
• Unfasten the three screws (3) on the heat exchanger
and take it out of the boiler.
• Unfasten both brass connection pieces (positions 1 and
2) on the old heat exchanger and screw these onto
the new one. Use new seals in the process!
• Mount the new heat exchanger in reverse order and
replace the seals.
• Fill and bleed the boiler, also, if necessary, the system
after installing the new heat exchanger.
• After completing the work, check for gas and water
leaks and perform a function check (see Chapter 6.4).
51Installation and maintenance instructions ecoTEC 0020029172_04
10 Replacing components
11 Vaillant Service
12 Recycling and disposal
10.5 Replacing PCB and display
Danger!
d
Before replacing the component, observe the
safety information in Chapter 10.1.
Danger!
e
Risk of fatal electric shock through contact
with live connections!
Disconnect the boiler from the power mains by
pulling out the mains plug or deenergising the
boiler using an isolating device with a contact
opening of at least 3 mm (e.g. fuses or power
switches). Only after this you may carry out
the installation.
• Comply with the assembly and installation manuals
provided with the spare parts.
Replacing the display or PCB
If you are replacing only one of the two components, the
parameter matching functions automatically. By
switching on the boiler, the new component takes over
the previously set parameters from the unreplaced
component.
11 Vaillant Service
To ensure efficient and reliable operation of your boiler
it is recommended that regular servicing is carried out
by your service provider.
Vaillant Applied System Sales
Vaillant Ltd.
Nottingham Road
Belper
Derbyshire DE56 1JT
United Kingdom
VaillantTraining: 08 45 601 88 85
E-mail: training@vaillant.co.uk
Vaillant After Sales Service: 08 70 850 30 72 (Mon-Fri
8:30 – 17:30)
Technical Help: 08 44 693 31 33 (Mon-Fri 8:30 – 17:30)
Fax: 017 73 52 59 46
E-mail: aftersales@vaillant.co.uk
12 Recycling and disposal
Simultaneously replacing display and PCB
If both components are replaced at the same time (in
event of spare part installation) the boiler enters failure
mode when it is started up and displays the fault
message "F.70".
Caution!
a
Risk of damage!
If you replace both components at the same
time, it is essential to check whether the correct spare part display for this boiler variant is
available. You must not use any other spare
part displays!
• Enter the number of the boiler variant under diagnosis
point "d.93" at the second diagnosis level in
accordance with Table 10.1 (see Chapter 9.1.2).
The PCB is now set to the boiler type and the
parameters of all adjustable diagnosis points correspond
to the factory settings. You can now make the specific
settings for the system.
Boiler Number of boiler variant (DSN)
ecoTEC VU GB 466/4-5 H 46
Both the gas fired boiler and its transport packaging
consist mainly of recyclable raw materials.
12.1 Boiler
The boiler and the accessories do not belong to
domestic waste. Make sure the old boiler and any
existing accessories are disposed of properly.
12.2 Packaging
The transport packaging is disposed by the recognised
skilled trade company that installed the boiler.
Note!
h
Please observe the applicable national legal
regulations.
Table 10.1 Boiler variant numbers
Installation and maintenance instructions ecoTEC 0020029172_0452
Technical data 13
13 Technical data
ecoTEC VU GB 466/4-5 H unit
Heat Output Range (heating 50/30 °C) 12,9 - 46,4 kW
Heat Output Range (heating 80/60 °C) 12,3 - 44,1 kW
Maximum Heat Input (Net) 45 kW
Net Efficiency at 100% load 98,4 %
Net Efficiency at 30% load 108,3 %
SEDBUK rating A
SAP seasonal Efficiency 90,5 %
Gas inlet working pressure required (natural gas) 20 mbar
Gas inlet working pressure required (LPG) 37 mbar
NOx class 5NOx level 42 mg/kWh
Percentage (after 5 minutes full load +/- 1) 8,8 %
CO
2
Recommended CO level 150 ppm
3
Gas flow rate (natural gas) 4,8 m
Gas flow rate (LPG) 3,5 kg/h
Rated water volume (when
Maximum flow temperature approximately 85 °C
Maximum operating pressure 3 bar
Condensate rate (pH value: 3.0-4.0) 4,5 l/h
Water content 4,5 l
Flue gas mass flow minimum/maximum 5.7 / 20.5 g/s
Flue gas temperature minimum/maximum 40 / 70 °C
Pressure drop across the heat exchanger (at full load and
Connections heating flow/return
Gas inlet 20 mm
Expansion relief valve 1/2 “ mm / ”
Condensate drain 19 mm
Air/flue gas connection 80/125 mm
Mounting weight 46 kg
Height 800 mm
Width 480 mm
Depth 450 mm
Electrical connection 230 / 50 V/Hz
Electrical power consumption minimum/maximum (with integrated pump) 138 / 180 W
T = 20 K)
T = 20 K) 350 mbar
1935 l/h
1“ internal
1.5“ external
/h
mm / ”
Type of protection IP X 4 D -
Certification number CE-0085BR0308
Table 13.1 Technical data ecoTEC
53Installation and maintenance instructions ecoTEC 0020029172_04
Benchmark Commissioning and
Servicing Section
It is a requirement that the boiler is installed and commissioned to the
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© Heating and Hotwater Industry Council (HHIC)
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
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SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
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THE AIR GAS RATIO VALVE IS FACTORY
SET AND MUST NOT BE ADJUSTED
DURING COMMISSIONING UNLESS THIS
ACTION IS RECOMMENDED FOLLOWING
CONTACT WITH THE MANUFACTURER.
If any such adjustment is recommended and
further checking of the boiler is required the
installer/service engineer must be competent
to carry out this work and to use the flue gas
If the boiler requires conversion to operate with
a different gas family (e.g. conversion from
natural gas to LPG) separate guidance will be
provided by the boiler manufacturer
NOTE
analyser accordingly.
The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas
As part of the installation process, especially where a flue has been fitted by persons other than the
boiler installer, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that manufacturer’s max. flue lengths have not been
exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the
The flue gas analyser should be of the correct type, as specified by BS 7967
manufacturer. The installer must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.
PRIOR TO CO AND COMBUSTION RATIO CHECK
supply pressure/rate checked as required prior to commissioning.
In accordance with boiler instructions, set boiler to operate at max. rate
(full load condition). Allow sufficient time for combustion to stabilise.
NOTE - Do not insert analyser probe during this period to avoid
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER
Insert analyser probe into air inlet test point and allow readings to stabilise.
NOTE - where no air inlet test point is provided then a flue integrity check
with the analyser is not possible. The installer should verify that flue
integrity has been visually checked in accordance with the yellow “Prior to
CO and combustion ratio check” box above before proceeding to the
“Check CO and combustion ratio at maximum rate” stage below.
SET BOILER TO MAXIMUM RATE
possible “flooding” of sensor.
Analyser readings indicate that combustion products
and inlet air must be mixing. Further investigation of
Check that flue and flue terminal are not obstructed.
VERIFY FLUE INTEGRITY
the flue is therefore required.
Check that flue components are assembled, fixed
and supported as per boiler/flue manufacturer’s
instructions.
Is
20.6%
O
2
and
CO
< 0.2%
2
YES
NO
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
COMMISSIONED UNTIL PROBLEMS ARE
Check all seals around the appliance burner,
internal flue seals, door and case seals.
FOR ADVICE.
THE APPLIANCE MUST NOT BE
IDENTIFIED AND RESOLVED.
Rectify where necessary.
Is
CO
less than
335ppm
and
ratio less
CO/CO
2
than 0.004
YES
NO
NO
O
20.6%
2
CO
Is
and
< 0.2%
2
YES
CHECK CO AND COMBUSTION RATIO AT MAX. RATE
With boiler still set at maximum rate, insert analyser probe into flue gas
sampling point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is
not specified in the manual, consult boiler manufacturer for guidance.
Is
NO
CO less than
350ppm and
ratio
CO/CO
2
less than 0.004
YES
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
NOTE - If manufacturer’s instructions do not specify how to set boiler to minimum
SET BOILER TO MINIMUM RATE
rate contact Technical Helpline for advice.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
COMMISSIONED UNTIL PROBLEMS ARE
COMMISSIONING CANNOT BE FULLY
COMPLETED, THE APPLIANCE MUST BE
DISCONNECTED FROM THE GAS SUPPLY IN
NOTE: Check and record CO and combustion ratio
at both max. and min. rate before contacting the
FOR ADVICE.
THE APPLIANCE MUST NOT BE
IDENTIFIED AND RESOLVED. IF
ACCORDANCE WITH THE GSIUR.
manufacturer.
NO
CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE
With boiler still set at minimum rate, insert analyser probe into flue gas sampling
NOTE - If no flue gas sampling point is present and the correct procedure is not
point. Allow readings to stabilise before recording.
specified in the manual, consult boiler manufacturer for guidance.
Is
CO less than
350ppm and
ratio
CO/CO
2
less than 0.004
YES
BOILER IS OPERATING SATISFACTORILY
Ensure test points are capped, boiler case is correctly replaced and
all other commissioning procedures are completed.
Complete Benchmark Checklist, recording CO and combustion ratio
no further actions required.
readings as required.
Supplier
Manufacturer
0020029172_04 GBIE 012014 – Subject to change
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