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
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