Vaillant ecoTEC plus 1006 VU GB 1006/5-5 Installation And Maintenance Instructions Manual Download

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Appendix

Installation and maintenance instructions ecoTEC plus 0020134823_07

Initial start-up checklist

Location

Competent person

Customer service tech-
nician

Name

Street/house number

Postcode

Town/city

Telephone

Start-up date

Serial number

Basic hydraulic diagram

G.1

Initial start-up checklist

Yes

Values

Unit

Installation, general

Building type (house/apartment building, special building)

Used for commercial purposes?

Year of manufacture

Insulation status/renovation

System output

Previous gas/energy consumption

or kWh/a

Heated surface

Number of heating circuits

–

Underfloor heating circuits

–

Radiator heating circuits

–

Ventilator heating circuits

Water hardness when starting up

mol/m

or mg/l

CaCO

₃

Type of cleaning carried out?

First flushing (cold) of the heating circuit carried out?

First flushing (cold) of the boiler carried out?

Which chemicals used for cleaning?

Which treatment of hot flush filling water?

Second flushing (hot) of the boiler carried out?

Maintenance schedule for checking levels of inhibitor?

System volume

Added additive: Designation, amount

Gas supply

Gas type

Net calorific value

kWh/m

Gas pressure regulator available?
If yes, which type?

Condensate discharge

Condensate trap filled?

Condensate discharge pipe routed with a downward
gradient?

Neutralisation device available (> 200 kW)?
If yes, which manufacturer?

Condensate pump available (if required)?

Condensate pump control line connected?

Hydraulics

Summary of Contents for ecoTEC plus 1006 VU GB 1006/5-5

Page 1: ...allation and maintenance instructions ecoTEC plus VU GB 5 5 GB IE Publisher manufacturer Vaillant GmbH Berghauser Str 40 D 42859 Remscheid Tel 492191 18 0 Fax 492191 18 2810 info vaillant de www vaillant de ...

Page 2: ...d purging the heating system 21 7 13 Filling the condensate trap 21 7 14 Checking and adjusting the gas setting 22 7 15 Checking leak tightness 24 7 16 Thoroughly flushing the heating system hot 25 8 Adapting the unit to the heating installation 25 8 1 Calling up diagnostics codes 25 8 2 Setting the partial heat load 25 8 3 Setting the pump overrun 25 8 4 Setting the maximum flow temperature 25 8 ...

Page 3: ...tart up checklist 46 G 1 Initial start up checklist 46 H Commissioning Checklist 49 I Position of the opening in the air flue pipe 52 I 1 Notes 52 I 2 Positioning of the opening of a fan supported flue system 52 I 3 Horizontal terminal positioning 53 J Treating the heating water 54 K Technical data 55 Index 57 ...

Page 4: ... system com ponents installing and setting up the product in ac cordance with the product and system ap proval compliance with all inspection and main tenance conditions listed in the instruc tions Intended use also covers installation in ac cordance with the IP code Any other use that is not specified in these instructions or use beyond that specified in this document shall be considered improper...

Page 5: ...nstalled below ground level liquid gas may accumulate at floor level if there are any leaks In this case there is a risk of explosion Make sure that liquid gas cannot escape from the product or the gas pipe under any circumstances 1 3 8 Risk of death due to blocked or leaking flue gas routes Installation errors damage tampering imper missible installation sites or similar can cause flue gas to esc...

Page 6: ...from electric shock if you touch live components Before commencing work on the product Disconnect the product from the power supply by switching off all power supplies at all poles electrical partition with a con tact gap of at least 3 mm e g fuse or cir cuit breaker Secure against being switched back on again Check that there is no voltage 1 3 15 Risk of material damage caused by frost Do not ins...

Page 7: ...tent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regu lations The Benchmark Checklist can be used to demon strate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commission ing and servicing work in accordance with the ...

Page 8: ...on e g 260 W Max electrical power consumption Information on the identification plate Meaning IP e g X4D Level of protection Heating mode P Nominal heat output range Q Heat input range Note Make absolutely sure that the product is compat ible with the gas group at the installation site 3 3 CE marking The CE marking shows that the products comply with the basic requirements of the applicable direct...

Page 9: ...tenance or re pair work Where units are installed in cascade observe the gradi ent of the flue pipe approx 50 mm m It is not necessary to maintain a clearance between the product and components made of combustible materials that go beyond the minimum clearances 4 5 Using the mounting template 1 Position the mounting template vertically over the in stallation site 2 Secure the template to the wall ...

Page 10: ...ining clips 2 so that the front casing is released 3 Pull the front casing forwards at the bottom edge 4 Lift the front casing upwards from the bracket 4 7 2 Installing the front casing 1 Place the front casing on the upper brackets 2 Push the front casing onto the product until both retain ing clips 2 snap into place at the front casing 3 Secure the front casing by tightening the screw 1 4 8 Remo...

Page 11: ...xplosion or scalding caused by incorrect installation Mechanical stresses in the connection pipes may lead to leaks Make sure that the connection pipes are free from mechanical stress when they are installed Caution Risk of material damage caused by residues in the pipelines Welding remnants sealing residues dirt or other residues in the pipelines may damage the product Flush the heating installat...

Page 12: ...e 5 2 Hydraulics installation Caution Risk of material damage due to high tem peratures Plastic pipes in the heating installation may become damaged by overheating if a fault occurs When using plastic pipes install a limit thermostat on the heating flow Caution Risk of material damage due to heat trans fer during soldering Only solder connectors if the connectors are not yet screwed to the service...

Page 13: ...dirt filter installed on the installation side upstream of the plate heat exchanger Heating side cleaning connections for backwashing the plate heat exchanger during maintenance work To this end various plate heat exchangers are available as accessories depending on the output of a product or whether it is a cascade system The pressure loss is ad justed to the pump groups that are offered as an ac...

Page 14: ...ed in accordance with national regulations Observe the local regulations on neutralising the con densate Note You can obtain neutralisation with or without a condensate pump as an accessory If required guide the drain hose 1 from the automatic air vent into the tundish Note The condensate drain pipework must have a continuous fall 45 mm per metre and should whenever possible terminate at a suitabl...

Page 15: ...or installation type B23P third party accessor ies are also permitted see the technical data in the appendix Only use Vaillant original air flue pipes If third party accessories are permitted for B23P ensure that the flue pipe con nections are properly routed sealed and secured against slipping out 1 Install the flue pipe using the installation manual 2 When installing the air flue pipe observe th...

Page 16: ...oE plug to a suitable flexible three core mains connection cable which complies with the relevant standards 9 Close the electronics box Page 16 10 Make sure that access to the mains connection is al ways available and is not covered or blocked 5 4 3 Carrying out the wiring Caution Risk of material damage caused by incor rect installation Mains voltage at the incorrect plug terminals on the ProE sy...

Page 17: ...7 multi functional module 1 Install the components in accordance with the respect ive instructions 2 Select D 027 Page 25 to actuate relay 1 on the multi functional module 3 Select D 028 Page 25 to actuate relay 2 on the multi functional module 5 4 7 2 Using the flue non return flap For cascade operation you must provide a flue non return flap for each product Either use only electrical flue non r...

Page 18: ...tart up CO2 analyser Digital or U tube manometer Flat blade screwdriver small 2 5 mm hex key 7 2 Carrying out the initial start up Note The complete heating system must be flushed at least twice Once with cold water and once with domestic hot water in accordance with the following instructions section Flushing the heating installation for the first time Initial start up must be carried out by a cu...

Page 19: ...rotection 7 4 Switching on the product Press the on off button on the product The basic display appears on the display 7 5 Running the installation assistants The installation assistant is displayed whenever the product is switched on until it has been successfully completed It provides direct access to the most important check programmes and configuration settings for starting up the product Conf...

Page 20: ...er successful ignition the product is operated at maximum heat input P 02 Minimum load check programme After successful ignition the product is operated at minimum heat input P 06 Filling mode check programme The burner and pump are switched off to fill or drain the product P 00 Purging Cancel Heating circuit 1 2 bar Note If the product is in error condition you cannot start any check programmes Y...

Page 21: ...oth service valves on the boiler are open 4 Slowly fill the boiler 5 Observe the increasing filling pressure in the boiler 6 Fill with water until the required filling pressure is reached 7 Close off the filling system but keep ready to top up as air is expelled during the purging process 8 To purge the boiler select check programme P 00 The boiler does not start up the external pump op erates int...

Page 22: ... the air analysis point 1 to check for flue gas recir culation 4 Use a flue gas analyser 5 If you discover CO or CO2 in the supply air search for the leak in the flue gas installation or for signs of flue gas recirculation 6 Eliminate the damage properly 7 Check again whether the supply air contains any CO or CO2 8 If you cannot eliminate the damage do not start up the product 7 14 3 Checking the ...

Page 23: ...duct Do not make any adjustments to the product Check the gas installation Do not start up the product If you cannot correct the failure notify the gas supply company and proceed as follows End the check programme P 01 Allow the boiler to cool down by allowing pump overrun to operate for a minimum of two minutes Close the gas stopcock Remove the pressure gauge and retighten the sealing screw 1 for...

Page 24: ...otation the CO content only changes after approx 1 turn of the adjusting screw overcoming the adjustment hysteresis The adjusting screw must protrude only slightly from the casing Select Cancel once the adjustments have been made If an adjustment is not possible in the specified adjust ment range you must not start up the product If this is the case inform Vaillant Customer Service Install the fro...

Page 25: ...tment in Checking and treating the heating water filling and supplementary water Page 18 11 Install the side section Page 11 12 Install the front casing Page 10 8 Adapting the unit to the heating installation To reset the most important system parameters use the Unit configuration menu item Menu Installer level Unit configuration Or manually relaunch the installation assistant Menu Installer level...

Page 26: ... 5 30 5 33 0 50 16 5 18 5 21 0 23 5 25 5 28 0 55 13 5 15 0 17 0 19 0 20 5 22 5 60 10 5 11 5 13 0 14 5 15 5 17 0 65 7 0 8 0 9 0 10 0 11 0 11 5 70 4 0 4 5 5 0 5 5 6 0 6 5 75 1 0 1 0 1 0 1 0 1 0 1 0 Note The remaining burner anti cycling time following a regular shutdown in heating mode can be called up under D 067 8 6 2 Resetting the remaining burner anti cycling time 1st option Menu Reset anti cycl...

Page 27: ...water volume at maximum heat input ΔT 23 K 3 Circulation water volume at maximum heat input ΔT 20 K A Circulation water volume l h B Remaining feed head mbar 100 kW boiler with high efficiency pump A B 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 1000 2000 3000 4000 5000 6000 7000 8000 1 2 3 100 85 70 60 53 1 Circulation water volume at minimum heat input 2 Circulation water volume at maxi...

Page 28: ...nt You require the following tool for the inspection and mainten ance WAF 8 socket spanner with extension Torx screwdriver 20 25 and 30 5 mm hex key Carry out all inspection and maintenance work in the order shown in the table Overview of inspection and maintenance work 9 1 Observing inspection and maintenance intervals Warning Risk of injury and a risk of material dam age caused by negligent insp...

Page 29: ...e and safe operation of the product To receive information about the available original spare parts contact the contact address provided on the back page of these instructions If you require spare parts for maintenance or repair work use only the spare parts that are permitted for the product 9 3 Using the function menu The function menu allows you to actuate and test individual components in the ...

Page 30: ...11 8 10 12 5 6 7 9 13 806 5 5 1006 5 5 1206 5 5 Danger Risk of poisoning and fire caused by es caping gas The gas pipe may become damaged Ensure that you do not damage the seals on the gas pipe when removing and in stalling the gas air mixture unit 7 Remove the ionisation line plug from the ionisation elec trode 11 and remove the earth connection plug from the earthing lug 8 Remove the ignition li...

Page 31: ...that any existing condensate neutraliser does not become damaged 3 Rinse away any loose dirt in the heat exchanger 1 with a sharp jet of water or use a plastic brush The water flows out of the heat exchanger through the drain 4 Install the condensate trap 9 7 Checking the burner 1 4 3 2 1 Check the surface of the burner for damage If you no tice any damage replace the burner including the seal Pag...

Page 32: ...ket for the insulating mat is installed properly again after it is replaced 3 Replace all seals at the sealing points opened during the maintenance work 8 9 10 11 13 5 6 7 12 11 8 10 12 5 6 7 9 13 806 5 5 1006 5 5 1206 5 5 4 4 4 Connect the gas air mixture unit 5 to the heat ex changer 7 5 Tighten the screws 6 in a cross wise pattern until the burner door fits closely and uniformly onto the mating...

Page 33: ...duct status S xx that is displayed on the Live Monitor Page 18 10 2 Calling up service messages If the maintenance symbol appears in the display there is a service message The maintenance symbol appears if you have set a mainten ance interval for example and it has elapsed The product is not in fault mode To obtain more information about the service message call up the Live monitor Page 18 Conditi...

Page 34: ... flow and in the heating return 6 Close the service valve in the cold water pipe 7 Drain the product if you want to replace water bearing components of the product 8 Make sure that water does not drip on live components e g the electronics box 9 Use only new seals 10 10 Replacing defective components 10 10 1 Replacing the gas valve assembly 2 2 806 5 5 1006 5 5 1206 5 5 1 1 1 Remove the gas pipe 1...

Page 35: ...ing mat lie above the cut outs for the burner door Torque 6 Nm 11 Install the ignition and monitoring electrodes Use new seals for this Torque 2 8 Nm 12 Install the gas air mixture unit Page 32 13 Check that the product functions correctly and check the leak tightness Page 24 10 10 3 Replacing the insulating mat If the safety cut out on the burner door has been triggered the insulating mat between...

Page 36: ...ed Condition Replacing the PCB and display at the same time Select the required language If you are replacing both components at the same time the product switches directly to the menu to select the language after switching on The factory set language setting is English Confirm your setting by pressing OK You are automatically taken to D 093 to set the device specific number Select the correct val...

Page 37: ...Target flow temp Appliance config Language DHW temperature Back Select Target flow temp Appliance config Language DHW temperature Back Select Appliance config Test programs Installer level Fault list Back Select Enter code 1 7 Back OK F 75 Fault Pump water shortage F 00 Interruption Flow sensor P 00 Pump is actuated Purging cyclically Back Select Gas type check Type of gas Select LPG Back Select S...

Page 38: ...Select Heating partial load Appliance config Accessory relay 2 Accessory relay 1 Back Select Heating partial load Appliance config Accessory relay 2 Contact data Back Select Heating partial load Appliance config Factory setting Contact data Back Select D 026 Auxiliary relay External pump Cancel OK D 026 Auxiliary relay Circulation pump Back D 027 Accessory relay 1 External pump Cancel OK D 027 Acc...

Page 39: ...t ad justable D 011 Status of external heating pump 0 Off 1 100 On Not ad justable D 014 Pump speed target value high efficiency pump Heating circuit pump target value in 0 Auto 1 53 2 60 3 70 4 85 5 100 4 85 D 016 24 V DC room thermostat open closed 0 Room thermostat open no heating mode 1 Room thermostat closed heating mode Not ad justable D 017 Heating flow return temperature control changeover...

Page 40: ...ual value in C Not ad justable D 041 Return temperature Actual value in C Not ad justable D 044 Digitised ionisation value Display field 0 to 1020 800 no flame 400 good flame Not ad justable D 046 Pump type 0 Relay with disable facility 1 PWM with disable facility 0 Relay with disable facility D 047 Outdoor temperature with Vaillant weather compensated control Actual value in C Not ad justable D 0...

Page 41: ... justable D 096 Default setting Reset all adjustable parameters to factory setting 0 No 1 Yes C Inspection and maintenance work Overview Note The table below lists the manufacturer requirements with respect to minimum inspection and maintenance inter vals If national regulations and directives require shorter inspection and maintenance intervals you should ob serve these instead of the intervals l...

Page 42: ...X 19 Open the service valves fill up the product heating installation to 1 0 4 5 bar depending on the static height of the heating installation and start the purging programme P 00 X 20 Perform a test operation of the product and heating installation including hot water generation and purge the system once more if necessary X X 21 Visually inspect the ignition and burner behaviour X X 22 Check the...

Page 43: ...temperature sensor interruption NTC plug not plugged in or has come loose multiple plug on the PCB not plugged in correctly interruption in cable harness NTC defective F 10 Flow temperature sensor short circuit NTC defective short circuit in cable harness cable housing F 11 Return temperature sensor short circuit NTC defective short circuit in cable harness cable housing F 20 Safety shutdown Tempe...

Page 44: ... DSN If spare parts were integrated Display and PCB replaced at the same time and Device Specific Number not reset incorrect cable harness liquefied petroleum gas coding resistor and DSN do not match F 73 Water pressure sensor signal in the wrong range too low Interruption short circuit of water pressure sensor interruption short circuit to GND in supply line to water pressure sensor or water pres...

Page 45: ...l sensor Flow sensor optional DCF connection Earth Earth Contact thermostat burner off Ext room th 3 4 contact 24 V Bus connection Controller room th digital Accessory output Select via D 26 Charging pump internal pump Ext ignition transformer supply Ioni signal Unit earth Mains connection Unit earth Fan Hall signal PWM Earth Display connection white white red blue blue pink Edge connector blue pi...

Page 46: ...diator heating circuits Ventilator heating circuits Water hardness when starting up mol m or mg l CaCO Type of cleaning carried out First flushing cold of the heating circuit carried out First flushing cold of the boiler carried out Which chemicals used for cleaning Which treatment of hot flush filling water Second flushing hot of the boiler carried out Maintenance schedule for checking levels of ...

Page 47: ...ng circuits sufficiently purged When installing a pump without a pump assembly Pressure loss between the pump and the unit 2 kPa 20 mbar at 4 m h required Distance between the pump and product is less than 0 5 m required Pump in the return required When using a third party pump Pump connected to BMU signal and voltage required Pump curve at least in accordance with the instructions required Domest...

Page 48: ...control Domestic hot water demand from control in ternal external Sensor positioned correctly and connected vrnetDIALOG installed correctly signal available Start up default settings CO content at max via P 1 before adjustment Vol CO content at max via P 1 after adjustment Vol Gas flow pressure at nominal heat loading max output for cascades kPa mbar CO content at min via P 2 Vol Gas volume flow a...

Page 49: ...intenance instructions 49 H Commissioning Checklist Heating and Hotwater Industry Council HHIC www centralheating co uk Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the completed in full ...

Page 50: ...ith the appropriate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Optimum start control Fitted Fitted Fitted Fitted ALL SYSTEMS Yes Yes CENTRAL HEATING MODE OR mbar OR mbar COMBINATION BOILERS ONLY Yes Yes DOMESTIC HOT WATER MODE OR mbar OR mbar Yes Temperature CONDENSING BOILERS ONLY Yes ALL INSTALLATIONS AND R...

Page 51: ...ng system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND AND SERVICE 02 AND AND SERVICE 03 AND AND SERVICE 04 AND AND SERVICE 05 AND AND SERVICE 06 AND AND SERVICE 07 AND AND SERVICE 08 AND AND SERVICE 09 AND AND SERVICE 10 AND AND ...

Page 52: ...A O Q P T G 4 D E Q Ja I 2 Positioning of the opening of a fan supported flue system Minimum clearances for concentric terminations Key Horizontal 70 kW up to 120 kW mm All systems 120 kW Products must disperse freely and not make contact with building surfaces 1 There should be no ventilation opening in the eaves within 900 mm of the terminal 2 These dimensions comply with the building regulation...

Page 53: ...intersection with pitched roof 600 R 5 Horizontal from opening windows on pitched or flat roofs 900 S 5 Above an opening roof light or windows on pitched roofs 600 T 5 Below an opening roof light or windows on pitched roofs 2 000 Products must disperse freely and not make contact with building surfaces 1 There should be no ventilation opening in the eaves within 900 mm of the terminal 2 These dime...

Page 54: ...rdness description Total Hardness mg l Calcium carbonate CaCO UK Degrees Clark C French Degrees f German Degrees dH Soft 150 11 15 9 Hard 150 300 11 21 15 30 9 18 Very Hard 300 21 30 18 mg l milligrammes per litre parts per million ppm 0 3 0 6 0 9 1 2 1 5 1 8 2 1 2 4 2 7 3 0 3 3 3 6 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 y mg CaCO x l A B 80 kW A 100 120 kW B 80 kW 100 120 kW...

Page 55: ...740 l h 4 485 l h Approx condensate quantity pH value 3 5 to 4 0 in heating mode 40 30 C 12 8 l h 16 0 l h 19 2 l h Remaining feed head of the high efficiency pump 0 065 MPa 0 650 bar 0 053 MPa 0 530 bar 0 042 MPa 0 420 bar Technical data General 806 VU GB 806 5 5 1006 VU GB 1006 5 5 1206 VU GB 1206 5 5 Designated country designation in accord ance with ISO 3166 GB Great Britain IE Ireland GB Grea...

Page 56: ...ensions width 480 mm 480 mm 480 mm Unit dimensions height 960 mm 960 mm 960 mm Unit dimensions depth 603 mm 603 mm 603 mm Approx net weight without pump group 68 kg 86 kg 90 kg Technical data Electrical 806 VU GB 806 5 5 1006 VU GB 1006 5 5 1206 VU GB 1206 5 5 Electrical connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz Built in fuse slow blow 4 A 4 A 4 A Min electrical power consumption 25 W 18 W 18...

Page 57: ... 19 Filling pressure 20 Flow temperature maximum 25 Flue gas route 5 Front casing 10 Front casing closed 6 Frost 6 Function menu 29 G Gas connection 11 Gas conversion 22 Gas setting 22 Gas type 12 Gas valve assembly 34 Gas air mixture unit 29 32 H Heat exchanger 31 35 Heating flow 13 Heating return 13 Heating system 21 Hot water temperature 19 I If you smell flue gas 5 If you smell gas 5 Inspectio...

Page 58: ...erature control 26 Risk of scalding 6 S Safety device 4 Scope of delivery 8 Self test 29 Service message 33 Service partner 33 Side section 11 Spare parts 28 29 Status codes 18 42 Switching on 19 T Target feed temperature 19 Test programmes 18 Tool 6 Transport 4 Treating the heating water 18 U Unit configuration 20 V Voltage 6 W Weight 9 ...

Page 59: ......

Page 60: ...rbyshire 1 1 DE56 1JT Telephone 0330 100 3461 info vaillant co uk www vaillant co uk These instructions or parts thereof are protected by copyright and may be reproduced or distributed only with the manufacturer s written consent Subject to technical modifications 0020134823_07 ...

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