Vaillant ecoTEC plus SERIES Instructions For Installation And Servicing Download

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Installation and Servicing ecoTEC plus

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Notes on the documentation . . . . . . . . . . . .

1.1.1

Other instructions supplied

with this appliance . . . . . . . . . . . . . . . . . . . . .

1.1.2

Retention of documents . . . . . . . . . . . . . . . .

1.1.3

Safety instructions and symbols . . . . . . . . .

1.2

ecoTEC plus boilers . . . . . . . . . . . . . . . . . . . .

1.3

General notes . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

General information . . . . . . . . . . . . . . . . . . . .

1.4.1

Gas category . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.2 Gas safety (installation and use) regulations 5

1.4.3 Gas testing and certification . . . . . . . . . . . .

1.4.4 Control of substances hazardous to health

1.4.5 Insulation pads . . . . . . . . . . . . . . . . . . . . . . . .

1.4.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.7 Manual handling guidance. . . . . . . . . . . . . . .

1.4.8 Gas leak or fault . . . . . . . . . . . . . . . . . . . . . . .

1.4.9 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.10 Sheet metal parts. . . . . . . . . . . . . . . . . . . . . .

1.4.11 Sealed components . . . . . . . . . . . . . . . . . . . .

1.4.12 Electrical supply failure . . . . . . . . . . . . . . . . .

1.4.13 Protection against freezing . . . . . . . . . . . . .

1.4.14 Boilers installed in a compartment or

cupboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.15 Boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.16 Condensate drain . . . . . . . . . . . . . . . . . . . . . .

1.4.17 Pluming from flue terminal . . . . . . . . . . . . . .

1.4.18 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.19 Maintenance and servicing . . . . . . . . . . . . . .

1.4.20 Technical data . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.21 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Statutory requirements . . . . . . . . . . . . . . . . .

1.6

Regulations, rules and guidelines . . . . . . . .

1.7

CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8

Benchmark. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9

Gas council numbers . . . . . . . . . . . . . . . . . . .

Boiler specifications. . . . . . . . . . . . . . . . . . . .

2.1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .

General requirements . . . . . . . . . . . . . . . . . . 10

3.1

Preliminary remarks for

room sealed appliances . . . . . . . . . . . . . . . . . 10

3.2

Related documents. . . . . . . . . . . . . . . . . . . . . 10

3.3

Installation site . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Flue options. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1 Flue termination . . . . . . . . . . . . . . . . . . . . . . . 12

3.5.2 Internal flue installation . . . . . . . . . . . . . . . . 12

3.6

Air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.7

Cupboard or compartment ventilation . . . . 12

3.8

Domestic hot water cylinder. . . . . . . . . . . . . 13

3.9

Condensate drain . . . . . . . . . . . . . . . . . . . . . . 13

3.10

Heating system controls . . . . . . . . . . . . . . . . 13

3.11

Draining tap . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.12

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.13

Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.14

Pump specification. . . . . . . . . . . . . . . . . . . . . 13

3.15

Cleanser and inhibitor . . . . . . . . . . . . . . . . . . 13

3.16

Open vented water system . . . . . . . . . . . . . . 15

3.17

Sealed water Systems . . . . . . . . . . . . . . . . . . 16

3.17.1 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.17.2 Expansion vessel. . . . . . . . . . . . . . . . . . . . . . . 16

3.17.3 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . 16

Contents

Page

3.17.4 Water make up . . . . . . . . . . . . . . . . . . . . . . . . 16

3.17.5 Filling a sealed water system . . . . . . . . . . . . 16

Boiler installation sequence . . . . . . . . . . . . . 17

4.1

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1.1

Sheet metal parts. . . . . . . . . . . . . . . . . . . . . . 17

4.1.2 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1.3 Timber frame buildings . . . . . . . . . . . . . . . . . 17

4.1.4 Contents included with delivery. . . . . . . . . . 18

4.2

Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.1 Other flue options . . . . . . . . . . . . . . . . . . . . . 18

4.3

Fitting the boiler hanging bracket . . . . . . . . 19

4.3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3.2 Removing the front casing . . . . . . . . . . . . . . 19

4.3.3 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3.4 Water connections . . . . . . . . . . . . . . . . . . . . . 20

4.3.5 Condensate trap and syphonic drain . . . . .

Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3.6 Installing the flue system . . . . . . . . . . . . . . . 20

4.4

Electrical connections . . . . . . . . . . . . . . . . . . 21

4.4.1 Connections to main supply . . . . . . . . . . . . . 22

4.4.2 Wiring system . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.4.3 Electrical board layout. . . . . . . . . . . . . . . . . . 23

4.4.4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.4.5 External electrical controls. . . . . . . . . . . . . . 25

4.4.6 Connection details for external time switches

and boiler terminal strip . . . . . . . . . . . . . . . . 25

4.4.7 Vaillant optional plug in timer accessories. 25

4.4.8 Connection details using the

VR 65 control centre . . . . . . . . . . . . . . . . . . . 25

4.4.9 Thermostatic radiator valves . . . . . . . . . . . . 25

Commissioning (Part I) . . . . . . . . . . . . . . . . . 26

5.1

Preliminaries - all systems . . . . . . . . . . . . . . 26

5.1.1

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.1.2 Initial Lighting . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1.3 Ignition problems . . . . . . . . . . . . . . . . . . . . . . 27

5.1.4 Flue problems . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1.5 Testing - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Natural Gas to LPG conversion . . . . . . . . . . 28

Functional checks commissioning (part II) . 29

7.1

Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.1.1

Domestic hot water . . . . . . . . . . . . . . . . . . . .

(If optional accessories are fitted). . . . . . . . 29

7.1.2

Pump exercise programme . . . . . . . . . . . . . . 29

7.1.3

Final flush of the heating system (hot) . . . . 30

7.2

Hand over to the user . . . . . . . . . . . . . . . . . . 30

7.3

Vaillant warranty. . . . . . . . . . . . . . . . . . . . . . . 30

Inspection and maintenance . . . . . . . . . . . . . 31

8.1

Initial inspection . . . . . . . . . . . . . . . . . . . . . . . 31

8.1.1

Safety instructions . . . . . . . . . . . . . . . . . . . . . 31

8.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.1.3 Functional check of boiler operation . . . . . . 31

8.1.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.1.5 Spark electrode. . . . . . . . . . . . . . . . . . . . . . . . 34

8.1.6 Removing the burner . . . . . . . . . . . . . . . . . . . 34

8.1.7 Combustion chamber and heat exchanger.. 35

8.1.8 Condensate drain . . . . . . . . . . . . . . . . . . . . . . 35

8.1.9 Inner casing panel seal check. . . . . . . . . . . . 36

8.1.10 Checking the expansion vessel (if fitted) . . 36

8.1.11 Re commissioning the boiler. . . . . . . . . . . . . 36

8.1.12 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . 36

Contents

Page

Summary of Contents for ecoTEC plus SERIES

Page 1: ...For the installer Instructions for installation and servicing ecoTEC plus GB Wall hung open vent condensing boiler...

Page 2: ...6 3 17 2 Expansion vessel 16 3 17 3 Pressure gauge 16 Contents Page 3 17 4 Water make up 16 3 17 5 Filling a sealed water system 16 4 Boiler installation sequence 17 4 1 Boiler location 17 4 1 1 Sheet...

Page 3: ...meter to factory settings 44 11 Parts replacement 44 111 1 Safety instructions 44 11 2 Replacing the burner 44 11 3 Replacing the gas valve 44 11 4 Replacing the fan 44 11 5 Replacing the heat exchang...

Page 4: ...the boiler The domestic hot water can only be adjusted on the boiler if it is installed with a Vaillant uniSTOR unvented cylinder and relevant controls Once the controls are set the boiler operates au...

Page 5: ...be used 1 4 7 Manual handling guidance During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance whilst lifting as the applianc...

Page 6: ...rgent with a damp cloth then a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paint work 1 4 19 Maintenance and servicing For the continued efficient and...

Page 7: ...cification CheSS 2 Controls for domestic central heating system and hot water BRECSU Certification This boiler certificated to the current issue of EN 483 for performance and safety It is important th...

Page 8: ...supply G20 Gross CV s t MJ m3 37 8 37 8 37 8 37 8 Maximum gas rate M3 h 1 61 2 0 3 02 4 06 Minimum gas rate M3 h 0 53 0 53 0 56 0 71 Burner CO2 Case on 9 3 0 2 0 5 9 3 0 2 0 5 9 3 0 2 0 5 9 0 0 2 0 5...

Page 9: ...ler specifications 2 Legend 1 Heating return pipe 22 2 Heating flow pipe 22 3 Gas connection 15 4 Hanging bracket 5 Flue hole flue system 303 933 6 Flue pipe connection 7 Condensate drain outlet conne...

Page 10: ...Building Regulations and reference should be made to the current ETCI rules for electrical installation Caution When tightening or slackening screwed connections always use suitable open ended spanner...

Page 11: ...ories These may result in damage and injury You will find a list of genuine flue pipes in the Vaillant installation manual for flue pipes The CE mark is valid only if the appliance is operated with Va...

Page 12: ...inal should not be nearer than 150 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...

Page 13: ...e system which will allow the entire system and hot water system to be drained Draining taps shall be to the current issue of BS 2879 3 12 Safety valve A safety valve need not be fitted to an open ven...

Page 14: ...d Servicing ecoTEC plus 14 3 General requirements ecoTEC plus 415 pressure loss graph ecoTEC plus 428 pressure loss graph ecoTEC plus 418 pressure loss graph ecoTEC plus 438 pressure loss graph Fig 3...

Page 15: ...supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres 90ft above the boiler The cold feed must be 15mm minimum size The vent must...

Page 16: ...the manufacturer The expansion vessel volume depends on the total water system volume and the initial system design pressure For any system an accurate calculation of vessel size is given in the curre...

Page 17: ...es The boiler must be mounted on a flat wall which is sufficiently robust to take its total weight see boiler specifications 2 1 4 1 2 Clearances The boiler should be positioned so that at least the m...

Page 18: ...n occur if you use other accessories These may result in damage and injury You will find a list of genuine flue pipes in the Vaillant installation manual for flue pipes The CE mark is valid only if th...

Page 19: ...of screw positions are used it may be necessary to use additional or alternative fixings to ensure adequate support Note If the boiler is to be fitted in a timber framed building ensure that the brack...

Page 20: ...pipe and couplings DO NOT use adhesive when connecting to the spigot 1 The condense drain pipe 2 should be non corrosive plastic The drain pipe should have a continuous fall of a least 45mm per metre...

Page 21: ...a minimum gap of 3mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively connection can be made...

Page 22: ...en yellow earth wire boiler terminal Earth sign Blue neutral wire boiler terminal N Brown live wire boiler terminal L Caution Do not connect any mains 230V power to the connections 7 8 9 or BUS Note E...

Page 23: ...e only Mains supply 230V 50Hz Room thermostat 230V 50Hz remove bridge on connection Heating pump 2A fuse slow Igniter Connection 230V Supply for accessory module eBUS accessory connection Burner cable...

Page 24: ...reen yellow green yellow X 20 18 red 24 Vdc X 20 9 blue earth X 20 4 grey PWM X 20 3 black Hall signal X 20 17 red 24 Vdc black link X 20 5 red X 20 7 black NTC return Ignition electrode Gas valve ass...

Page 25: ...hermostat 4 4 6 Connection details for external switches and boiler terminal strip See schematic layout fig 4 11 4 4 7 Vaillant optional plug in timer accessories Refer to the instructions supplied wi...

Page 26: ...urrent edition of IS 813 The gas supply to the boiler can be purged by slackening the union connection on the gas service valve beneath the boiler see fig 5 2 Ensure that there is adequate ventilation...

Page 27: ...o Fault This is indicated by the fault code F 28 or F 29 in the display The display also shows the flame symbol with a cross through it 2 see fig 5 4 Automatic ignition can only take place after you m...

Page 28: ...e test programs by holding the key see fig 6 2 and turning power on Press until P 1 is displayed for max rate Press i to operate appliance in this mode Allow appliance to stabilise Measure the CO2 at...

Page 29: ...nal accessories are fitted see Section 7 1 1 7 1 Heating Switch on the appliance Make sure that there is a heating demand Press i to activate the status indicator As soon as a heat demand is received...

Page 30: ...l to the desired setting If optional Vaillant accessories are fitted Instruct the user in the safe and efficient operation of the boiler Show the user how to operate any external controls Explain to t...

Page 31: ...supply either by removing the fuse from a fused spur or pulling the plug out if connected to a socket outlet Protect the electronics box from spray water Before working on the appliance turn off the p...

Page 32: ...if maintenance schedule is required from steps 2 3 or 5 above Clean the primary heat exchanger Fit new burner door seal kit observe the assembly instructions enclosed with the kit Refit the burner mo...

Page 33: ...h a flue gas analyser see section 9 If a flue gas analyser is not available remove the outer and inner case see figs 8 1 and 8 2 and taking care not to touch any components check the flame picture thr...

Page 34: ...pply at the gas service cock Note Do not disconnect at the gas valve Remove the two gas pipe bracket securing screws from underside of inner case see fig 8 5 Drop down the electronics box into the ser...

Page 35: ...ris from combustion chamber using a soft brush and vacuum cleaner Carefully flush any remaining debris through the condensate trap ensure the water is kept away from electrical components Fig 8 7 Comp...

Page 36: ...ve cap from expansion vessel charge point Check that the internal charge pressure of the expansion vessel is to the correct design pressure If the pressure is lower than this the vessel should be re p...

Page 37: ...alue with removed appliance front see table 9 1 by turning A throttle see fig 9 2 Turn to the left higher CO2 content Turn to the right lower CO2 content Note Only for natural gas Adjust only in incre...

Page 38: ...ntrols are on and calling for heat if no external controls are fitted boiler terminals 3 and 4 must be linked Check that the boiler anti cycling economiser is not engaged 10 1 1 Status codes The statu...

Page 39: ...The diagnostic information is divided into two diagnostic levels The second diagnostic level can be reached only after entering a password Caution Access to the second diagnostic level must be used e...

Page 40: ...nd target value terminal 7 d 10 Status internal heating pump 1 on 0 off d 11 Status external heating pump 1 to 100 on 0 off d 12 Cylinder charging pump via accessory module 1 to 100 on 0 off d 13 Hot...

Page 41: ...er of 2006 Activation of solar reheating Setting range 0 to 30 solar reheating disabled factory setting 3 activation of min hot water target value 60 C for solar reheating d 60 Number of safety temper...

Page 42: ...multiple faults occur the corresponding fault codes are displayed alternately for about two seconds each Display Meaning Display value adjustable value d 78 Storage charging temperature limit target...

Page 43: ...ive F 63 EEPROM error Electronics defective F 64 Electronics NTC fault Short circuit in flow or return NTC or electronics defective F 65 Electronics temperature too high Electronics too hot due to ext...

Page 44: ...out only by a qualified engineer Only use genuine spare parts for repairs Make sure the parts are correctly fitted and that their original position and alignment are retained 11 1 Safety instructions...

Page 45: ...other Remove flexible tubes from adapter Lift off the adapter Remove the drain connection downstream of the condense trap Remove the two condense trap securing screws Lift up and carefully remove the...

Page 46: ...he card and paper industry The sections of EPS Styropor are required in order to protect equipment in transit EPS is 100 recyclable and CFC free The foil wrapping and securing straps are likewise made...

Page 47: ...Installation and Servicing ecoTEC plus 47 Appendix 14...

Page 48: ...Installation and Servicing ecoTEC plus 48...

Page 49: ...Installation and Servicing ecoTEC plus 49...

Page 50: ...Installation and Servicing ecoTEC plus 50 Notes...

Page 51: ...Installation and Servicing ecoTEC plus 51 Notes...

Page 52: ...0020020828_02 GB 08 2006 Subject to alteration...

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Vaillant ecoTEC plus SERIES, Instructions For Installation And Servicing

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