Vaillant ecoTEC pro 28 Instructions For Installation And Servicing Download Page 4

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Instructions for installation and servicing ecoTEC

1 Introduction

1 Introduction

1.1 

Notes on the documentation

The following information is intended to help you 
throughout the entire documentation. 
Further documents apply in combination with this instal-
lation and maintenance manual.

We assume no liability for any damage caused by 
non-observance of these manuals.

1.1.1 Applicable 

documents

The following additional documents are provided with 
the appliance:

For the owner of the system:

Brief users instructions
(only ecoTEC plus) 

 

 

no. 838404

Benchmark logbook 

 

 

no. 800371

Warranty card with return envelope 

no. 802922

For the qualified technician:

Installation and maintenance manual 

no. 839592

Assembly manual for flue accessories no. 

835296

The manuals for any accessories and controllers used 
also apply.

1.1.2  Preservation of documents

Please pass on this installation manual to the owner of 
the system. The owner shall preserve the manuals so 
that they are available when required.

1.1.3  Safety instructions and symbols

Please observe the safety instructions in this manual for 
the installation of the appliance!
Symbols used in the manual are explained below:

  Danger!

Immediate danger to life and limb!

  Caution!

Potentially dangerous situation for the product 
and environment!

  Note

Useful information and instructions.

•  Symbol for a necessary task
-  List for function descriptions or general list

1.2 Introduction

  Note 

This boiler must be installed and serviced by a 
competent person in accordance with the Gas 
Safety (Installation and Use) Regulations 1998. 
In the UK ‘CORGI’ registered installers under-
take the work in compliance with safe and sat-
isfactory standard.

ecoTEC 800 and pro range

The ecoTEC 800 and pro range is a fully automatic, wall 
mounted, room sealed condensing (high efficiency) com-
bination boiler for central heating and domestic hot 
water.
Domestic hot water is supplied directly from the boiler, 
without requiring a copper cylinder, cold water tank, 
feed and expansion vessel and associated pipework. 
Domestic hot water has priority over central heating.
The ecoTEC 800 range consists of 2 models with out-
puts of 23 kW and 31 kW for domestic hot water and a 
pro version with an output of 28 kW for domestic hot 
water.
All versions are available in natural gas. The ecoTEC plus 
831 is also available in LPG.
ecoTEC combination boilers incorporate a warm start 
facility that keeps the domestic hot water heat exchang-
er hot, providing an instantaneous delivery of domestic 
hot water. The temperature in the domestic hot water 
heat exchanger is limited by the boiler control system 
and it is not necessary to install a scale reducer on the 
cold mains to the boiler. However, in areas that get 
exceptionally hard water, a scale reducer may be fitted 
to prevent scale formation in the hot water system 
pipes. The heating system can be filled using the built–in 
filling loop contained within the boiler.

ecoTEC plus 600 range

The ecoTEC plus 600 range is a fully automatic, wall 
mounted, room sealed condensing (high efficiency) sys-
tem boiler for central heating and domestic hot water 
(where a separate indirect hot water storage cylinder is 
also incorporated in the system). The ecoTEC 600 range 
consists of models with outputs of 12, 15, 18, 24 and 30 
kW. All ecoTEC 600 range boilers are available in Natural 
Gas. The ecoTEC plus 618 and 630 are also available in 
LPG.

1.3 General 

Notes

The boilers have been designed for use with a sealed 
central heating system, and come fully tested and 
assembled with a built in circulating pump, expansion 
vessel and diverter valve (ecoTEC plus 800 and pro). 
The boilers are easily mounted on any internal wall and 
can be installed with either a horizontal or vertical RSF 
(room sealed fan assisted) flue.
The boilers use a standard flue system (100 mm or 
125 mm outside diameter). Flue extensions and addition-
al bends and elbows are available for the flue system to 
increase the flexibility. If desired, an inhibitor may be 
used in the system. Guidance on the use of inhibitors is 
contained in these instructions.
All boilers have a built in diagnostic system which indi-
cates the operational status of the boiler. This feature 
provides key information to aid commissioning and fault 
finding. The data badge is fitted to the underside of the 
boiler. See text of General Requirements for installation 
requirements or notes.

Summary of Contents for ecoTEC pro 28

Page 1: ...plus 612 ecoTEC plus 615 ecoTEC plus 618 ecoTEC plus 624 ecoTEC plus 630 ecoTEC plus 824 ecoTEC plus 831 ecoTEC pro 28 Instructions for installation and servicing ecoTEC Wall hung room sealed fan assi...

Page 2: ...13 Electrical connection 22 4 13 1 General requirements 22 4 13 2 Connection to the main supply 23 4 13 3 Electric board layout 24 4 13 4 Connection of programmable thermostats 27 4 14 Controls ecoTEC...

Page 3: ...e condensation water siphon 42 7 4 Checking the expansion vessel 43 7 5 Recommissioning the boiler 43 7 6 Test operation 43 8 Troubleshooting 44 8 1 Logical fault finding procedure 44 8 1 1 Status cod...

Page 4: ...coTEC 800 range consists of 2 models with out puts of 23kW and 31kW for domestic hot water and a pro version with an output of 28kW for domestic hot water All versions are available in natural gas The...

Page 5: ...the adherence to the inspec tion and maintenance conditions Danger Any incorrect use is forbidden The appliances must be installed by a qualified engineer who is responsible for adhering to the exist...

Page 6: ...rature at minimum thermal load 40 C flow 30 C return at maximum thermal load 80 C flow 60 C return 40 70 C C NOx class 5 Protection class IP X4D max flow temperature 85 C Adjustable flow temperature D...

Page 7: ...ad 80 C flow 60 C return 1 9 5 5 1 9 6 9 2 8 8 3 4 1 11 1 4 7 13 8 g s g s Exhaust temperature at minimum thermal load 40 C flow 30 C return at maximum thermal load 80 C flow 60 C return 40 70 C C NOx...

Page 8: ...nnection 15mm only 800 series 3 Gas connection 15mm 4 Hot water connection 15mm only 800 series 5 Heating flow pipe 22mm 6 Hanging bracket 7 Flue hole flue system 60 100 8 Flue hole flue system 80 125...

Page 9: ...er valve with by pass 7 Pump 8 Aqua Sensor 9 Electronics box 10 Pressure sensor 11 Hot water heat exchanger 12 Gas valve 13 Heat exchanger 14 Flue pipe connection 1 2 3 4 5 7 9 14 13 12 10 Fig 2 3 Fun...

Page 10: ...n BS 5449 Specification for forced circulation hot water for domestic premises BS 5546 Specification for gas hot water supplies for domestic premises BS 6700 Services supplying water for domestic use...

Page 11: ...s extra 1 sticker each for tank and ventilation above Fig Table 3 1 Scope of delivery for ecoTEC plus 600 series 1 2 3 4 6 5 8 9 7 Fig 3 2 Scope of delivery for ecoTEC plus 800 series DO NOT remove th...

Page 12: ...flat vertical wall which must be suffi ciently 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 Build...

Page 13: ...nu ine Vaillant flue pipes Malfunctions can 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...

Page 14: ...rminal on the same wall 300 M Distance from adjacent for vertical Flue 500 Table 3 4 Terminal position for a fan assisted concentric flue Note In addition the terminal should not be nearer than 150 mm...

Page 15: ...ogies Tandem House Marlow Way Croydon CR0 4XS Tel 0870 8700362 3 10 2Filling and preparing heating system The system can be filled using the built in filling loop ecoTEC plus 800 series only or via a...

Page 16: ...is fitted with an automatic air vent Additional provision should be made to enable the heating system to be vented during filling and commissioning either by automatic air vents or manually 3 12 Conde...

Page 17: ...and condensate drain 4 1 2 Unpack the boiler To unpack the boiler cut both plastic carton straps open box and lift out the polystyrene top packing Lift the cardboard box upwards Note Care should be ta...

Page 18: ...Lift the boiler 3 up to the wall so that it is slightly above the hanging bracket 1 Note Lift the boiler from either side at the bottom edge Lower the boiler slowly onto the hanging bracket so that t...

Page 19: ...Insert the union nut 2 and the pinching ring 3 on the gas connection pipe 1 to the heater Insert the union nut 6 and the pinching ring 5 on the conduit arc provided with ecoTEC plus appliances 7 Inser...

Page 20: ...tra care should be taken to avoid damage to isolation valves through heat transfer 4 10 1 Heating flow and return connection Note Before connecting the heating circuit to the boiler all pipework and r...

Page 21: ...10 2Pressure Relief Valve 1 2 3 Fig 4 11 Installing the drain pipe on the pressure release valve of the heating system picture shows ecoTEC 800 plus Caution To ensure fumes do not escape through the s...

Page 22: ...ap with a 75mm 3 seal The connection should preferably be made down stream of the sink waste trap If the connection is only possible upstream then an air break is needed between the two traps This is...

Page 23: ...the control panel Fig 4 13 Opening the electronics box Unclip the bottom of the terminal box cover and hinge back to reveal the connection plugs Feed the power supply flex into the appliance and the c...

Page 24: ...24 Instructions for installation and servicing ecoTEC 4 13 3 Electric board layout Fig 4 15 Connection wiring ecoTEC 4 Boiler installation sequence...

Page 25: ...black X 20 8 blue X 2 12 green X 2 11 red X 2 9 black Pump X 20 18 red 24 VDC X 20 9 blue earth X 20 16 blue earth X 20 13 black X 20 12 black X 20 4 grey PWM X 20 3 black Hall signal X 20 17 red 24...

Page 26: ...nsor NTC return X 20 5 red X 20 7 black X 20 7 black X 20 8 blue X 2 10 black X 2 14 brown X 2 12 green X 2 11 red X 2 9 black Pump X 20 18 red 24 VDC X 20 9 blue earth X 20 16 blue earth X 20 13 blac...

Page 27: ...ection details for programmable thermostats 4 14 Controls ecoTEC plus 800 and pro only 4 14 1 External electrical controls The boiler terminals 3 4 and 5 are for connecting exter nal electrical contro...

Page 28: ...EP 4002 EP 5002 Smiths Timeguard SupplyMASTER FST11 FST17 Sunvic Select 107 N 1 A B C N 4 2 L L 3 3 4 1 2 6 5 E 4 L 3 N 3 E N E 2 3 4 N E 1 L L 3 5 6 4 L N 2 3 4 L N 3 4 1 L N 2 3 4 L N 3 4 1 L N 2 3...

Page 29: ...or use in systems with thermostatic radiator valves no separate system by pass is required For opti mum fuel economy where TRV s are used they must be used in conjunction with a boiler control interlo...

Page 30: ...thermostat 2 1 C YL 3 3 2 2 BK 1 2 2 1 1 RED C 1 1 3 ACL Drayton HTS3 Danfoss Randall ATC Tower CS1 Honeywell L641 Horstmann HTC1 Siemens Landis Staefa RAM 1 Sunvic SA 2452 8 4 7 E Cylinder thermosta...

Page 31: ...all ATC Tower CS1 Honeywell L641 Horstmann HTC1 Siemens Landis Staefa RAM 1 Sunvic SA 2452 10 7 E Cylinder thermostat 3 E 2 E E EARTH BLUE BROWN GREY ORANGE Central heating 2 port motorised valve 4 E...

Page 32: ...ing the heating system 5 4 1 Checking the filling pressure of the heating system bar i F P plus pro bar 1 2 Fig 5 1 Checking the filling pressure of the heating system Note The ecoTEC appliances come...

Page 33: ...filling pipe of the heating system Open the cold water dispensing valve Slowly open the filling valve and let the water flow into the heating system Ventilate the lowest heating ele ment until the wa...

Page 34: ...of the condensate water siphon 5 7 Adjusting the pumping capacity Only in ecoTEC plus The capacity of the two stage pump can be adjusted to the requirements of the heating system If needed change the...

Page 35: ...ve U gauge Tighten the test point screw and check for leaks Record appliance working gas inlet pressure mbar in the Benchmark Installation Commissioning and Service Log Book 5 9 3 Checking the gas rat...

Page 36: ...ltaneously to cancel adjustment mode Adjustment mode is also cancelled if no button is operated for a period of 4 minutes Appliance Heating output in kW ecoTEC plus 612 5 12 ecoTEC plus 615 5 15 ecoTE...

Page 37: ...ating system and the heater quickly and fully Close the drain valve Fill the heating system again with water as described in Section 5 4 4 Release water from the system until the system design pressur...

Page 38: ...be obtained from Vaillant Customer Service Centres 7 1 2 Safety instructions Important Before starting any maintenance work Isolate the mains electricity supply by disconnecting the plug at the socket...

Page 39: ...nts if necessary X X 7 Check re pressurise expansion vessel as necessary X 8 Open the maintenance taps fill up the appliance system up to approx 1 0 2 0 bar depending on the static height of the syste...

Page 40: ...kwards to remove from the appliance Turn off the gas service valve Turn off the boiler CH service valves Loosen screw release the front case spring retaining clips located beneath the front edge of th...

Page 41: ...components Any water used to clean the main heat exchanger will drain through the condensate trap Avoid pointing the water jet directly at the insulating surface 2 on the back of the heat exchanger I...

Page 42: ...line to hold the gas fittings Turn on the gas supply and test for soundness Refit the air inlet pipe ensuring that the blue seal in the air intake pipe is correctly located 7 3 Cleaning the condensati...

Page 43: ...heating system 7 5 Recommissioning the boiler Carry out electrical safety checks Turn on the electrical supply Open the boiler CH service valves Carry out function checks of boiler operation as previ...

Page 44: ...y shows the status code e g S 04 for Burner mode Heating The display of the status codes can be cancelled as fol lows Press the i key or Do not press any key for about 4 minutes The current heating fl...

Page 45: ...alue by holding down the i key for approx 5 seconds until the display no longer flashes You can end the diagnosis mode as follows Press the i and keys simultaneously or Do not press any key for approx...

Page 46: ...number 00 to 99 d 90 Digital regulator status 1 identified 0 unidentified eBUS Address 10 d 91 DCF status with connected external probe with DCF77 receiver 0 no reception 1 reception 2 synchronised 3...

Page 47: ...ting max output d 78 Storage charging temperature limit target flow tem perature in storage mode Adjustment range in C 55 to 90 Factory setting 80 d 80 Heating operating hours in h d 81 Water heating...

Page 48: ...ion plug defective ionisation current stopped cable electrode faulty earthing in appliance electronics defective F 29 Flame goes off during operation and subsequent ignition attempts failed Gas supply...

Page 49: ...all adjustable diagnosis points now correspond to the factory settings 9 Parts replacement The tasks listed below in this section may be carried out only by a qualified engineer Only use genuine spar...

Page 50: ...ull out the plug 3 from the fan Remove the three screws 2 on the compact thermo module 1 Remove the complete gas valve fan unit 5 Fig 9 3 Gas fitting fan screwed joint Remove both fixing screws 5 on t...

Page 51: ...he work check for water leaks and perform a function check see Section 7 6 9 5 Replacing primary heat exchanger Danger Before replacing the component comply with the safety instructions in Section 9 1...

Page 52: ...g electronics and display Danger Before replacing the component comply with the safety instructions in Section 9 1 Comply with the assembly and installation manuals provided with the spare parts Repla...

Page 53: ...le 9 2 by turning the screw 2 Turn to the left higher CO2 content Turn to the right lower CO2 content Note Only for natural gas Adjust only in increments of 1 8 turn and wait approx 1 minute after eac...

Page 54: ...rgely 92 of metal components designed for eventual recycling by incorpo ration into the smelting process of a steelworks This gives these parts virtually unlimited scope for subse quent re use All pla...

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