Vaillant ecoTEC VU 466/4 Installation And Maintenance Instructions Manual Download Page 4

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Installation and maintenance instructions ecoTEC 0020029172_03

Description of the boiler

2.1 Design

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!

When using accessories observe the minimum
gaps/mounting clearances (see Chapter 4.5).

2 Description of the boiler

Summary of Contents for ecoTEC VU 466/4

Page 1: ...For the heating engineer Installation and maintenance instructions ecoTEC Gas fired wall hung high efficiency boiler VU 466 4 GB ...

Page 2: ...g the CO2 concentration 35 8 1 4 Adjusting the CO2 concentration or the air ratio 36 8 1 5 Inspection and maintenance work steps 37 8 2 Filling draining the boiler and heating installation 38 8 2 1 Filling the boiler and the heating installation 38 8 2 2 Draining of the boiler 38 8 2 3 Draining the entire system 38 Contents Contents 1 Notes on the documentation 3 1 1 Storage of documents 3 1 2 Saf...

Page 3: ...apply exclusively to the boiler with the following part number Type designation Article number ecoTEC VU GB 466 4 5 H 0010004139 Table 1 1 Type designation and article number The article number of the boiler can be found on the identification plate 8 3 Maintenance of the compact thermal module 38 8 3 1 Dismounting the compact thermal module 38 8 3 2 Cleaning the heat exchanger 39 8 3 3 Checking th...

Page 4: ...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 hNote When using accessories observe the minimum gaps mounting clearances see Chapter 4 5 2 Description ...

Page 5: ...e the boiler Children must be watched to ensure that they do not play with the boiler The boiler is intended for use as a heater in closed hot water central heating installations Any other or additional use is considered to be improper The manufacturer supplier will not be held liable for claims resulting from improper use The operator alone bears the risk Intended use also includes observance of ...

Page 6: ...s 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 boi...

Page 7: ...e 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 Only for commercial applianc...

Page 8: ...l 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 hNote 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 ...

Page 9: ... 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 ele...

Page 10: ...ons below before choosing where to install the boiler a Caution 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 cl...

Page 11: ...on 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 h No...

Page 12: ...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 eac...

Page 13: ...r 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 pu...

Page 14: ... 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 For more detailed information on examples of systems and system equipment contact your Vaillant sales support point a Caution The following system diagrams are schematic representation...

Page 15: ...ng 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 The charging circuit connection downstream of the low loss header enables the choice of an individual cylinder size and of a charging pump h Note Observe that non return valves...

Page 16: ... 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 boi...

Page 17: ...ipe 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 5 5 Heating connection a Caution Ensure strainless assembly of the supply lines to avoid leakages in the...

Page 18: ...k 2 1 7 d c 6 5 a 3 4 3 b Fig 5 11 Condensate drainage pipework Legend a Internal stackpipe b Internal drainage system c Gully d Soakaway 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 1...

Page 19: ...ould be sucked dry Before the boiler is switched on the siphon must have been filled with water to prevent flue gas from leaking via the siphon see Chapter 6 2 3 5 8 Electrical connection e Danger Risk of fatal electric shock through contact with live connections The electrical installation may only be carried out by a recognised skilled trade company Always switch off the power supply first and e...

Page 20: ...ng see Chapter 4 8 5 8 2 Connecting controllers Mount the controllers in accordance with the corresponding operating and installation manuals The required connections to the electronic system of the boiler e g for external controllers external sensors etc should be performed as follows Remove the front casing of the boiler see Chapter 4 8 and tilt the electronic box 3 forwards see Fig 5 12 Unclip ...

Page 21: ...ee corresponding operating manual 5 8 4 Additional relay grey plug on the PCB and VR40 2 in 7 multifunctional module Additional relay grey plug on the PCB With the ecoTEC it is possible to actuate one additional component via the additional relay You can select the installed components via diagnosis point d 26 at diagnosis level 2 see Chapter 9 1 2 VR40 2 in 7 multifunctional module If you wish to...

Page 22: ...1 17 3 4 16 Igniter X14 5 7 8 12 13 14 18 9 Cylinder thermostat connection 1 C1 C2 Cylinder NTC sensor1 Flow rate sensor Fan Flow temperature sensor Return temperature sensor Gas valve Ignition electrode Appliance earth Mains 1 2 1 Earth natural black Hall signal PWM signal 24V 2 3 4 5 4 Signal P Water pressure sensor X 11 Fig 5 14 Connection diagram of ecoTEC continued on next page 1 You must not...

Page 23: ...tory link fitted Optional ext controller room thermostat 7 8 9 continuous analogue Bus connection for optional accesories Safety circuit connection 230 volt mains input Internal pump Connector for controller accessories VRC 430 Earth Earth DCF connection Low loss header sensor External sensor Remote control circulation pump PWM signal internal pump 24 V 230 V Fan Additional relay e g external heat...

Page 24: ...subsequently removed from the heating installation by draining it completely Cleaning agents should not remain in the heating installation longer than 24 hours This cleaning process must take place before a new boiler is fitted in accordance with BS 7593 Recommendations on the use of system cleaning agents can be obtained from Sentinel Betz Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 420 9595 or...

Page 25: ...r on when it is empty and disappears automatically when it is filled a Caution Risk of damage from leaking water If the pressure drops frequently the reason for the loss of heating water must be identified and eliminated Open the combined filling and emptying valve and the draw off valve slowly and add water until the required system pressure is shown on the pressure gauge display Close the draw o...

Page 26: ... preset at the factory for operation on the type of gas defined on the identification plate No measurement of the combustion is necessary to set up the boiler Do not adjust the multifunctional automatic gas valve Ensure that the boiler has been installed in accordance with these instructions the integrity of the flue system and the flue seals as described in the flue installation instructions encl...

Page 27: ...he boiler and inform the Vaillant Service Solutions 0870 6060 777 If the measured gas flow rate is within the tolerance limits shown in Table 6 1 then proceed as follows Take the boiler out of operation by Pressing the and i buttons simultaneously and turn down both thermostat control knobs Record the boiler maximum gas flow rate onto the Benchmark gas boiler commissioning checklist 6 3 3 Checking...

Page 28: ...oiler Make sure that there is no leakage at the sealing screw Put the front casing back on Reset boiler controls for normal operation Record the appliance gas inlet working pressure mbar in the Benchmark gas boiler commissioning checklist 6 4 Checking the appliance function If the installation is complete and the gas setting has been checked perform a function check before starting up the boiler a...

Page 29: ...he manuals in a handy location near the ecoTEC but not in or on the boiler Instruct the operator about measures taken to ensure the supply of combustion air and flue gas guiding Point out that these measures particularly must not be altered Explain to the operator how to check the water level filling pressure of the system and show the operator how to refill and bleed the heating installation when...

Page 30: ...on The display shows the respective diagnosis information If necessary use the or keys to change the value display flashes Save the new value by holding the i button pressed for about 5 seconds until the display stops flashing You can finish the diagnosis mode as follows Push the i and buttons simultaneously or avoid pressing any buttons for about 4 minutes The current heating flow temperature or ...

Page 31: ...e control eBUS not yet supported 9 legionella pump not active 1 d 28 Switch of relay 2 on the multifunctional module 2 in 7 1 circulation pump 2 ext Pump 3 charging pump 4 vapour extraction hood 5 ext solenoid valve 6 ext fault message 7 not active 8 remote control eBUS not yet supported 9 legionella pump not active 2 d 50 Offset for minimum speed in rpm 10 adjustment range 0 to 300 30 d 51 Offset...

Page 32: ...5 minutes for 5 minutes once the overrun time has elapsed 7 2 3 Setting of maximum flow temperature The maximum flow temperature for the heating is set at the factory to 75 C Under diagnosis point d 71 it can be set to between 40 and 85 C 7 2 4 Setting of burner anti cycling time To prevent frequent switching on and off of the burner energy loss an electronic restart lockout is activated for a spe...

Page 33: ...nics incorporate a feature that enables you to determine the maintenance intervals for the boiler This function serves to provide a signal after a specific adjustable number of burner operating hours that the boiler needs to be maintained The service signal SEr and the current flow temperature are shown alternately in the display of the ecoTEC once the specified number of burner operating hours ha...

Page 34: ...ctual condition of the respective boiler and compare it with the specified condition This is done by measuring checking and observing Maintenance is required in order to eliminate any deviations of the actual condition from the specified condition This normally is done by cleaning adjustment and if neces sary replacing individual components that are subject to wear You must carry out an annual ins...

Page 35: ...vice valves in the heating flow and return Remove the front casing from the boiler When removing any water carrying components ensure that water is kept away from all electrical components Always perform the following steps after performing any inspection or maintenance work Always use new seals and O rings when parts are replaced Open the service valves in the heating flow and return Reconnect th...

Page 36: ... to turn the screw Turn to the left higher CO2 concentration Turn to the right lower CO2 concentration hNote Natural gas Only perform the adjustment in increments of 1 8 turn and wait approximately 1 minute after each adjustment until the value stabilises Liquid gas Only perform the adjustment in very small increments approximately 1 16 turns and wait approximately 1 minute after each adjustment u...

Page 37: ...d correct them if necessary x x 8 Close the gas isolation valve and the service valves x 9 Dump the pressure in the boiler on the water side observe pressure gauge and check the charge pressure of the expansion vessel Top up if necessary x 10 Remove the compact thermal module x 11 Check the integrity of all combustion circuit seals especially the burner door seal If there are any damages repair th...

Page 38: ...e 8 3 Maintenance of the compact thermal module 8 3 1 Dismounting the compact thermal module The compact thermal module consists of the speed controlled fan the gas air combination valve the gas feed mixture pipe to the fan premix burner and the premix burner itself These four individual parts form the compact thermal module component H Danger Danger of burning or scalding There is danger of being...

Page 39: ...to the PCB and fan Protect the downfolded electronic box and also the fan against splash water 2 3 4 1 Fig 8 4 Cleaning the heat exchanger Dismount the compact thermal module as described under 8 3 1 Clean the heating coil 2 of the heat exchanger 3 using commercially available essence of vinegar Flush with water The water flows out of the heat exchanger through the condensate siphon You can also c...

Page 40: ... cable 4 Fig 8 3 at the gas valve Connect the gas supply with a new seal to the gas valve Use the spanner flat at the flexible gas line to hold up the gas valves 1 Fig 8 6 Checking for gas tightness a Caution Open the gas feed and check the gas tightness of the boiler with leak detector spray Check the screwed connection 1 particularly carefully Make sure the blue sealing ring in the air intake pi...

Page 41: ...ing 6 Pull the filter 5 upwards out of the air separator You can either clean the filter with hot water or replace it with a new one Insert the filter into the air separator Screw the brass cover onto the air separator 8 6 2 Cleaning the air separator If the collector tray on the inside of the casing next to the filter is heavily soiled you can completely dismount the air separator 2 clean it with...

Page 42: ...r generation see Chapter 6 4 2 Document the inspection maintenance tasks carried out in the form provided in the inspection or maintenance contract 9 Troubleshooting h Note Whenever possible please quote the fault message displayed F xx and the status of the boiler S xx when contacting the Vaillant customer service or your Vaillant service partner If the display flashes SEr this means that you sho...

Page 43: ...4 Boiler remains within the waiting time of the operation block function due to a water lack temperature gradient S 59 Waiting time minimum quantity of circulation water not achieved S 85 Service info Check quantity of circulation water S 96 Return temperature sensor test running heating demands are blocked S 97 Water pressure sensor test running heating demands are blocked S 98 Flow return temper...

Page 44: ...ot water generation enabled by eBUS controller 1 yes 0 no d 29 Actual value circulation water quantity of flow rate sensor Actual value in m3 h d 30 Control signal for the gas valve 1 on 0 off d 33 Fan speed target value in rpm 10 d 34 Fan speed actual value in rpm 10 d 35 not relevant Not relevant d 40 Flow temperature actual value in C d 41 Return temperature actual value in C d 44 Digitalised i...

Page 45: ... 8 remote control eBUS not yet supported 9 legionella pump not active d 50 Offset for minimum speed in rpm 10 setting range 0 to 300 factory setting 30 d 51 Offset for maximum speed in rpm 10 setting range 99 to 0 factory setting 45 d 60 Number of safety thermostat shutdowns Number d 61 Number of faults of the automatic combustion system Number of unsuccessful ignitions in the last attempt d 64 Av...

Page 46: ... again causes the display to switch back to the diagnosis point that was called up Table 9 3 Diagnosis codes at diagnosis level 2 continued 9 1 3 Fault messages The fault messages displace all other displays when failures occur Occuring failures are displayed as F e g F 10 see Tab 9 4 If several failures occur simultaneously each fault message is displayed for approximately two seconds on an alter...

Page 47: ...uring start up Ignition failed Gas meter defective gas pressure monitor has been triggered air in gas gas inlet working pressure too low Thermal isolator device TAE has been triggered condensate duct blocked failure at gas valve multiple plug on PCB incorrectly plugged in break in cable harness ignition system ignition transformer ignition cable ignition plug ignition electrode defective ionisatio...

Page 48: ... programs You can also exit the check programs by not pushing any button for 15 minutes Display Meaning P 0 1 Check Program Dearation The heating circuit and the hot water circuit are bled via the automatic air vent the cap of the automatic air vent must be released 1 x i button Start bleeding heating circuit display view HP 2 x i button Start bleeding charging circuit display view SP 3 x i button...

Page 49: ...ater bearing components of the boiler Make sure that water does not drip on live components e g the electronic box Use only new seals and O rings After completing the work perform a tightness check and function check see Chapter 6 4 10 2 Replacing the burner d Danger Before replacing the component observe the safety information in Chapter 10 1 Dismount the compact thermal module as described in Ch...

Page 50: ...nect the boiler from the power mains as described in Chapter 10 1 and close the gas isolation valve Close the service valves in the heating flow and return and drain the boiler Dismount the compact thermal module as described under 8 3 1 1 4 5 2 3 Fig 10 4 Replacing the heat exchanger Pull out the clip 4 of the condensate siphon 5 Unfasten the screw connections on the condensate siphon and pull it...

Page 51: ...e any other spare part displays Enter the number of the boiler variant under diagnosis point d 93 at the second diagnosis level in accordance with Table 10 1 see Chapter 9 1 2 The PCB is now set to the boiler type and the parameters of all adjustable diagnosis points correspond to the factory settings You can now make the specific settings for the system Boiler Number of boiler variant DSN ecoTEC ...

Page 52: ... LPG 3 5 kg h Rated water volume when T 20 K 1935 l h Maximum flow temperature approximately 85 C Maximum operating pressure 3 bar Condensate rate pH value 3 0 4 0 4 5 l h Water content 4 5 l Flue gas mass flow minimum maximum 5 7 20 5 g s Flue gas temperature minimum maximum 40 70 C Pressure drop across the heat exchanger at full load and T 20 K 350 mbar Connections heating flow return 1 internal...

Page 53: ......

Page 54: ... BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr r a b m E L B A C I L P P A F I E R U S S E R P G N I T A R E P O R E N R U B M U M I X A M COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACC...

Page 55: ...NY NAME TEL No ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No ID CARD SERIAL No COMMENTS SIGNATURE SERV...

Page 56: ...0020029172_03 GB 062010 Subject to alterations ...

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