Related Manuals for Vaillant ecoTEC plus
Summary of Contents for Vaillant ecoTEC plus
- Page 1 Instructions for installation and servicing For the heating engineer Instructions for installation and servicing ecoTEC ecoTEC plus ecoTEC pro GB, IE...
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Page 2: Table Of Contents
4.15.3 Connection details for external time switches Type plate ..............10 and boiler terminal strip .........37 4.15.4 Vaillant optional plug in timer accessories ..37 General requirements ..........11 4.15.5 Connection details using the VR 65 Control Preliminary remarks for room sealed Center ................37... - Page 3 Replacing fan or gas valve ........67 Replacing expansion vessel ........68 Replacing primary heat exchanger ..... 69 Replacing electronics and display ......70 Recycling and disposal ...........71 Vaillant service ............72 EC declaration of conformity ......73 Instructions for installation and servicing ecoTEC 839592_13...
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Page 4: Introduction
28 kW for domestic hot water. – Risk of severe personal injury – Risk of slight personal injury All versions are available in natural gas. The ecoTEC plus 831 is also available in LPG. Symbol denoting danger ecoTEC combination boilers incorporate a warm start –... -
Page 5: General Notes
All ecoTEC system boilers are available in Natural Gas. – Gas appliances directive (90/396/EEC) The ecoTEC plus 618 and 630 are also available in LPG. – Electromagnetic compatibility directive with threshold class B (89/336/EEC) – Low voltage directive (73/23/EEC) -
Page 6: Gas Council Numbers
Gas council numbers ecoTEC pro 24 47-044-36 ecoTEC pro 28 47-044-30 ecoTEC plus 824 47-044-31 ecoTEC plus 831 47-044-32 ecoTEC plus 831 Propane 47-044-34 ecoTEC plus 837 47-044-33 ecoTEC plus 612 41-044-44 ecoTEC plus 615 41-044-45 ecoTEC plus 618 41-044-46... -
Page 7: Boiler Specifications
Boiler specifications Boiler specifications Technical data ecoTEC plus ecoTEC pro Technical data Units CH heat output range 80 °C flow/60 °C return 6.7 – 19.0 8.7 – 24.0 12.0 – 28.0 6.7 – 19.0 9.0 – 24.0 60 °C flow/40 °C return 6.9 –... - Page 8 Boiler specifications ecoTEC plus Technical data Units CH heat output range 80 °C flow/60 °C return 4.9 – 12.0 4.9 – 15.0 6.7 – 18.0 8.7 – 24.0 10.0 – 30.0 12.0 – 37.0 60 °C flow/40 °C return 5.1 – 12.3 5.1 –...
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Page 9: Dimensions
Boiler specifications Dimensions ecoTEC plus 630: ecoTEC plus 637, ecoTEC plus 837: Fig. 2.1 Dimensions in mm Legend: Heating return pipe Ø 22 mm 2 Cold water connection Ø 15 mm (combination boilers only) 3 Gas connection Ø 15 mm 4 Hot water connection Ø... -
Page 10: Installation
Boiler specifications Installation Fig. 2.3 Function elements of system boilers Legend: Expansion vessel Fig. 2.2 Function elements of combination boilers 2 Air intake pipe 3 Burner module Legend: 4 Ignition electrode Expansion vessel 5 Fan 2 Air intake pipe 7 Pump 3 Burner module 9 Electronics box 4 Ignition electrode... -
Page 11: General Requirements
Part 1 Code of practice for domestic heating and hot This appliance should only be installed in conjunction with water. either a Vaillant flue system or an alternative approved Part 2 Code of practice for low and medium temperature system (details of flue approval categories can be found hot water systems. -
Page 12: Contents Included With Delivery
Your competent person connected your gas-fired wall- hung boiler to the power mains during installation. If the The Vaillant ecoTEC is delivered pre-mounted in a power supply is cut, it is possible that parts of the heat- package unit. Check that all the parts have been ing system may be damaged by frost. - Page 13 General requirements Fig. 3.1 Contents included with delivery of ecoTEC plus Fig. 3.2 Contents included with delivery of ecoTEC plus system boilers combination boilers DO NOT remove the boiler from the polystyrene base at DO NOT remove the boiler from the polystyrene base at this stage.
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Page 14: Installation Site
General requirements rent ETCI rules, in respect of the installation of a boiler in a room containing a bath or shower. Danger! Risk of death from electric shock when installing an appliance that is independent of ambient room air in a room with a bath or shower! If electric switches and controls are installed too close to a bath or shower, there is a risk... -
Page 15: Gas Supply
Vaillant flue pipes. You will find 25 m. a list of genuine flue pipes in the Vaillant A vertical flue system is also available. Refer to flue installation manual for flue pipes. -
Page 16: Flue Termination
General requirements Fig. 3.6 Art. No. 303 209 Fig. 3.8 Flue termination Vertical flues must not terminate within 600 mm of an openable window, air vent or any other ventilation opening. Caution! Possible material damage caused by lubri- cating the seals! Mineral oil-based lubricants may damage the seals. -
Page 17: Air Supply
General requirements The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of the building. Terminal position Directly below an opening, above an opening or hori- zontal to an opening, air brick, opening window, etc. Below gutters, soil pipes or drain pipes Below eaves Below balconies... -
Page 18: Guide To System Requirements
3.10.2 Filling and preparing heating system The system can be filled using the built in filling loop (ecoTEC plus combination boilers only) or via a separate filling point fitted at a convenient position on the heating circuit. The connection must be removed when filling is completed. - Page 19 General requirements Inform the operator of the necessary measures in case you have used any of these additives. Inform the operator of the required procedures for frost protection. Observe the applicable national regulations and technical standards for the treatment of filling and top-up water.
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Page 20: Pressure Relief Valve
The circulating pump is included in the boiler. The residual primary circuit pressure to facilitate filling and testing. pump discharge height depending on the by-pass valve is shown in Fig. 3.10.1 (ecoTEC plus) and 3.10.2 (ecoTEC plus 637 / 837). 3.10.5 Expansion vessel The operating mode of the 2-step pump can be adjusted below the diagnosis number “d.19”, see section 8.1.2. -
Page 21: System By-Pass
3.12 Condensate trap The boiler is fitted with a siphonic condensate discharge (ecoTEC plus) or a condensate trap (ecoTEC pro) incorporating a water trap of 140 mm. Instructions for installation and servicing ecoTEC 839592_13... -
Page 22: Boiler Installation Sequence
Boiler installation sequence Boiler installation sequence bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Clear the route Transporting the appliance before attempting the lift. -
Page 23: Required Minimum Distances/Assembly Clearances
Boiler installation sequence resistant gloves with good grip to protect against sharp minimise strain on back. Always use assistance if edges and ensure good grip when handling appliance. required. Recommend wear suitable cut resistant gloves Positioning of Appliance for Final Installation – above with good grip to protect against sharp edges and worktop, foreseeable obstructions etc. -
Page 24: Unpack The Boiler
Boiler installation sequence > The boiler can be correctly flued, i.e. the flue terminal 4.2.3 Using boiler template position is located in accordance with these instruc- tions and the air/flue duct can be installed in accord- ance with the flue installation instructions supplied. >... -
Page 25: Flue Exit
Boiler installation sequence > Mark the position of the hanging bracket fixing holes. Fitting the boiler > Drill 2 holes Ø 10 mm for the hanging bracket. > Lift the boiler (3) up to the wall so that it is slightly Use alternative fixing holes where necessary. -
Page 26: General Instructions For Heating System
Boiler installation sequence General instructions for heating system Danger! Risk of death from incorrectly installed gas system! Caution! An improper gas installation may impair the Risk of damaged boiler caused by contami- operational safety of the appliance and result nated lines! in material damage or personal injury. -
Page 27: Cold Water Mains Inlet And Hot Water Outlet (Ecotec Combination Boilers Only)
4.10 Cold water mains inlet and hot water outlet (ecoTEC combination boilers only) Fig. 4.5 Fitting the gas connection (example ecoTEC plus com- bination boiler) > Fit the union nut (2) and the compression olive (3) to the gas connection pipe (1) of the boiler. -
Page 28: Condensate Drain Pipe
Fig. 4.8 Installing the condensate drain pipe (picture shows ecoTEC plus combination boiler) The ecoTEC plus appliances are fitted with a siphonic trap (The filling height is 145 mm). The siphon collects The condensate discharge pipe must terminate in a suit- the accumulated condensate in a container of approx. -
Page 29: Heating Connection
Fig. 4.9 Installing the heating flow and return connection for ecoTEC plus combination boiler > Insert the seal (1) and fit the service valve (2) to the return connection of the appliance. - Page 30 22 mm pre-bended copper tail (5). > Fully insert pipe (5) into the service valve. Tighten the union nuts in this position. ecoTEC plus system boiler Fig. 4.11 Heating-side flow and return connection for ecoTEC plus system boiler > Insert a seal (1) and fit the service valves (2) to the flow and return connection of the appliance.
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Page 31: Pressure Relief Valve
16 (3 x 0.75 to 3 x 1.5 mm ) should be used. Fig. 4.12 Installing the drain pipe on the pressure release valve of the heating system (picture shows ecoTEC plus combination boiler) The pressure release valve for the heating system is integrated in the appliance. -
Page 32: Connection To The Main Supply
Boiler installation sequence Danger! 4.14.2 Connection to the main supply Risk of electrocution as a result of an improper electrical connection! An improper electrical connection may nega- tively affect the operational safety of the boiler and result in material damage or per- sonal injury. - Page 33 Boiler installation sequence - + 7 8 9 3 4 5 - + 7 8 9 3 4 5 Fig. 4.14 Wiring system > Connect the flex to the L, N and earth plug to the ter- minal block. Green/yellow (earth) wire – boiler terminal Earth sign Blue (neutral) wire –...
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Page 34: Electric Board Layout
Mains supply: 230 V/50 Hz Room thermostat 230 V/50 Hz (remove bridge on connection) Heating pump With ecoTEC pro: 1-step pump (plug with 3-pin) With ecoTEC plus: 2-step pump (plug with 5-pin) 2A fuse, slow Igniter Connection: 230 V Supply for accessory module Fig. - Page 35 X 2/10 black X 2/2 black (earth) Plate heat X 2/6 green (signal) exchanger X 2/5 violet (signal) X 2/1 black ecoTEC plus only: Hot water outlet X 20 — 230V Electronic control box Fig. 4.16 Connection wiring ecoTEC combination boiler...
- Page 36 Boiler installation sequence return Ignition electrode flow X 20/5 red X 20/7 black X 20/8 blue X 20/7 black X 20/13 black Thermal fuse X 20/12 black Fan unit Gas valve assembly Plug coupling X 20/16 blue (earth) X 20/4 grey (PWM) X 20/3 black (Hall signal) X 20/18 red (24 VDC) X 20/17 red (24 VDC)
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Page 37: Controls
00 2012 9873 Allows Weather compensator to add solar control functio- nality Table 4.1 Vaillant controls and accessories 4.15.2 External electrical controls The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. -
Page 38: Connection Details For External Time Switches And Boiler Terminal Strip
4.20 Automatic pump spin control (APS) ecoTEC plus system boilers and external 2- or 3-way- valves. Connect the VR 65 Controll Center as described The boiler incorporates a built in control which will spin in the enclosed manual. -
Page 39: Commissioning Part I
Commissioning Part I Commissioning Part I The ecoTEC appliances come with a manome- ter and a digital pressure indicator. The manometer allows you to quickly check whether the filling pressure is in target range Preliminary electrical checks or not even when the appliance is turned off. If the appliance is in operation, you can dis- Check the electrical installation by carrying out short play the exact pressure by pressing the “-”... -
Page 40: Ecotec Plus Combination Boiler Filling Loop
> Only in ecoTEC plus combination boilers: Connect the filling pipe as described in Section 5.4.2. > Only in ecoTEC plus system boilers and in ecoTEC pro combination boilers: As described in Section 5.4.3 join a hose between the cold water dispensing valve and the filling pipe of the heating system. -
Page 41: Initial System Flush ("Cold")
> Refit the lower part of the condensate siphon. Adjusting the pumping capacity Only in ecoTEC plus boilers: The capacity of the two-stage pump can be adjusted to the requirements of the heating system. If needed, change the setting of the operating mode dependent pump speed under the diagnostic number “d.19”... -
Page 42: Adjusting The By-Pass
Commissioning Part I Adjusting the by-pass Checking the gas setting The appliances have an adjustable by-pass valve. The pressure can be adjusted between 170 and Caution! 350 (mbar) hPa. Approx. 250 (mbar) hPa is preset (mid- Malfunctions or reduction in working life of position). -
Page 43: Checking For Tightness Of The Flue Gas Installation And Flue Gas Recirculation
Commissioning Part I > Ensure that all other gas appliances in the property 5.9.1 Checking for tightness of the flue gas installation and flue gas recirculation are turned off. > Measure the gas flow rate at the gas meter. > Check the integrity off the flue gas installation >... -
Page 44: Checking The Gas Inlet Working Pressure
> If the measured gas flow rate lies outside the toler- ance limits specified in Table 5.1, do not operate the boiler and inform the Vaillant Service Solutions (0870 6060 777). If the measured gas flow rate is within the tolerance limits shown in Table 5.1, then proceed as follows:... - Page 45 Commissioning Part I Fig. 5.8 Measuring the gas inlet working pressure > Loosen the sealing screw marked “in” (1) on the gas valve. > Connect a digital pressure gauge or U-tube manome- ter (2). > Open the gas isolation valve of the boiler. >...
- Page 46 If the gas inlet working pressure at the reference test point (1) is not within the permissible range and you cannot correct the failure, notify the gas supply company or the Vaillant Service Solutions team and proceed as follows: > Take the boiler out of operation by - Pressing the + and i buttons simultaneously and turn down both thermostat control knobs.
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Page 47: Refitting The Case
To reset the appliance from natural gas to > Hook the top of the front casing over the lip on the LPG mode, you need the Vaillant conversion top of the boiler chassis and push the bottom of the front casing into place. -
Page 48: Functional Checks (Commissioning Part Ii)
Functional checks (commissioning part II) Functional checks the appliance is running correctly in normal mode and the display shows “S. 4”. (commissioning part II) plus Functional checks 6.1.1 Procedure After installing and checking the gas supply pressure, perform a function check before commissioning the appliance and handing over to the user. -
Page 49: Handing Over To The User
Vaillant undertakes to rectify any manufacturing defect > Refit the boiler casing (see section 5.10). that occurs within twenty-four months of the installation > Only in ecoTEC plus appliances: Attach the bottom date. cover to the boiler by sliding the front edge of the... -
Page 50: Inspection And Maintenance
To ensure the faultless operation, long term availability - The flue gas analyser used must be one meeting the of all functions and long working life of your Vaillant requirements of BS7927 or BS-EN50379-3 and be cali- boiler and to prevent modifications to the approved brated in accordance with the analyser manufacturers’... -
Page 51: Safety Instructions
Inspection and maintenance > When removing any water carrying components During any inspection and maintenance or after change of parts of the combustion circuit, the following must be ensure that water is kept away from all electrical checked: components. - The appliance has been installed in accordance with Always perform the following steps after performing any the relevant installation instructions. -
Page 52: Adjusting The Co2 Concentration (Or The Air Ratio)
Inspection and maintenance 7.1.4 Adjusting the CO2 concentration (or the air ratio) Danger! Increased risk of poisoning due to incorrect settings! Incorrect setting may increase the risk of poi- soning. > If one of the flue gas values is greater than the acceptable values in Table 7.1 then check - the integrity of the complete flue... - Page 53 > If you are not able to adjust the boiler cor- rectly and the flue gas values remain higher than allowed in Table 7.1, call the Vaillant Service Solutions. > Do not start up the boiler. Instructions for installation and servicing ecoTEC 839592_13...
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Page 54: Inspection And Maintenance Work Steps
Inspection and maintenance 7.1.5 Inspection and maintenance work steps Column 2 Maintenance Column 1 Ins- must be carried pection must be No. Activity out at regular carried out each intervals – but year no longer than 5 years Check the air flue gas installation for leaks and for proper fixation and ensure it is not blocked or damaged and is fitted correctly, complying with the relevant installation instructions. -
Page 55: Servicing The Burner Module
Inspection and maintenance Servicing the burner module 7.2.1 Removing the burner module The burner module consists of the burner, fan, gas valve and the gas supply (mixer tube). These four components make up the complete assembly, the burner module. Danger! Risk of being burned or scalded by hot components! There is danger of being burned or scalded at... -
Page 56: Cleaning The Integral Condensation Heat Exchanger
Inspection and maintenance 7.2.2 Cleaning the integral condensation heat exchanger Caution! Risk of damage from water spray! If you fail to protect the electronics box ade- quately, water can penetrate the box during cleaning and may damage the electronics. > Protect the folded down electronics box against sprayed water. -
Page 57: Checking The Burner
Inspection and maintenance 7.2.3 Checking the burner Fig. 7.5 Checking burner The burner (1) is maintenance-free and needs no cleaning. > Check the burner surface for damage, replace the burner if necessary. > After checking/replacing the burner, re-assemble the burner module in the boiler as described in Section 7.2.4. -
Page 58: Cleaning The Condensate Siphon
Inspection and maintenance > Reconnect the gas supply (3) to the gas valve, ensur- > Remove the lower part (1) of the condensate siphon ing that a new sealing washer is used and correctly by turning the bayonet catch in anticlockwise direc- located. -
Page 59: Test Operation
Inspection and maintenance > Check gas flow rate as previously detailed. Test operation > Check for water leaks. > Refit case, ensuring that a good seal is obtained. Always perform the following checks after completing any maintenance task: > Commission the appliance according to the relevant operating manual. -
Page 60: Troubleshooting
Troubleshooting Troubleshooting The display shows the status code, e.g. S.4 for “Burner mode - Heating”. The display of the status codes can be cancelled as follows: > Press the “i” key or Logical fault finding procedure > Do not press any key for about 4 minutes. These checks must be carried out before attempting to The current heating flow temperature appears in the dis- use the fault finding guide. -
Page 61: Diagnostic Codes
Troubleshooting 8.1.2 Diagnostic codes Display Meaning Heating mode (all models): In the diagnostic mode, you can change certain S. 0 No heat demand parameters or display more information. S. 1 Fan running The diagnostic information is divided into two diagnostic S. - Page 62 Warm start temperature target value in °C, 40 to 65 °C d. 7 (ecoTEC plus combination boiler only) Storage temperature target value (system boiler only) in °C, 15 °C for left stop, then 40 to 70 °C 0 = open (no heat request) d.
- Page 63 Digitised ionisation potential Display range of 0 to 102, > 80 no flame, < 40 even flame Outside temperature d.47 Actual value in °C (with weather compensating Vaillant controller only) d.67 Remaining burner anti cycling time in min d.76 Appliance variant (device specific number) 00 to 99 d.90...
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Page 64: Fault Codes
Troubleshooting Display Meaning Display value/adjustable value d.50 Offset for minimum speed in rpm/10, adjustment range: 0 to 300 d.51 Offset for maximum speed in rpm/10, adjustment range: -99 to 0 d.58 From the third quarter of 2006: Setting range: 0 to 3 Activation of solar reheating 0 = solar reheating disabled (factory setting) 3 = activation of min. -
Page 65: Fault Memory
Troubleshooting 8.1.4 Fault memory The fault memory stores details of the ten most recent faults. > Press the ”i” and ”–” buttons simultaneously. > Use the ”+” button to scroll back through the list of memorised errors. To cancel fault error memory display mode, proceed as follows: >... - Page 66 Troubleshooting Code Meaning Cause NTC broken, NTC cable broken, Defective connection at NTC, Defec- F. 0 Flow–NTC open circuit tive connection at electronics Return–NTC open circuit NTC broken, NTC cable broken, Defective connection at NTC, Defec- F. 1 tive connection at electronics F.10 Flow NTC short circuit NTC defective, short circuit in cable harness, cable/casing shortcut...
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Page 67: Test Programs
Troubleshooting Test programs Special functions can be triggered on the appliances by activating various test programs. These programs are given in detail in the Table 8.5. > The test programs P.0 to P.6 will be started when “Power ON” is turned on and the “+” key is pressed for 5 s. -
Page 68: Parts Replacement
Parts replacement Parts replacement Replacing burner The tasks listed below in this section may be carried out only by a competent person approved at the time by the Danger! Health and Safety Executive and in accordance with the Risk of personal injury and/or material Gas Safety (Installation and Use) Regulations 1998. -
Page 69: Replacing Expansion Vessel
Parts replacement > After completing the work, check for gas leaks and perform a function check (see section 7.6). Replacing expansion vessel Danger! Risk of personal injury and/or material damage as a result of improper installation! You need to follow the corresponding safety instructions in order to safely replace the component. -
Page 70: Replacing Primary Heat Exchanger
Parts replacement > Pull out the expansion vessel (3) forwards. > Guide the new expansion vessel back into the appli- ance. > Re-connect the new expansion vessel using a new seal. > Refix the retaining plate. > Check the pressure of the expansion vessel (minimum pressure (0.75 bar) 75 kPa). -
Page 71: Replacing Electronics And Display
(see section 7.6). parameters of all adjustable diagnostics numbers correspond to the factory settings. Appliance Device specific number ecoTEC plus 612 ecoTEC plus 615 ecoTEC plus 618 ecoTEC plus 624 ecoTEC plus 630 ecoTEC plus 637... -
Page 72: Recycling And Disposal
Recycling and disposal 10 Recycling and disposal Both the Vaillant ecoTEC and the associated transport packaging consist primarily of recyclable raw materials. The Vaillant ecoTEC and all accessories and packaging must not be disposed of in the normal household rubbish. Make sure that the old unit and any existing accessories and the transport packaging is handed over to a proper disposal organisation. -
Page 73: Vaillant Service
Vaillant service Vaillant service To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agree- ment. Contact Vaillant Service Solutions (0870 6060 777) for further details. Instructions for installation and servicing ecoTEC 839592_13... -
Page 74: Ec Declaration Of Conformity
EC declaration of conformity EC declaration of conformity Instructions for installation and servicing ecoTEC 839592_13... - Page 75 Installation, Commissioning and Service Record...
- Page 76 Please affix the label from the top of the boiler over this area. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statuatory rights.
- Page 77 Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
- Page 80 Supplier Manufacturer...