Vaillant ecoTEC exclusive 832 Installation And Maintenance Instructions Manual
Gas wall boilers with condensing appliance technology
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Summary of Contents for Vaillant ecoTEC exclusive 832
- Page 1 For the installer Installation and maintenance instructions ecoTEC exclusive Gas wall boilers with condensing appliance technology ecoTEC exclusive 832 ecoTEC exclusive 838 GB, IE...
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Page 2: Table Of Contents
5.10.4 Details for the connection of an external timer necessary ..............38 to the connection rail ..........19 Test operation............38 5.10.5 Optional plug-in timers by Vaillant ....... 19 5.10.6 Wiring diagrams............20 Troubleshooting ..........39 Diagnostics ..............39 Start-up .............. 22 9.1.1... -
Page 3: Notes On The Documentation 1
10.5 Replacing electronics and display ......47 lation and maintenance manual. We accept no liability for any damage caused by fail- Vaillant service ..........47 ure to observe these instructions. Recycling and disposal ........47 Other applicable documents For the owner of the system: Technical data ........... -
Page 4: Description Of The Appliance
Key to Fig. 4.2 Expansion vessel 8 Aqua-Sensor 2 Air intake pipe 9 Electronics box Vaillant Ltd. supports the Benchmark Initiative. 3 Burner assembly 10 Pump You will find the Benchmark Logbook on the 4 Ignition electrode 11 Auto air vent last page of this instruction manual. -
Page 5: Gas Council Numbers
Intended use Improper use or unsuitable tools can cause The Vaillant ecoTEC exclusive is a state-of-the-art appli- damage, such as gas or water leaks. ance which has been constructed in accordance with recognised safety regulations. Nevertheless, danger to 3.1.1... -
Page 6: Related Documents
3 Safety instructions and regulations Related documents European installation directive The installation of the appliance and any associated hot water system must be in accordance with (but not limit- Caution! ed to) the following; COSHH regulations, Gas Safety (In- Installation and maintenance of the unit may stallation and Use) Regulations 1998, Health and Safety only be undertaken by a competent person ap- Document No. -
Page 7: Assembly 4
Assembly 4 Assembly 4.1.1 Transporting the appliance The Vaillant ecoTEC exclusive is delivered pre-assem- Important: bled in a package unit. With regards to the Manual Handling Opera- tions, 1992 Regulations, the following lift oper- Scope of delivery ation exceeds the recommended weight for a Check the delivery for completeness and lack of damage one man lift. -
Page 8: 4 Assembly
4 Assembly Carriage of carton from point of delivery to point of Unpacking of appliance from carton. installation – first or higher floor, cellar. • Recommend 2 persons unpack appliance from carton. • Recommend 2-person lift or 1 person with use of sack •... - Page 9 Assembly 4 Positioning of Appliance for Final Installation – above Positioning of Appliance for Final Installation – in worktop, foreseeable obstructions etc. roof space restricting installation. • If appliance weight is over 25 kg always use 2 persons • If appliance weight is over 25 kg always use 2 persons to move where practical.
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Page 10: Dimensioned Drawing And Dimensions For Connection
4 Assembly Dimensioned drawing and dimensions for connection Ø 20 Ø 20 Ø 20 100 100 Fig. 4.2 Dimensions for connection (mm) Key to Fig. 4.2 Flue connection 2 Mounting bracket 3 Heating return 4 Cold water connection 5 Gas connection 6 Hot water connection 7 Heating flow ecoTEC exclusive installation and maintenance instructions / 0020017768_04... -
Page 11: Installation Site
Assembly 4 Installation site Particularly in hairdessing salons, lacquering and finish- The site of erection of the boiler should allow proper ing workshops, cleaning facilities, etc., the appliance connection of the air/exhaust ducting. In addition, there must be operated independently of the ambient air. Oth- should be adequate room for maintenance work and air erwise, a separate installation room is required to guar- circulation around the boiler. -
Page 12: Mounting The Appliance
5 Installation Installation Mounting the appliance Danger! The Vaillant ecoTEC exclusive may only be in- stalled by a suitably qualified heating engineer approved at the time by the Health and Safety Executive who also assumes the responsibility for installing the appliance properly and fully... -
Page 13: Hot Water And Cold Water Connections
The dynamic gas connection pressure must be at least 19 – 23 mbar for natural gas and 37 mbar for propane The Vaillant ecoTEC exclusive is set in the factory to a gas. nominal water quantity of 11.6 l/min. (38 kW unit) and •... -
Page 14: Heating Connection
5 Installation Heating connection Pressure Relief Valve Fig. 5.3 Heating connection Fig. 5.4 Fitting the pressure relief valve The pressure relief valve and filling loop connection is Caution! provided within the boiler cardboard box and should be Mount the heating lines so they are tension- assembled as shown below. -
Page 15: Flue Pipe
Vaillant appliances are only system-certified if of up to 21 m. You can also get a vertical system. Fur- genuine Vaillant flue pipes are used. Only use ther information can be obtained from the installation genuine Vaillant flue pipes. Malfunctions can instructions for the flue pipe. -
Page 16: Air Connection
5 Installation BS 5440–1: We recommend that the terminal of a fan-assisted flue pipe system be positioned as follows: a) At least 2 m from an opening in the building directly opposite, and b)so that the combustion products do not flow out at right angles to a boundry. -
Page 17: Condensate Discharge
Installation 5 Condensate discharge nection head of 75 mm (fitted within the boiler al- ready). The connection should be made after the drain siphon if possible. If the installation is only possible in front of the siphon, there must be a ventilation valve between the two siphons. -
Page 18: Connection Of Controllers, Accessories And External Installation Components
5 Installation 5.10.2 Connection of controllers, accessories and external installation components The following controllers, accessories and installation components can be connected to the ecoTEC exclusive (see Table 5.2). - + 7 8 9 3 4 5 The installation should be carried out in accordance with the individual instruction manual. -
Page 19: Details For The Connection Of An External Timer To The Connection Rail
4 on the boiler must be interrupted by the contacts of the room thermostat (see circuit diagram Fig. 5.14). 5.10.5 Optional plug-in timers by Vaillant Further details for the connection can be found in the relevant instructions of the accessories. The cover on the connection box should be replaced after all the elec- trical connections have been made. -
Page 20: Wiring Diagrams
5 Installation 5.10.6 Wiring diagrams Connection eBUS accessories Cable harness compact thermal module PWM pump Connection accessories module Diagnosis via eBUS, vrnetDIALOG External sensor External flow or return sensor Cable harness hydraulics Connection for external eBUS controller Caution: Do not connect mains voltage! Room thermostat 24 V: Danger of damage to Connection 7, 8 and 9... - Page 21 Installation 5 Return temperature Flow temperature Ignition electrode sensor (NTC) sensor (NTC) X 20/5 red X 20/7 black X 20/8 blue X 20/7 black Plug connection Gas valve 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) X 20/9 blue (Earth)
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Page 22: Start-Up
• When using additives, follow the additive manufactur- er‘s instructions without exception. - if the limits given in the following tables are not ad- Vaillant accepts no liability for the compatibility of any hered to. additive or its effectiveness in the entire heating sys-... -
Page 23: Filling And Venting From The Heating Side
Start-up 6 Caution! Note! Risk of material damage if the heating water is The ecoTEC units are supplied with a pressure treated with unsuitable frost or corrosion pro- gauge and a digital pressure display (2). Using tection agents! the pressure gauge you can perform a quick Frost and corrosion protection agents may check whether the filling pressure is within the cause changes in the seals, noises during heat-... -
Page 24: First Flushing Of The System
Conversion from natural gas to liquid gas or the installation out of the heating system before the vice versa may only be undertaken by Vaillant boiler is started up. service personnel or a suitably qualified install- •... -
Page 25: Checking The Connection Pressure (Gas Inlet Working Pressure)
Start-up 6 20 mbar when the appliance is operating at the maxi- mum heat input. The inlet working pressure to the appli- ance is measured at the appliance multi-functional gas valve on the valves inlet pressure test point, see fig. 6.5. Due to internal appliance pressure losses the reading at the inlet of the appliance gas valve may be lower than the design pressure of 20 mbar. -
Page 26: Checking Co Content And Setting If Necessary (Setting The Air Figure)
• Check the function of the heating (see Chapter 6.3.1) and the hot water preparation (see Chapter 6.3.2) • Hand the unit over to the user. The Vaillant ecoTEC exclusive has status codes which indicate the operating condition of the appliance in the Fig. 6.6 Checking/adjusting the CO content display. -
Page 27: Heating
Start-up 6 Fig. 6.9 Display during hot water preparation 6.3.3 Subsequent flushing through of the heating system ("hot") • Allow the appliance to run until both the appliance Fig. 6.7 Function check and the heating system have reached their operating 6.3.1 Heating temperature. -
Page 28: Handing Over The Appliance To The Owner
It is strongly recommended that a maintenance contract be taken out to ensure regular maintenance. Further information can be obtained from Vaillant Service So- lutions (0870 6060 777). • Enter the operating pressure of the central heating... -
Page 29: Adapting The Appliance To The Heating System 7
Adapting the appliance to the heating system 7 Adapting the appliance to the heat- ing system The ecoTEC exclusive units are fitted with a digital in- formation and analysis system. Selection and setting the parameters In the diagnostic mode, you can change the various pa- rameters required to match the boiler to the heating system. -
Page 30: Overview Of The Settable Installation Parameters
Default Appliance-specific Display Meaning Adjustable parameters setting setting Heating partial load ecoTEC exclusive 832 27 kW 22 kW ecoTEC exclusive 838 30 kW 27 kW Pump overrun time for heating operation 2 - 60 min 5 min (starts after completion of heat demand) Max. -
Page 31: Setting The Burner Anti-Cycle Time
Adapting the appliance to the heating system 7 7.2.5 Setting the burner anti-cycle time Set maximum burner anti-cycle time [min] (target) Feed [°C] 10,0 15,0 20,0 25,0 30,0 35,0 40,0 45,0 50,0 55,0 60,0 14,0 18,5 23,0 27,5 32,0 36,5 41,0 45,0 50,0... -
Page 32: Setting The Pump Output
1200 1400 1600 1800 • Regulate the pressure using the setting screw (1). Volumeflow [l/h] Pres- Fig. 7.2 Characteristic pump line for ecoTEC exclusive 832 and 838 Position of the setting sure Notes/application screw (mbar) Key to Fig. 7.2 Right-hand stop... -
Page 33: Inspection And Maintenance 8
• Reapply the front cover to the device. • Check all the functions of the appliance. In order to ensure all the functions of the Vaillant appli- ance over a long period, only genuine Vaillant spare parts may be used when undertaking maintenance, serv- ice and repair work. - Page 34 8 Inspection and maintenance Column 1 Inspection Column 2 Activity must be Maintenance carried out once a year Check the air/gas flue system and ensure it is not blocked, damaged and is fitted correctly. Measure the gas rate during operation (see chapter ‚Start-up‘). If the gas rate is lower than the minimum gas rate follow the maintenance instructions (column 2).
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Page 35: Filling/Draining The Heating Installation
• Pull the two plugs of the ignition und grounding lines off the ignition electrode (4). Danger! • Only ecoTEC exclusive 832: Pull the cable plug off the There is danger of being burned or scalded at fan motor and the cable off the gas fitting. -
Page 36: Clean The Heat Exchanger
8 Inspection and maintenance 8.4.2 Clean the heat exchanger 8.4.4 Installing the burner assembly Caution! Protect the electronics box turned down against sprayed water. Fig. 8.4 Replacing silicone gaskets • Insert the new graphite seals (1) in the burner flange. Danger! The two seals (1 - fig. -
Page 37: Maintaining The Secondary Heat Exchanger
Inspection and maintenance 8 • Only ecoTEC exclusive 832: Insert the cables on the • Release the clamp (1) on the preference changeover fan motor and the cable on the gas fitting. valve. Only ecoTEC exclusive 838: Close the mains coupling •... -
Page 38: Checking The Expansion Vessel
8 Inspection and maintenance Checking the expansion vessel Checking the gas setting 8.8.1 Checking the connection pressure (gas inlet working pressure) To check the connection pressure proceed as described in Chapter 6.1.2. 8.8.2 Checking CO content and adjusting if necessary To check the air figure proceed as described in Chapter 6.2.2. -
Page 39: Troubleshooting 9
Troubleshooting Display Meaning Heating mode Note! No heat required If you wish to contact the Vaillant Service Team, Fan start please refer to the error code displayed (F.xx) Water pump flow and the appliance status (S.xx) if possible. Ignition Burner mode... -
Page 40: Diagnosis Codes
9 Troubleshooting 9.1.2 Diagnosis codes In the diagnosis mode, you can change certain para- meters or display more information. The diagnosis information is divided into two diagnosis levels. The 2nd diagnosis level can be reached only after entering a password. Caution! The access to the 2nd diagnosis level may only be used by a qualified heating engineer. - Page 41 Digitalised ionisation voltage Display range 0 to 102, >80 no flame, <40 good flame display External temperature (with weather-controlled d.47 actual value in °C Vaillant controller) d.67 Remaining burner locking time in minutes d.76 Appliance variant (device specific number) 00 to 99 d.90...
- Page 42 9 Troubleshooting Display Meaning Display value/adjustable value target value internal pump in % - possible settings: d.14 Pump speed target value 0=Auto, 1=53, 2=60, 3=70, 4=85, 5=100 % (Factory setting: Auto) d.17 Heating flow/return regulation changeover 0 = flow, 1 = return (factory setting: 0) d.18 Pump mode (return flow) 0 = overrun 1 = continuous, 2 = winter (Factory setting: 0)
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Page 43: Error Codes
Troubleshooting 9 9.1.3 Error codes You can exit the error memory display as follows: The error codes displace all other displays when errors • Press the "i" button or occur. • Do not press any button for about 4 minutes. If many errors occur simultaneously, the relevant error codes are displayed alternately for approx. -
Page 44: Test Programs
9 Troubleshooting Code Meaning Cause F.71 Constant value feed NTC Feed NTC faulty F.72 Flow and/or return sensor fault Flow and/or return sensor is faulty (tolerance too great) Signal water pressure sensor in the wrong range Line to water pressure sensor is interrupted or has F.73 (too low) a short-circuit to 0V or water pressure sensor faulty... -
Page 45: Replacing Components 10
Replacing components 10 10 Replacing components 10.2 Replacing burner The tasks listed below in this section may be carried out Danger! only by a heating engineer approved at the time by the Before replacing the component, comply with Health and Safety Executive. the safety instructions in Section 10.1. -
Page 46: Replacing Fan Or Gas Fittings
• Release the gas supply pipe (4) on the gas valve. • Pull out the plug from the gas valve. • Only ecoTEC exclusive 832: Pull out the plug from the fan printed circuit board. Only ecoTEC exclusive 838: Open the coupling of the mains input. -
Page 47: Replacing Electronics And Display
The Vaillant ecoTEC exclusive and all accessories and the previously set parameters from the components the packaging must not be disposed of in the household that are not replaced. -
Page 48: Technical Data
13 Technical data 13 Technical data ecoTEC exclusive Unit Nominal heat output range P at 40/30 °C 11,0 - 29,3 12,1 - 32,4 Nominal heat output range P at 50/30 °C 10,8 - 28,7 11,9 - 31,8 Nominal heat output range P at 60/40 °C 10,5 - 27,9 11,5 - 30,9 Nominal heat output range P at 80/60 °C... -
Page 49: Appendix
Appendix Appendix EC declaration of conformity ecoTEC exclusive installation and maintenance instructions / 0020017768_04... - Page 50 ecoTEC exclusive installation and maintenance instructions / 0020017768_04...
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Page 51: Benchmark Gas Boiler Commissioning Checklist
Installation, Installation, Commissioning and Commissioning and Service Record Service Record ecoTEC exclusive installation and maintenance instructions / 0020017768_04... - Page 52 Please affix the label from the rear cover of the control box over this area.
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Page 53: Service Interval Record
0020008345-06 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below . Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.