Vaillant ecoTEC plus 612 Instructions For Installation And Servicing
Wall hung room sealed fan assisted condensing boiler
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- Instructions for installation and servicing (184 pages) ,
- Installation and maintenance instructions manual (52 pages) ,
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Summary of Contents for Vaillant ecoTEC plus 612
- Page 1 For the installer Instructions for installation and servicing ecoTEC Wall hung room sealed fan assisted condensing boiler ecoTEC plus 612 ecoTEC plus 615 ecoTEC plus 618 ecoTEC plus 624 ecoTEC plus 630 ecoTEC plus 824 ecoTEC plus 831 ecoTEC pro 28...
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Page 2: Table Of Contents
Type plate ....... 4.14.6 Vaillant optional plug in timer accessories . . . - Page 3 Contents Inspection and maintenance ... . 38 Initial inspection......7.1.2 Safety instructions.
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Page 4: Introduction
1 Introduction Introduction ecoTEC 800 and pro range The ecoTEC 800 and pro range is a fully automatic, wall Notes on the documentation mounted, room sealed condensing (high efficiency) com- The following information is intended to help you bination boiler for central heating and domestic hot throughout the entire documentation. -
Page 5: Ce Marking
(92/42/EEC) as condensing appliance. - The Gas Applaince (Safety) Regulations 1992 - The boiler (Efficiency) Regulations 1993 Vaillant Ltd. supports the Benchmark initiative. In the information pack, you will find a Benchmark Logbook. It is very important that... -
Page 6: Boiler Specifications
2 Boiler specifications Boiler specifications Technical data ecoTEC plus ecoTEC pro Technical data Units CH heat output range 80 °C flow/60 °C return 6.0 – 18.0 8.7 – 24.0 8.7 – 24.0 60 °C flow/40 °C return 6.1 – 18.6 9.0 –... - Page 7 Boiler specifications 2 ecoTEC plus Technical data Units CH heat output range 80 °C flow/60 °C return 4.0 – 12.0 4.0 – 15.0 6.0 – 18.0 8.7 – 24.0 10.0 – 30.0 60 °C flow/40 °C return 4.1 – 12.3 4.1 –...
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Page 8: Dimensions
2 Boiler specifications Dimensions Fig. 2.1 Dimensions in mm Legend: Heating return pipe Ø 22 mm 2 Cold water connection Ø 15 mm (only 800 series) 3 Gas connection Ø 15 mm 4 Hot water connection Ø 15 mm (only 800 series) 5 Heating flow pipe Ø... -
Page 9: Installation
Boiler specifications 2 Installation Fig. 2.3 Function elements of 600 series Legend: Fig. 2.2 Function elements of 800 series Expansion vessel 2 Air intake pipe Legend: 3 Compact thermal module Expansion vessel 4 Ignition electrode 2 Air intake pipe 5 Fan 3 Compact thermal module 7 Pump 4 Ignition electrode... -
Page 10: Type Plate
(e.g. gas or water leak- This appliance shall only be installed in conjunction with age)! a Vaillant flue system. Install the flue system as detailed in the separate flue installation instructions supplied with this boiler. Scope of delivery and accessories... - Page 11 General requirements 3 Fig. 3.1 Scope of delivery for ecoTEC plus 600 series Fig. 3.2 Scope of delivery for ecoTEC plus 800 series 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 12: Installation Site
3 General requirements Installation site The location chosen for the boiler must permit the provi- sion of a satisfactory flue termination. The location must also provide adequate space for servicing and air circu- lation around the boiler. The boiler may be installed in any room, although particular attention is drawn to the requirements of BS7671 (IEE Regulations), the electrical provisions of the Building Standards (Scotland) -
Page 13: Gas Supply
Danger! Fig. 3.5 Art. No. 303 900 Vaillant appliances are certified only for use with genuine Vaillant flue pipes. Only use genu- ine Vaillant flue pipes. Malfunctions can occur if 3.6.2 Optional 125 mm flue system you use other accessories. These may result in A concentric flue system of 125 mm outside diameter is damage and injury. -
Page 14: Flue Termination
3 General requirements Flue termination Note The following details refer to both flue systems. In addition, the terminal should not be nearer a. The terminal must be located where the combustible than 150 mm to an opening in the building fab- substances can escape freely at all times. -
Page 15: Electrical Supply
General requirements 3 Electrical supply 3.10.3 Pressure relief valve A 230 V, ~ 50 Hz single phase electricity supply fused to A pressure relief valve is provided with the boiler. This 3 Amp. must be provided in accordance with the latest safety device is required on all sealed C.H. -
Page 16: Pump Specifications
3 General requirements 4 Boiler installation sequence Boiler installation sequence 3.11 Pump specifications 3.11.1 Circulating pump Required minimum distances/assembly clear- only ecoTEC plus: ances The circulating pump is included in the boiler. The resid- ual pump discharge height depending on the by-pass valve is shown in Fig. -
Page 17: Select Position For Boiler
Boiler installation sequence 4 4.1.1 Select position for boiler Refer to section ‘Boiler location’ for information regard- ing the appliance location. In general the boiler must be positioned such that: • There is adequate space around the boiler for service and maintenance •... -
Page 18: Flue Exit
4 Boiler installation sequence Flue exit Note • If using rear flue mark the position of the air/flue duct Lift the boiler from either side at the bottom and its circumference. edge Other flue options • Lower the boiler slowly onto the hanging bracket so Flue instructions for other flue systems such as vertical that the cross member at the rear of the boiler fully RSF flues, flues run to the side of the boiler and the use... -
Page 19: Gas Connection
Boiler installation sequence 4 Gas connection • Insert the union nut (6) and the pinching ring (5) on the conduit arc provided with ecoTEC plus appliances Note (7). With the spacer frame (Art. No 308 650), the • Insert the maintenance tap (4) until the stopper on pipes can be laid in front of the wall upwards the gas connection pipe and the conduit arc until the behind the appliance. -
Page 20: Heating Connection
4 Boiler installation sequence ecoTEC plus, 800 series Fig. 4.8 Installing the heating flow and return connection for ecoTEC plus, 800 series Fig. 4.7 Installing the hot and cold water connection (ecoTEC • Insert the seal (1) and screw in the maintenance tap pro) (2) at the return connection of the appliance. -
Page 21: Pressure Relief Valve
Boiler installation sequence 4 ecoTEC pro • Insert the conduit elbows until the stopper in the maintenance taps. Tighten the union nuts in this posi- tion. 4.10.2 Pressure Relief Valve Fig. 4.9 Heating flow and return connection for ecoTEC pro •... -
Page 22: Condensate Drain Pipe
4 Boiler installation sequence 4.11 Condensate drain pipe b) connecting into the internal discharge branch (e.g. sink waste or washing machine) with an external termina- tion, the condensate discharge pipe should have a minimum diameter of 22 mm with no length restriction and should incorporate a trap with a 75 mm (3) seal. -
Page 23: Connection To The Main Supply
Boiler installation sequence 4 Danger! Mains connection terminals L and N remain live even when the boiler on/off control is switched off. - + 7 8 9 3 4 5 Note Do not connect any power voltage to the con- nections 7-8-9. -
Page 24: Electric Board Layout
4 Boiler installation sequence 4.13.3 Electric board layout Fig. 4.15 Connection wiring ecoTEC Instructions for installation and servicing ecoTEC... - Page 25 Boiler installation sequence 4 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 Gas valve assembly Fan unit 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)
- Page 26 4 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 27: Connection Of Programmable Thermostats
Smiths Timeguard ProgramaSTAT PRT11, PRT17 Sunvic TLX 6501 Sunvic TLX RFP, TLX RFD Vaillant VRT 230, 220 Fig. 4.18 Connection details for programmable thermostats 4.14 Controls (ecoTEC plus 800 and pro only) 4.14.1 External electrical controls 4.14.2 Connection of external controls... -
Page 28: Connection Of Time Switches
4 Boiler installation sequence 4.14.4 Connection of time switches ACL Drayton Tempus 1, Tempus 2 Lyfestyle LP111, LP711 ACL Drayton Switchmaster SM300 ACL Drayton Switchmaster 980 Danfoss Randall 103 Series Danfoss Randall Set 1E, TS975 Danfoss Randall TS715 Grässlin Towerchron QE1, QM1 Honeywell ST610A, ST6100C... -
Page 29: Connection Details For External Time Switches
4.20). 4.18 Circulating pump The boiler incorporates a built in circulating pump that is 4.14.6 Vaillant optional plug in timer accessories fully prewired (no additional wiring is necessary). The Refer to the instructions supplied with the optional pump incorporates an automatic overrun period after accessories for connection details. - Page 30 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Cylinder thermostat Room thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC ACL Drayton Digistat 2, 3, 4 Tower CS1 ACL Drayton RTS 1, 2 Honeywell L641...
- Page 31 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Cylinder thermostat Room thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC ACL Drayton Digistat 2, 3, 4 Tower CS1 ACL Drayton RTS 1, 2 Honeywell L641...
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Page 32: Commissioning Part I
5 Commissioning Part I Commissioning Part I Note The ecoTEC appliances come with a manometer and a digital pressure indicator. Preliminary electrical checks The manometer allows you to quickly check Check the electrical installation by carrying out short whether the filling pressure is in target range or circuit, earth continuity and resistance to earth tests and not even when the appliance is turned off. -
Page 33: Filling The Heating System In Ecotec Pro And Ecotec Plus (600 Series)
Commissioning Part I 5 Note • Slowly open the filling valve and let the water flow into Both stop valves must be closed while operat- the heating system. Ventilate the lowest heating ele- ing the heating system and the filling pipe must ment until the water flows out at the vent valve with- be again detached at the double check valve. -
Page 34: Filling The Condensation Water Siphon
5 Commissioning Part I Filling the condensation water siphon 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 setting of the operating mode dependent pump speed under the diagnosis point “d.19”... -
Page 35: Checking The Gas Supply
• Loosen the sealing screw marked “in” (1) on the gas the tolerance limits specified in Table 5.1, do not valve assembly. operate the appliance and inform the Vaillant • Connect a digital or a U gauge (2). Customer Service. -
Page 36: Refitting The Case
5.12 Gas changeover Note To reset the appliance from natural gas to LPG mode, you need the Vaillant conversion kit Art. No. 308 681. To reset the appliance from LPG to natural gas mode, you need the Vaillant conversion kit Art. -
Page 37: Heating
Commissioning Part I 5 Commissioning Part II 6 plus Fig. 6.3 Display indicator during water heating 6.1.4 Final flush of the heating system (“hot”) • Operate the appliance until the appliance and the Fig. 6.1 Function check heating system are up to temperature. •... -
Page 38: Handing Over To The User
Only genuine Vaillant spare parts may be used for Note inspections, maintenance and repair work to ensure the The boiler is fitted with a combustion analysis long-term working order of all functions of your Vaillant test point. -
Page 39: Maintenance
Inspection and maintenance 7 7.1.3 Maintenance Before commencing any servicing or maintenance work, carry out an initial inspection of the system as follows: • Inspect the flue, pipework and electrical connections for indications of damage or deterioration. • Inspect the air supply and ventilation arrangements of the installation. -
Page 40: Servicing The Compact Thermal Module
7 Inspection and maintenance Servicing the compact thermal module • Remove screw (1) and remove the air intake pipe (2). 7.2.1 Removing the compact thermal module The compact thermal module consists of the burner, fan, gas valve und the gas supply (mixer tube). These four components make up the complete assembly, the com- pact thermal module. -
Page 41: Cleaning The Integral Condensation Heat Exchanger
Inspection and maintenance 7 Note 7.2.3 Checking the burner You can suspend the compact thermo module on the hook (11) while carrying out maintenance tasks. • After removing the thermal compact module, clean the components as described below. 7.2.2 Cleaning the integral condensation heat exchanger Caution! Protect the electronics box against sprayed... -
Page 42: Cleaning The Condensation Water Siphon
7 Inspection and maintenance Cleaning the condensation water siphon Fig. 7.7 Refitting the compact thermal module • Insert the compact thermo module (9) in the integral Fig. 7.9 Cleaning the condensation water siphon condensation heat exchanger (10). • Tighten the four nuts (4) on the left/right sides until Danger! the burner door fits closely and uniformly to the stop Note that if the boiler is run with an empty... -
Page 43: Checking The Expansion Vessel
Inspection and maintenance 7 Checking the expansion vessel 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- ously detailed. -
Page 44: Troubleshooting
8 Troubleshooting Troubleshooting • Press the “i” key 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 use the fault finding guide. display again. -
Page 45: Diagnosis Codes
Troubleshooting 8 8.1.2 Diagnosis codes In the diagnosis mode, you can change certain parame- ters or display more information. The diagnosis information is divided into two diagnosis levels. The second diagnosis level can be reached only after entering a password. Caution! Access to the second diagnosis level must be used exclusively by a qualified technician. - Page 46 8 Troubleshooting Display Meaning Display value/adjustable value d.00 Heating part load Adjustable heating part load in kW (factory setting: max. output) d.01 Water pump over run time for heating mode 1 - 60 min (factory setting: 5 min) d.02 Max. burner anti cycling period at 20 °C Flow tempera- 2 - 60 min (factory setting: 20 min) ture d.03...
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Page 47: Fault Codes
Troubleshooting 8 Display Meaning Display value/adjustable value d.61 Number of lock outs Number of unsuccessful ignitions in the last attempt d.64 Average ignition time in seconds d.65 Maximum ignition time in seconds d.68 Successful ignitions in the first attempt Quantity d.69 Successful ignitions in the second attempt Quantity... - Page 48 8 Troubleshooting Code Meaning Cause F.00 Flow–NTC: Flow–NTC cable defective/broken, NTC faulty NTC broken, NTC cable broken, Defective connection at NTC, Defective connection at electronics F.01 Return–NTC: Return–NTC cable defective/broken, NTC faulty NTC broken, NTC cable broken, Defective connection at NTC, Defective connection at electronics F.02 Drinking water outlet probe stopped (<-10 °C)
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Page 49: Test Programs
Troubleshooting 8 Parts replacement 9 Test programs Important: Special functions can be triggered on the appliances by Before starting any maintenance work: activating various test programs. Isolate the mains electricity supply by discon- These programs are given in detail in the necting the plug at the socket outlet (if there is Table 8.4. -
Page 50: Replacing Fan Or Gas Valve
9 Parts replacement • Mount the new burner with a new seal. Ensuring that the notch in the burner aligns with the burner viewing window. • Install the compact thermo module as described in Section 7.2.4. • After completing the work, check for gas leaks and perform a function check (see Section 7.6)! Replacing fan or gas valve Danger! -
Page 51: Replacing Primary Heat Exchanger
Parts replacement 9 Replacing primary heat exchanger Danger! Before replacing the component, comply with the safety instructions in Section 9.1. • Disconnect the appliance from the mains as described in Section 9.1, and close the service cock in the gas supply pipe. -
Page 52: Replacing Electronics And Display
• Turn the holder to the side around the rivet (1), pull Appliance Device specific number the primary heat exchanger downwards to the right ecoTEC plus 612 and remove it from the appliance. ecoTEC plus 615 • Mount the new primary heat exchanger in reverse ecoTEC plus 618 order and replace the seals. -
Page 53: Check Co 2 Content And If Necessary Set (Air-Ratio Adjustment)
Parts replacement 9 Check CO content and if necessary set (air- Note ratio adjustment) Only for natural gas: Adjust only in increments of 1/8 turn and wait approx. 1 minute after each adjustment until the value stabilises. Only for liquid gas: Adjust only in very small increments (approx. -
Page 54: Recycling And Disposal
10 Recycling and disposal 10 Recycling and disposal The design of all Vaillant products takes into account the subsequent recycling and/or eventual safe scrapping of each component used. Vaillant’s in–house rules set strict standards in this respect. The selection process used for...