Vaillant ecoTEC plus 806 VU GB 806/5-5 Installation And Maintenance Instructions Manual
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Summary of Contents for Vaillant ecoTEC plus 806 VU GB 806/5-5
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Page 1: Ecotec Plus
Installation and maintenance instructions For the competent person Installation and maintenance instructions ecoTEC plus VU GB .../5‑5 GB, IE Publisher/manufacturer Vaillant GmbH Berghauser Str. 40 D-42859 Remscheid Tel. +49 21 91 18‑0 Fax +49 21 91 18‑2810 info@vaillant.de www.vaillant.de... - Page 2 Contents Contents 7.12 Flushing the heating installation for the first time ("cold") ............21 7.13 Filling the condensate trap ........21 Safety ..............4 7.14 Checking and adjusting the gas ratio setting..21 Action-related warnings ......... 4 7.15 Checking leak-tightness ........24 Intended use ............
- Page 3 Contents Status codes – Overview ........41 Overview of fault codes ........42 Connection diagram .......... 44 Initial start-up checklist........45 Initial start-up checklist ........45 Commissioning Checklist......... 48 Opening of the flue pipe........51 Positioning of the opening of a fan-supported flue gas guiding............
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Page 4: Installation And Maintenance Instructions Ecotec Plus 0020134823
1 Safety Safety this document shall be considered improper use. Any direct commercial or industrial use Action-related warnings is also deemed to be improper. Classification of action-related warnings Caution. The action-related warnings are classified in Improper use of any kind is prohibited. accordance with the severity of the possible danger using the following warning signs and General safety information... - Page 5 Safety 1 1.3.5 Danger caused by improper 1.3.8 Risk of injury during transport due operation to a high product weight. ▶ Make sure that the product is transported Improper operation may present a danger to you and others, and cause material damage. by at least two people.
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Page 6: Regulations (Directives, Laws, Standards) 6
1 Safety 1.3.14 Risk of material damage caused by frost ▶ Do not install the product in rooms prone to frost. 1.3.15 Risk of corrosion damage due to unsuitable combustion and room Sprays, solvents, chlorinated cleaning agents, paint, adhesives, ammonia com- pounds, dust or similar substances may lead to corrosion on the product and in the air/flue pipe. -
Page 7: Notes On The Documentation
1206 (VU GB 1206/5‑5) 0010010791 41-044-70 Benchmark Vaillant is a licensed member of the Benchmark Scheme. Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved... - Page 8 Serial number for identification; 7th to 16th digits = Enclosed unit fastening product article number Bag with small parts VU… Vaillant gas-fired wall-hung boiler for Gas connection piece heating Service valve (1 1/2 inches), red handle ecoTEC plus Product description Service valve (1 1/2 inches), blue handle H, G20 –...
- Page 9 Installation 4 Product dimensions and connection Minimum clearances and installation dimensions clearances 350 mm (110/160 mm Optional approx. 200 diameter flue pipe) Clearance of 600 mm At least 450 mm for in front of the product cascade design for easy access during 400 mm maintenance work ▶...
- Page 10 4 Installation Wall-mounting the product Pull the front casing forwards at the bottom edge. Lift the front casing upwards from the bracket. Conditions: The load-bearing capacity of the wall is sufficient, The fixing material may be used for the wall 4.8.2 Installing the front casing ▶...
- Page 11 Installation 5 Installation 4.10 Removing/installing the side section (as required) Danger! 4.10.1 Removing the side section Risk of explosion or scalding caused by incorrect installation. Stresses in the supply line can cause leaks. ▶ Make sure there is no voltage in the sup- ply lines when they are installed.
- Page 12 This pump group has a connection option for an expansion vessel (right-hand connection) and an expansion relief valve (left-hand connection). You can find information about avail- able accessories from the Vaillant price list or from the con- tact address provided on the reverse of this document. ▶...
- Page 13 Installation 5 5.2.2 Installing an expansion vessel Depending on your choice of pump group, the following re- maining feed heads are available in the unit supply: Power Description Remaining feed head 80 kW Modulating pump 0.042 MPa (0.420 bar) 100 kW Modulating pump 0.026 MPa (0.260 bar)
- Page 14 5 Installation 5.2.5 Connecting the condensate drain pipework Ensure that all components that are installed in the heating installation are suitable for a max. operating pressure of 6 bar. min. Danger! ▶ Risk of scalding! When making the condensate pipe connections ensure that there is adequate branch ventilation and that there Heating water that leaks from the exit point of can be no backflow of water into the boiler via the con-...
- Page 15 Opening/closing the electronics box age due to unapproved air/flue pipes. 5.4.1.1 Opening the electronics box Vaillant boilers are certified only with Vaillant original air/flue pipes. The use of other ac- cessories may cause personal injury and ma- terial damage, as well as operating faults. For...
- Page 16 5 Installation 5.4.3 Carrying out the wiring 5.4.4 Connecting the pump group Caution. Risk of material damage caused by incor- rect installation. Mains voltage at the incorrect plug terminals on the ProE system may destroy the elec- tronics. ▶ Do not connect any mains voltage to the eBUS terminals (+/-).
- Page 17 Operation 6 Operation 5.4.7 Connecting additional components You can use the multi-functional module to actuate two addi- Operating concept of the product tional components. The operating concept and the read-off and setting facilities The following components can be actuated: of the operator level are described in the operating instruc- –...
- Page 18 7 Start-up Start-up You must treat the heating water in the following cases: – If the entire filling and supplementary water quantity dur- Auxiliary service equipment: ing the operating life of the system exceeds three times the nominal volume of the heating installation, or The following test and measuring equipment is required for –...
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Page 19: Calling Up Appliance Config. And Diagnostics
Start-up 7 ▶ Inform the operator about the measures required for frost current heat demand of the system. The setting can also be protection. changed at a later point using D.000. Switching on the product 7.5.6 Auxiliary relay and multi-functional module ▶... -
Page 20: Heating Circuit
7 Start-up 7.11 Filling and purging the heating installation Display Meaning Flush the heating installation thoroughly before filling it. P.02 Minimum load check programme: After successful ignition, the product is operated at Select the check programme P.06. minimum heat input. ◁... -
Page 21: Time ("Cold")
If you want to operate the product with liquid gas, do not start up the product. A gas conversion must only be carried out by Vaillant Cus- tomer Service or the manufacturer of the product. ▶ Notify Vaillant Customer Service or the manufacturer of the product that you want a gas conversion carried out. - Page 22 7 Start-up Conditions: The product design is compatible with the local gas group Conditions: Gas flow rate not in the permissible range ▶ ▶ Proceed as described below. Check all of the piping and ensure that the gas flow rates are correct.
- Page 23 Start-up 7 – Permissible gas flow pressure for operation with G20 natural gas: 1.6 … 2.3 kPa (16.0 … 23.0 mbar) Should the pressure recorded at the reference test point in the boiler be lower than indicated check if there is any blockage in the pipework or if the pipework is un- dersized.
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Page 24: Checking Leak-Tightness
▶ If an adjustment is not possible in the specified adjust- ment range, you must not start up the product. ▶ If this is the case, inform Vaillant Customer Service. ▶ Install the front casing. (→ Page 10) 7.15 Checking leak-tightness ▶... -
Page 25: Adapting The Unit To The Heating Installation
25 minutes for 5 minutes once the overrun time has elapsed. When operating in cascade with a low loss Menu → Installer level Appliance config. header or system separation, Vaillant recommends the Eco Or manually relaunch the installation assistant. operating mode. -
Page 26: Burner Anti-Cycling Time
9 Inspection and maintenance Burner anti-cycling time Setting the maintenance interval 8.6.1 Setting the burner anti-cycling time If you set the maintenance interval, the message that the product must be serviced appears in the display, together To prevent frequent switching on and off of the burner and with the maintenance symbol , after a configurable number thus prevent energy losses, an electronic restart lockout... -
Page 27: Observing Inspection And Maintenance Intervals
Inspection and maintenance 9 Observing inspection and maintenance mally done by cleaning, setting and, if necessary, replacing individual components that are subject to wear. intervals As the competent person, you determine the maintenance Warning. intervals (at least once every two years) and their scope Risk of injury and a risk of material dam- based on the how you define the condition of the product age caused by negligent inspection and... -
Page 28: Carrying Out Electronics Self-Tests
9 Inspection and maintenance Carrying out electronics self-tests Conditions: Applies for 100 kW and 120 kW Menu → Installer level → Test programs → Electronics self-test You can use the electronics self-test to check the PCB in advance. Removing the gas-air mixture unit Note The gas-air mixture unit consists of four main components:... -
Page 29: Cleaning The Heat Exchanger
Inspection and maintenance 9 Remove the plugs (12) and (13) from the fan motor by pushing in the latching lug. 10. Remove the plug from the gas valve (10). 11. Remove the plug from the upper safety cut-out (8). 12. Undo the screws (6) on the burner door. 13. -
Page 30: Checking The Burner
9 Inspection and maintenance Checking the burner Remove the electrodes (1) from the burner door from above. Insert the new electrodes with new seals. – Torque: 2.8 Nm Cleaning the condensate trap Check the surface of the burner for damage. If you no- tice any damage, replace the burner and seal, see "Re- placing the burner (→... -
Page 31: Draining The Product
Troubleshooting 10 Conditions: Applies for 80 kW – Torque: 2 Nm Conditions: Applies for 100 kW and 120 kW – Torque: 2.8 Nm Warning. Risk of poisoning and fire caused by es- caping gas! Gas can escape through leaks. ▶ Check the gas tightness at the gas con- nection using leak detection spray. -
Page 32: Contacting Your Service Partner
10 Troubleshooting 10.1 Contacting your service partner Overview of fault codes (→ Page 42) If you contact your Vaillant service partner, if possible, 10.5 Resetting the fault memory please mention ▶ To delete the entire fault list, press (Delete, OK) –... -
Page 33: Replacing Defective Components
Troubleshooting 10 10.10 Replacing defective components After installing the new gas valve, carry out a leak- tightness test (→ Page 24), and set the gas ratio 10.10.1 Replacing the gas valve (→ Page 21). 10.10.2 Replacing the burner 806/5-5 Remove the gas-air mixture unit. (→ Page 28) Remove the ignition and monitoring electrode. -
Page 34: Troubleshooting
10 Troubleshooting 16. Install the ignition and monitoring electrodes. Use new seals for this. – Torque: 2.8 Nm 17. Install the gas-air mixture unit. (→ Page 30) 18. Check that the product functions correctly and check the leak-tightness (→ Page 24). 10.10.3 Replacing the insulating mat If the safety cut-out on the burner door has been triggered, the insulating mat between the burner door and burner room... -
Page 35: Completing Repair Work
Decommissioning 11 13 Customer service Disconnect the unit from the power mains and secure it against being switched back on again. To ensure efficient and reliable operation of your boiler it is Conditions: Replacing the display or PCB recommended that regular servicing is carried out by your ▶... -
Page 36: Installer Level Menu Structure – Overview
Appendix Appendix Installer level menu structure – Overview Menu Information Reset burner off time Installer level Back Select Enter code Installer level F.00 Fault list F.75 Interruption Test programs Fault Appliance config. Flow sensor Pump water shortage Back Back Select Installer level Test programs Gas type check... - Page 37 Appendix Appliance config. Comfort mode Target flow temp. Comfort on DHW temperature Comfort mode Cancel Back Select Appliance config. D.026 D.026 DHW temperature Auxiliary relay Auxiliary relay Comfort mode Auxiliary relay Circulation pump External pump Back Select Back Cancel Appliance config. D.027 D.027 Comfort mode...
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Page 38: Overview Of Diagnostics Codes
Appendix Overview of diagnostics codes Default Own setting Code Parameter Values or explanations setting D.000 Heating partial load Adjustable heating partial load in kW Auto Auto: Product automatically adjusts max. partial load to current system demand D.001 Overrun time of internal heating 2 …... - Page 39 D.046 Pump type 0 = Relay with disable facility 0 = Relay with disable 1 = PWM with disable facility facility D.047 Outside temperature (with Vaillant Actual value in °C Not ad- weather compensator) justable D.050 Offset for minimum speed...
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Page 40: Inspection And Maintenance Work Overview
Appendix Default Own setting Code Parameter Values or explanations setting D.072 Internal pump overrun after cylinder Adjustable from 0 to 10 mins 2 min charging D.076 Device specific number 82 = VU 806 Not ad- justable 81 = VU 1006 80 = VU 1206 D.077 Limit on cylinder charging output in Adjustable cylinder charging output in kW... - Page 41 Appendix Mainten- ance Inspection Work (at least (annual) every 2 years) Check, and if necessary correct, the charge pressure of the expansion vessel. Remove the gas-air mixture unit (burner door with fan and gas valve). Check all seals and the insulating mat in the combustion area. If you notice any damage, replace the seals or insulating mat.
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Page 42: E Overview Of Fault Codes
Appendix Status code Meaning S.32 Waiting period because of fan speed deviation S.34 Frost protection mode active S.36 Target value of the eBUS controller is < 20 °C and is blocking heating mode S.37 Fan waiting period: Fan failure in operation S.39 "Burner off contact"... - Page 43 Appendix Code Meaning Cause F.34 Safety switch-off: Pressure monitoring Exhaust gas pressure switch: Cable break, blocked flue gas route Water pressure switch: Hydraulic leakage, air in the heating circuit F.35 Fault: Air/flue pipe Air/flue pipe blocked F.49 Fault: eBUS Short circuit on eBUS, eBUS overload or two power supplies with differ- ent polarities on the eBUS –...
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Page 44: F Connection Diagram
Appendix Connection diagram Display Pump PWM signal connection Water pressure sensor Cylinder sensor (optional) white Cylinder contact white “C1-C2“ white Coding resistor (optional) Gas valve Flow sensor blue Flow sensor Flue gas Safety Safety cut-out cut-out Remote control circulation pump External sensor Flow sensor (optional) DCF connection... -
Page 45: G Initial Start-Up Checklist
Appendix Initial start-up checklist Location Competent person Customer Service tech- nician Name Street/house number Postcode Town/city Telephone Start-up date Serial number Hydraulic scheme Initial start-up checklist Values Unit System, general Building type (single/multiple-occupancy house, special building) Used for commercial purposes? Year of manufacture Insulation status/renovation System output... - Page 46 Appendix Values Unit Low loss header If yes, which type? Number of mixers Cylinder – Buffer cylinder (if yes, which type?) – Domestic hot water cylinder (if yes, which type?) Pumps – Secondary circuit (if yes, which type?) – Heating circuits (if yes, which type?) Number of diaphragm expansion tanks –...
- Page 47 Values Unit Other heat generators Solar system, heat pump, solid fuel boiler? If yes, which type? Control system Vaillant controller If yes, which type? Third-party controller If yes, which type? Room thermostat, outside thermostat If yes, which type? Heating demand from which controller?
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Page 48: H Commissioning Checklist
Appendix Commissioning Checklist Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the completed in full. www.centralheating.co.uk © Heating and Hotwater Industry Council (HHIC) Installation and maintenance instructions ecoTEC plus 0020134823_04... - Page 49 Appendix GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
- Page 50 Appendix SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ²...
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Page 51: I Opening Of The Flue Pipe
Appendix Opening of the flue pipe D, E Positioning of the opening of a fan-supported flue gas guiding Minimum dimen- Installation site sions Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm Horizontally to an opening, air bricks, opening windows, etc., that can be opened. -
Page 52: I.2 Text From Bs 5440-1 On Fan-Supported Flue Gas Guiding
Appendix Text from BS 5440-1 on fan-supported flue gas guiding BS 5440–1: It is recommended that the fanned flue gas system terminal is positioned as follows: – At least 2 m from an opening in the building directly opposite, and –... -
Page 53: K Technical Data
Appendix Technical data Technical data – Output 806 (VU GB 806/5‑5) 1006 (VU GB 1006/5‑5) 1206 (VU GB 1206/5‑5) Nominal heat output range at 50/30 °C 16.5 … 82.3 kW 20.74 … 102.8 kW 24.7 … 123.4 kW Nominal heat output range at 60/40 °C 16.0 …... - Page 54 Appendix 806 (VU GB 806/5‑5) 1006 (VU GB 1006/5‑5) 1206 (VU GB 1206/5‑5) Permitted pressure difference in the flue pipe 50 Pa 50 Pa 50 Pa for installation type B23p as cascade opera- (0.00050 bar) (0.00050 bar) (0.00050 bar) tion max. Air/flue gas connection 110/160 mm 110/160 mm...
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Page 55: Index
Index Index Gas ratio setting ..............21 Gas valve ................33 Gas-air mixture unit ............28, 30 Air index setting..............23 Heat exchanger ............. 29, 34 Air/flue pipe ................. 14 Air/flue pipe, installed ............4 Heating flow................. 12 Heating installation .............. 20 Appliance config. - Page 56 Index Self-test ................27 Service message..............32 Service partner ..............32 Setting the pump output ............26 Side section................. 11 Spare parts................27 Status codes..............17, 41 Switching on ................ 19 Target feed temperature............19 Test programmes ..............17 Tool ..................5 Transport ................
- Page 60 0020134823_04 18.02.2016 Vaillant Ltd. Nottingham Road Belper Derbyshire DE56 1JT Telephone 0330 100 3461 info@vaillant.co.uk www.vaillant.co.uk © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent. We reserve the right to make technical changes.