Vaillant ecoTEC plus VU 446/5-5 (H-GB) Installation And Maintenance Instructions Manual
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- Page 1 Installation and maintenance instructions ecoTEC plus VU 446/5-5 (H-GB) VU 606/5-5 (H-GB) GB, IE, NZ Publisher/manufacturer Vaillant GmbH Berghauser Str. 40 D-42859 Remscheid Tel. +492191 18 0 Fax +492191 18 2810 info@vaillant.de www.vaillant.de...
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Page 2: Table Of Contents
Contents Contents Running the installation assistants ...... 24 Preventing low water pressure ......25 Safety ..............3 Flushing the heating installation for the first time ("cold") ............25 Action-related warnings ......... 3 Using check programmes ........25 Intended use ............3 7.10 Check and gas setting ......... -
Page 3: Safety
Safety 1 – compliance with all inspection and main- Safety tenance conditions listed in the instruc- Action-related warnings tions. Classification of action-related warnings Intended use also covers installation in ac- The action-related warnings are classified in cordance with the IP code. accordance with the severity of the possible Any other use that is not specified in these danger using the following warning signs and... - Page 4 1 Safety ▶ Warn other occupants in the building by 1.3.5 Risk of death due to blocked or leaking flue gas routes yelling or banging on doors or walls. ▶ Leave the building immediately and ensure Installation errors, damage, tampering, imper- that others do not enter the building.
- Page 5 Safety 1 1.3.9 Risk of death from escaping flue gas when the front casing is installed and closed. Applicability: Not for Great Britain 1.3.14 Risk of being burned or scalded by If you operate the product with an empty con- hot components densate siphon, flue gas may escape into the ▶...
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Page 6: Regulations (Directives, Laws, Standards)
1 Safety 1.3.19 Risk of material damage caused by leak detection sprays and fluids Leak detection sprays and fluids block the filter for the mass flow sensor on the Venturi, thereby destroying the mass flow sensor. ▶ During repair work, do not apply any leak detection sprays or fluids to the covering cap on the filter for the Venturi. -
Page 7: Notes On The Documentation 2
41-694-29 Benchmark Applicability: Great Britain 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
4 Set-up CE marking Information on the Meaning data plate Serial number For quality control purposes; 3rd and 4th digits = year of production For quality control purposes; 5th and 6th digits = week of production The CE marking shows that the products comply with the For identification purposes;... -
Page 9: Transporting The Product
Set-up 4 Transporting the product Dimensions Applicability: Great Britain OR Ireland Important: With regard to the regulations of 1992 concern- ing the manual handling of loads, the product exceeds the weight that can be lifted by a single person. 4.3.1 General Applicability: Great Britain OR Ireland... -
Page 10: Minimum Clearances
4 Set-up Wall-mounting the product Gas pressure connec- Stopcock in the heating tion flow Gas stopcock Connection for the air/flue pipe Stopcock in the heating Drain for the dynamic return air separation system Dimension A VU 446/5-5 (H-GB) 405 mm VU 606/5-5 (H-GB) 473 mm Minimum clearances... -
Page 11: Removing/Installing The Side Section
Set-up 4 4.10 Removing/installing the side section Pull the front casing forwards at the bottom edge (C). Lift the front casing upwards from the bracket (D). 4.10.1 Removing the side section 4.9.2 Installing the front casing Caution. Risk of material damage caused by mech- anical deformation. -
Page 12: Installation
5 Installation Installation Number for Control Number Carrying out the the basic system of cir- wiring diagram cuits Sample system installations 0020253233 Basic control See appendix or ▶ Use the basic installation diagrams as examples. contact customer ▶ Select the basic installation diagram based upon which service for special you want to configure your installation. - Page 13 Installation 5 5.1.3 Basic system diagram type 3: Decoupled The product can control a decoupled heating circuit and a directly connected domestic hot water cylinder. heating circuit plus one decoupled domestic hot water cylinder Number for Control Number Carrying out the the basic system of cir-...
- Page 14 5 Installation ▶ ▶ Connect the external pump for the decoupled heating In order to control the cylinder's post-heating, connect circuit to the plug X16 for the main PCB. a VR 10 temperature sensor or a thermostat to the plug ▶...
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Page 15: Selecting The Domestic Hot Water Cylinder
Installation 5 ▶ Requirements In order to control the cylinder's post-heating, connect a VR 10 temperature sensor or a thermostat to the plug ▶ Make sure that the existing gas meter is capable of that is connected to the main PCB. passing the rate of gas supply required. -
Page 16: Connecting Gas And Water
5 Installation Connecting gas and water product before you carry out the gas leak- tightness test. Danger! ▶ If, during gas leak-tightness tests, you Risk of explosion or scalding caused by have closed the gas stopcock that is in- incorrect installation. stalled upstream of the product, relieve the gas line pressure before you open this Mechanical stresses in the connection pipes... - Page 17 Installation 5 Note In order to keep heat losses to a minimum, we recommend that you provide heat insulation for the water pipe spigots on the product's outlet and on the installation. ▶ If you are using plastic pipes in the heating installation, install a safety cut-out in the heating flow.
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Page 18: Installing And Connecting The Air Pipe And Flue Pipe
IGEM / UP / 10 for the conditions regarding aerating and installing the attachment for the air/flue pipe. – https://www.vaillant.co.uk Condition: Installation in damp rooms ▶ Connect the product to a room-sealed air/flue system. -
Page 19: Electrical Installation
Installation 5 5.6.2 B23 installation 5.7.1.2 Closing the electronics box Close the cover by pushing it downwards onto the elec- Applicability: Except Great Britain, Except Ireland tronics box. Ensure that all of the clips audibly click into the retain- A flue system for permitted unit type B23 (atmospheric gas- ers. - Page 20 5 Installation Alternatives 2 ‒ Connecting a 24 V extra low 5.7.3 Establishing the power supply voltage room temperature control: Provide one common power supply for the boiler and ▶ Instead of the bridge, connect the control to the 24 V for the corresponding control: plug.
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Page 21: Operation
Operation 6 5.7.6.2 Using the VR 40 (2 in 7 multi-functional Calling up appliance config. and diagnostics module) menu Install the components in accordance with the respect- To recheck and reset the most important system parameters, ive instructions. call up the Appliance config. menu item. Select D.027 to actuate relay 1 on the multi-functional Menu →... - Page 22 7 Start-up ▶ Check the pH value of the removed water at 25 °C. Applicability: Great Britain ▶ If the value is below 8.2 or above 10.0, clean the installa- OR Ireland tion and treat the heating water. OR New Zealand ▶...
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Page 23: Filling The Condensate Siphon
Start-up 7 Filling the condensate siphon Unclip the lower section of the siphon (1) from the up- per section of the siphon (2) without removing the pro- duct's front casing. Remove the float (3). Open the plugs (2) and then connect the filling/draining Fill the lower section of the siphon with water up to 10 cock connection to a heating water supply in accord- mm below the upper edge of the condensate discharge... -
Page 24: Starting Up The Product
7 Start-up Starting up the product Note ▶ Check programme P.00 runs for approx. Press the product's on/off button. ◁ 6.5 minutes for each circuit. The basic display appears on the display. At the end of the filling procedure, the filling pressure of the heating installation must be at Running the installation assistants least 0.02 MPa (0.2 bar) above the counter-... -
Page 25: Preventing Low Water Pressure
Start-up 7 Preventing low water pressure Display Meaning To prevent damage to the heating installation that is caused P.00 Purging check programme: by low filling pressure, the product is fitted with a water The internal pump is cyclically actuated. pressure sensor. If the filling pressure falls below 0.1 MPa The heating circuit and the domestic hot water circuit (1.0 bar), the product indicates low pressure by displaying a are purged via the air separation system. - Page 26 7 Start-up Condition: The product design is not compatible with the local gas type Applicability: VU 606/5-5 (H-GB) ▶ Qnw from Do not start up the product. H gas in m³/h P gas in m³/h ▶ the data Carry out a gas conversion in accordance with your in- −10% −10% Nom.
- Page 27 Start-up 7 ▶ ▶ Connect a digital manometer or U-tube manometer If you cannot correct the failure, notify the gas supply (B). company and proceed as follows: ▶ End check programme P.01. Alternatives 2 ‒ Measuring the gas pressure at ▶...
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Page 28: Checking Leak-Tightness
7 Start-up – Set values, G20 natural gas (→ Page 61) Inform Customer Service. Set values, G31 liquefied petroleum gas (→ Page 62) Install the front casing. (→ Page 11) Remove the front casing. (→ Page 10) 7.10.6 Gas conversion procedure Applicability: VU 446/5-5 (H-GB) Note Condition: The CO₂... -
Page 29: Thoroughly Flushing The Heating Installation ("Hot")
Adapting the unit to the heating installation 8 7.12 Thoroughly flushing the heating installation Adapting the heating settings ("hot") 8.2.1 Setting the maximum heating output Applicability: Great Britain The maximum heating output for the product is set to Auto OR Ireland at the factory. - Page 30 8 Adapting the unit to the heating installation 8.2.3 Resetting the remaining burner anti-cycling 8.2.5.2 Help when adjusting a heating installation or time when checking the flow rate 1st option You can use diagnostics code D.029 to display the flow rate in real time (in l/min).
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Page 31: Setting The Maintenance Interval
Handing over to the end user 9 Handing over to the end user Applicability: VU 606/5-5 (H-GB) When you have finished the installation, attach the sticker supplied in the end user's language to the front 1200 of the product. Explain to the end user how the safety devices work 1000 and where they are located. -
Page 32: Querying The Fault Memory
10 Troubleshooting – 10.4 Querying the fault memory Take all necessary precautions to ensure that it cannot be switched back on again. Menu → Installer level → Fault list Remove the front casing. (→ Page 10) The product has a fault memory. You can use this to query Close the gas stopcock. - Page 33 Troubleshooting 10 Remove the entire unit from the fan, Venturi and gas Disconnect the test system's silicone pipe for checking valve assembly. the airflow rate (1). Undo the nuts (1) on the gas valve assembly. Undo the fixing screw (2) and remove the air intake pipe Remove the clip (2).
- Page 34 10 Troubleshooting Remove the clips (1). Loosen the flow (2) and return pipe (3). 18. Reinstall the components in the reverse order. You Remove the condensate discharge hose (4) from the must use new seals at position (4) and (5). Follow the heat exchanger.
- Page 35 Troubleshooting 10 ▶ Instead of grease, use only water or com- Applicability: VU 606/5-5 (H-GB) mercially available soft soap to aid install- ation. 12. Replace the seals. 13. Insert the flow and return pipes into the heat exchanger as far as they will go. 14.
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Page 36: 11 Inspection And Maintenance
11 Inspection and maintenance 10.9.9 Replace the main PCB and/or the control 10.9.9.2 Replacing the PCB for the user interface element's PCB Caution. Risk of material damage caused by incor- rect repairs. Using an incorrect PCB may lead to damage to the electronics. -
Page 37: Using The Function Menu
Inspection and maintenance 11 11.1 Using the function menu 11.3.2 Removing the compact thermal module The function menu allows you to actuate and test individual Danger! components in the heating installation. Risk of death and risk of material damage Menu → Installer level → Test programs → Function menu caused by hot flue gas. - Page 38 11 Inspection and maintenance maximum acid content of 5%). Allow the vinegar to act on the heat exchanger for 20 minutes. Use a plastic brush or sufficiently strong jet of water to remove the loosened dirt. In doing so, ensure that no spraying water reaches the other components.
- Page 39 Inspection and maintenance 11 – 11.3.7 Cleaning the rainwater collector's draining Tightening torque: 6 Nm circuit Reconnect the plugs (1), (2), (3), (4) and (5). Connect the gas pipe (4) using a new seal. Open the gas stopcock. Make sure that there are no leaks. Ensure that the rainwater collector is not dirty or Check that the sealing ring in the air intake pipe (3) is blocked and, if required, clean it.
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Page 40: Draining The Product
11 Inspection and maintenance Fill the lower section of the siphon with water up to 10 Replace the seal on the air separation system's hous- mm below the upper edge of the condensate discharge ing. pipe. Reattach the housing for the air separation system and Re-insert the float (3). -
Page 41: Completing Inspection And Maintenance Work
Applicability: New Zealand For contact details for our customer service department, you can write to the address that is provided on the back page, or you can visit www.vaillant.com. Applicability: Great Britain OR Ireland To ensure efficient and reliable operation of your boiler it is recommended that regular servicing is carried out by your service provider. -
Page 42: Appendix
Appendix Appendix Overview of diagnostics codes Applicability: VU 446/5-5 (H-GB) OR VU 606/5-5 (H-GB) Note Since the code table is used for various products, some codes may not be visible for the product in question. Default User-spe- Code Parameter Values or explanations setting cific setting D.000... - Page 43 Appendix Default User-spe- Code Parameter Values or explanations setting cific setting D.024 Status of the air pressure monitor 0 = open Not ad- justable 1 = closed D.025 Domestic hot water generation en- 0 = No abled by eBUS control 1 = Yes D.026 Control of the optional grey relay...
- Page 44 Appendix Default User-spe- Code Parameter Values or explanations setting cific setting D.067 Remaining burner anti-cycling time Not ad- justable D.068 Unsuccessful ignitions at 1st attempt Number of unsuccessful ignitions Not ad- justable D.069 Unsuccessful ignitions at 2nd at- Number of unsuccessful ignitions Not ad- tempt justable...
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Page 45: B Status Codes - Overview
Appendix Default User-spe- Code Parameter Values or explanations setting cific setting D.148 Target value for the available pres- 100 … 400 mbar 200 mbar sure in the cylinder charging circuit D.149 Precise information about circulation If fault F.75 occurs, read the explanation below for fault F.75 the relevant value of the diagnostics code in order to analyse the problem. -
Page 46: C Fault Messages - Overview
Appendix Status code Meaning S.96 Return sensor test running, heating demands are blocked. S.97 Water pressure sensor test running, heating demands are blocked. S.98 Flow/return sensor test running, heating demands are blocked. S.108 Purging process is running Fault messages – Overview Message Possible cause Measure... - Page 47 Appendix Message Possible cause Measure ▶ F.27 Safety shutdown: Flame Gas solenoid valve not leak- Check that the gas solenoid valve works correctly. simulation tight ▶ Moisture on the PCB Check that the PCB works correctly. ▶ Flame monitor defective Replace the flame monitor.
- Page 48 Appendix Message Possible cause Measure ▶ F.33 Air pressure switch fault PCB defective Replace the PCB. Excessive counter-pressure in Ensure that there is no risk of excessive counter-pressure. the air/flue pipe If required, protect the product (wind guard, cascade lines with a larger diameter, etc.).
- Page 49 Appendix Message Possible cause Measure F.75 Pump fault/water defi- D.149 = 5, no pressure peak Check the system pressure. ciency detection Purge the heating installation (purge programme). Check the water pressure sensor. Replace the water pressure sensor. D.149 = 6, no feedback from Check the pump's cable harness.
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Page 50: D Wiring Diagram
Appendix Wiring diagram Burner X100 eBUS 230V~ 1 2 3 4 Installation and maintenance instructions ecoTEC plus 0020261389_02... - Page 51 Appendix Main PCB (BMU) Plug for the domestic hot water cylinder's contact (optional) PCB for the control element (AI) Water pressure sensor Gas valve assembly Heating pump control signal Temperature sensor in the heating flow Control of the optional relay D.026 Temperature sensor in the heating return Power supply for the prioritising diverter valve or Pressure switch...
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Page 52: E Basic Installation Diagram
Appendix Basic installation diagram 0020253233 Installation and maintenance instructions ecoTEC plus 0020261389_02... - Page 53 Appendix 0020259030 0020261389_02 ecoTEC plus Installation and maintenance instructions...
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Page 54: Key For The Basic System Diagrams
Appendix Key for the basic system diagrams Component Meaning Heat generator Heat generator circulation pump Cylinder charging pump Circulation pump Heating pump Monovalent domestic hot water cylinder Expansion relief valve Potable water expansion relief valve Safety group – drinking water connection Heating diaphragm expansion vessel Diaphragm expansion vessel –... - Page 55 Appendix Maintenance work Interval Check that the connections/electrical plug connections have been con- Annually nected correctly/function correctly Check that the gas stopcock and service valves function correctly Annually Checking and treating the heating water/filling and supplementary water Annually Checking the pre-charge pressure of the external expansion vessel at regular intervals Cleaning the heat exchanger at regular intervals...
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Page 56: G Commissioning Checklist
Appendix Commissioning Checklist Applicability: Great Britain 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 0020261389_02... - Page 57 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 58 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...
- Page 59 Appendix PRIOR TO CO AND COMBUSTION RATIO CHECK NOTE The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas THE AIR GAS RATIO VALVE IS FACTORY supply pressure/rate checked as required prior to commissioning. SET AND MUST NOT BE ADJUSTED As part of the installation process, especially where a flue has been fitted by persons other than the DURING COMMISSIONING UNLESS THIS boiler installer, visually check the integrity of the whole flue system to confirm that all components are...
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Page 60: H Position Of The Opening In The Air/Flue Pipe
Appendix Position of the opening in the air/flue pipe Applicability: Great Britain OR Ireland D, E Positioning of the opening of a fan-supported flue gas pipe Applicability: Great Britain OR Ireland 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. -
Page 61: I Horizontal Terminal Positioning
Appendix Horizontal terminal positioning Applicability: Great Britain OR Ireland BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows: a) at least 2 m from an opening in the building directly opposite, and b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely to cause a nuisance to a neighbour or discharge over a walkway or patio. -
Page 62: K Technical Data
Appendix Set values, G31 liquefied petroleum gas VU 446/5-5 VU 606/5-5 (H-GB) (H-GB) 9.9 ± 1.0 vol. CO₂ after 5 minutes Checking 10.1 ± 1.0 vol. in full load mode with during start- front casing closed 9.9 ± 0.3 vol. Checking 10.1 ±... - Page 63 Appendix VU 446/5-5 (H-GB) VU 606/5-5 (H-GB) Diameter at the outlet of the gas stopcock, inside thread 1" 1" Diameter of the heating pipe at the product outlet, outside thread 1 1/2" 1 1/2" Diameter at the outlet of the heating connection, outside thread 1 1/2"...
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Page 64: Index
Index Index Front casing, closed .............. 5 Frost ..................5 Function menu..............37 Additional relay..............24 Air ratio setting ..............27 Gas connection ..............16 Air separation system, filter ..........40 Gas setting ................25 Gas type ................15 Air/flue pipe ................. 18 Air/flue pipe, installed ............ - Page 65 Index Restarting the installation assistant........24 Return temperature control ..........31 Safety device................. 4 Self-test for the components ..........37 Serial number ................ 8 Service message..............31 Service partner ..............31 Setting the CO₂ content............27 Setting the pump curve ............30 Setting the pump output ............
- Page 68 Nottingham Road Belper 1 1 Derbyshire 1 1 DE56 1JT Telephone 0330 100 3461 info@vaillant.co.uk www.vaillant.co.uk Vaillant Group International GmbH Berghauser Strasse 40 42859 Remscheid Tel. +492191 18 0 www.vaillant.info © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.
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