Vaillant ecoTEC plus VU GB 5-5 Series Installation And Maintenance Instructions Manual
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Vaillant ecoTEC plus VU GB 5-5 Series Installation And Maintenance Instructions Manual

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VU GB .../5‑5
en Installation and maintenance instructions

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Summary of Contents for Vaillant ecoTEC plus VU GB 5-5 Series

  • Page 1 ecoTEC plus VU GB .../5‑5 en Installation and maintenance instructions...

  • Page 2: Table Of Contents

    Installation and maintenance Running the installation assistants ...... 29 Restarting the installation assistants ....30 instructions Using check programmes ........30 Contents Test programmes..........30 Checking and treating the heating water/filling and supplementary water ........30 Safety ..............4 9.10 Filling the condensate trap ........
  • Page 3 13.4 Querying the fault memory ........46 13.5 Resetting the fault memory........46 13.6 Resetting parameters to factory settings ..... 46 13.7 Performing diagnostics ........46 13.8 Using check programmes ........46 13.9 Preparing the repair work ........46 13.10 Procuring spare parts ..........

  • Page 4: Safety

    – Start-up Safety – Inspection and maintenance Intended use – Repair The product is intended as a heat generator – Decommissioning for sealed heating installations and for do- ▶ Proceed in accordance with current tech- mestic hot water generation. nology. The product must only be installed in installa- ▶...
  • Page 5 the gas supply company as soon as you monia compounds, dust or similar sub- are outside the building. stances. ▶ Ensure that no chemical substances are 1.3.2 Flue gas stored at the installation site. ▶ If you are installing the product in Flue gases may cause poisoning, while hot flue gases may also cause burns.

  • Page 6: Heating Water

    ▶ Install the necessary safety devices in the installation. You can find a list of relevant standards at: 1.3.12 Risk of death from leaks if the https://www.vaillant.co.uk/standards product is installed below ground level Liquid gas accumulates at floor level. If the...

  • Page 7: Guarantee And Customer Service

    To register your Vaillant appliance visit: https://self-service.vaillant.co.uk/warranty-registration 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 at the time by the Health and...

  • Page 8: Technical Data

    Technical data Technical data – General VU GB 806/5‑5 (H-GB) VU GB 1006/5‑5 (H-GB) VU GB 1206/5‑5 (H-GB) ecoTEC plus 806 ecoTEC plus 1006 ecoTEC plus 1206 Designated country (designation in accord- GB (Great Britain), IE GB (Great Britain), IE GB (Great Britain), IE ance with ISO 3166) (Ireland)
  • Page 9 Technical data – Heating VU GB 806/5‑5 (H-GB) VU GB 1006/5‑5 (H-GB) VU GB 1206/5‑5 (H-GB) ecoTEC plus 806 ecoTEC plus 1006 ecoTEC plus 1206 85 ℃ 85 ℃ 85 ℃ Maximum flow temperature (default setting: 75 °C) 30 to 85 ℃ 30 to 85 ℃...

  • Page 10: Notes On The Documentation

    Notes on the documentation Hot Water Association Vaillant is a full member of the Hot Water Association and ▶ Always observe all operating instructions enclosed with promotes the scheme in association with its cylinder range. the installation components. Details are available on the web site www.vaillant.co.uk ▶...

  • Page 11: Design Of The Product

    Reset any external controls, to resume normal operation of the central heating. If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this call your Installation/Servicing company or Vaillant service. 5.6.2 Overheating Safety The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens.

  • Page 12: Frost Protection

    5.6.3 Frost protection The appliance has a built in frost protection device that pro- tects the boiler from freezing. With the gas and electric sup- plies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the tem- perature of the boiler water falls below 12 °C.

  • Page 13: Set-Up

    Set-up Product dimensions and connection dimensions For fault-free operation and a long service life for the product, you must only install the product in installations with system separation (plate heat exchanger). Checking the scope of delivery ▶ Check that the scope of delivery is complete and intact. 6.1.1 Scope of delivery Num-...

  • Page 14: Installation Site

    Installation site Compartment Ventilation This boiler is not suitable for outdoor installation. This boiler The boilers are very high efficiency appliances. may be installed in any room. However if the boiler is being As a consequence the heat loss from the appliance casing installed in a room containing a bath or shower it must only during operation is very low.
  • Page 15 6.6.2 Position of the air/flue terminal The diagram is relevant for the installation of boilers with a gross heat input > 70 kW net but less than 333 kW net. For further information see the current IGEM UP/10 and the risk assessment appendix for guidance on suitable flue terminal locations. For installations above 333 kW net input, refer to the “Clean Air Act,”...

  • Page 16: Horizontal Terminal Positioning

    Minimum clearances for concentric terminations Flue system to be Directly below an opening, air brick, opening windows 2,500 designed and In- Above an opening, air brick, opening windows stalled according to IGEM UP/10. Horizontally to an opening, air brick, opening windows Use the risk assess- D (1,4,9) Below metal gutter, drain/soil pipe (extending out to clear)
  • Page 17 Balcony/eaves Gutter Adequately secured The flue pipe must protrude beyond any overhang air/flue gas pipe Horizontal Termination 0020134823_09 ecoTEC plus Installation and maintenance instructions...

  • Page 18: Using The Mounting Template

    Using the mounting template 6.9.2 Installing the front casing Position the mounting template vertically over the in- Place the front casing on the upper brackets. stallation site. Push the front casing onto the product until both retain- Secure the template to the wall. ing clips (2) snap into place at the front casing.

  • Page 19: Removing/Installing The Side Section (As Required)

    6.11 Removing/installing the side section (as required) 6.11.1 Removing the side section Caution. Risk of material damage caused by mech- anical deformation. Removing both side sections may cause mechanical distortion in the product, which may cause damage to the piping, for ex- ample, and potentially result in leaks.

  • Page 20: Installation

    Installation Gas installation 7.4.1 Performing the gas installation Installation requirements Caution. 7.1.1 Information on the gas group Risk of material damage caused by incor- In the as-supplied condition, the product is preset for opera- rect gas installation. tion with the gas group indicated on the data plate. Excessive test pressure may cause damage 7.1.2 Purging the liquid gas tank...

  • Page 21: Hydraulics Installation

    (left-hand connection). You can find information about avail- – Large expansion vessel: ≥ 10 l able accessories from the Vaillant price list or by contacting the contact address provided on the back page of these in- Check that the volumetric capacity of the expansion structions.

  • Page 22: Connecting The Condensate Discharge Pipe

    ▶ ory. The minimum circulation water volume in the unit cir- Install the expansion relief valve drain to a cuit is only guaranteed if you use original accessories in the professional standard. unit circuit, provided that the maximum pressure losses in the piping are not exceeded.
  • Page 23 7.5.6.1 Overview of the condensate discharge systems 7.5.6.1.1 Direct Connection to internal soil and vent stack Ø22mm min. Preferred option ▶ Connect the condensate discharge (3) on the condensate 7.5.6.1.2 Direct connection to external soil and vent trap (2) to a condensate discharge pipe that has a min- stack imum internal diameter of 19 mm (30 mm internal dia- meter for all external pipes that are fed out of the build-...
  • Page 24 7.5.6.1.4 Internal termination into combined sink Open end of pipe direct into gulley below ground level but above water level waste Susceptible to siphonage, must terminate in a gulley 7.5.6.1.7 External termination into rain water down pipe 100mm ≥ 3 m Ø22mm Ø32mm ≤...

  • Page 25: Flue Installation

    When the boiler is installed in a cascade or commercial premises, then follow the requirements of IGEM / UP 10 for the flue termination and ventilation requirements: – https://www.vaillant.co.uk Electrical installation Only qualified electricians may carry out the electrical install- ation.

  • Page 26: Establishing The Power Supply

    7.7.1 Opening/closing the electronics box 7.7.3 Establishing the power supply 7.7.1.1 Opening the electronics box Caution. Risk of material damage due to high con- nected voltage. At mains voltages greater than 253 V, elec- tronic components may be damaged. ▶ Ensure that the nominal voltage of the mains is 230 V (+10%/-14%) ~50 Hz.

  • Page 27: Connecting Additional Components

    7.7.4 Connecting the pump group 7.7.6 Connecting additional components You can use the multi-functional module to actuate two addi- tional components. The following components can be actuated: – Circulation pump – External pump – Cylinder charging pump – Extraction hood –...

  • Page 28: Operation

    Operation Operating concept of the product The operating concept and the read-out and setting options of the end user level are described in the operating instruc- tions. An overview of the read-out and setting options of the in- staller level can be found in the section "Overview of the menu structure –...

  • Page 29: Start-Up

    Start-up 9.5.1 Language ▶ Set the required language. Carrying out the initial start-up ▶ Press (OK) twice to confirm the set language and to avoid unintentionally changing it. Note The complete heating system must be flushed If you have unintentionally set a language that you do not at least twice: Once with cold water and once understand, proceed as follows to change it: with domestic hot water in accordance with the...

  • Page 30: Restarting The Installation Assistants

    Restarting the installation assistants Checking and treating the heating water/filling and supplementary water You can restart the installation assistant at any time by call- ing it up in the menu. Caution. Menu → Installer level → Start inst. assistant Risk of material damage due to poor-qual- ity heating water Using check programmes ▶...

  • Page 31: Filling The Condensate Trap

    We accept no liability for the compatibility of any additive or Fill the lower section of the condensate trap with water its effectiveness in the rest of the heating system. up to about 10 mm below the upper edge. Secure the lower section of the condensate trap cor- Additives for cleaning measures (subsequent rectly to the condensate trap again.

  • Page 32: Filling And Purging The Boiler And Heating System

    Observe the increasing filling pressure in the boiler. gas, do not start up the product. Fill with water until the required filling pressure is A gas conversion must only be carried out by Vaillant cus- reached. tomer service or the manufacturer of the product.

  • Page 33: Checking The Gas Flow Rate

    9.15.4 Checking the gas flow pressure If you cannot eliminate the damage, do not start up the product. 9.15.3 Checking the gas flow rate The boiler is fitted with a multifunctional automatic gas valve which ensures that the precise air/gas ratio is provided under all operating conditions.
  • Page 34 ▶ Do not make any adjustments to the Test values Unit Natural product. gas H ▶ Check the gas installation. CO₂ after 5 minutes in full load 9.0 ±1.0 Vol.–% ▶ mode with front casing closed Do not start up the product. CO₂...

  • Page 35: Thoroughly Flushing The Heating System ("Hot")

    Test value Unit Natural Note gas H The actual reading on the digital pressure gauge should ideally be 0,05 MPa (0,5 bar) CO₂ at minimum load with re- Vol.–% 8.4 to 8.8 moved front casing plus an additional pressure corresponding to the highest point of the system above the base of the boiler –...

  • Page 36: Adapting The Unit To The Heating Installation

    10.4 Setting the maximum flow temperature Condition: Water hardness: > 3.57 mol/m³ – Water temperature: ≤ 50 ℃ You can set the maximum flow temperature for the heating mode under D.071 (default setting: 75 °C). 10 Adapting the unit to the heating 10.5 Setting the return temperature control system...

  • Page 37: Setting The Maintenance Interval

    80 kW boiler with high-efficiency pump Note The remaining burner anti-cycling time following a regular shutdown in heating mode can be called 1200 up under D.067. 1100 10.6.2 Resetting the remaining burner anti-cycling time 100 % 1000 1st option Menu → Reset anti-cycling time The current burner anti-cycling time appears in the display.

  • Page 38: Handing Over To The End User

    100 kW boiler with high-efficiency pump 120 kW boiler with high-efficiency pump 1100 1200 100 % 1100 1000 100 % 1000 85 % 85 % 70 % 70 % 60 % 60 % 53 % 53 % 1000 2000 3000 4000 5000 6000 7000 8000 1000 2000 3000 4000 5000 6000 7000 8000 Circulation water Circulation water...
  • Page 39 ▶ Inform the end user that they must have the product maintained in accordance with the specified intervals. ▶ Pass all of the instructions and documentation for the product to the end user for safe-keeping. ▶ Inform the end user about measures taken to ensure the supply of combustion air and flue gas guiding, and instruct the operator that he must not make any changes.

  • Page 40: Inspection And Maintenance

    12 Inspection and maintenance 12.5 Observing inspection and maintenance intervals 12.1 Complete Service Interval Record section Warning. ▶ After servicing, complete the relevant Service Interval Risk of injury and a risk of material dam- Record section of the Benchmark Checklist located on age caused by negligent inspection and the inside back pages of this document.

  • Page 41: Preparing The Maintenance Work

    12.9 Checking the electrical plug connections based on the how you define the condition of the product during the inspection. Carry out all inspection and mainten- Use the main switch to switch off the product. ance work in the sequence shown in Appendix C. Disconnect the product from the power supply by switching off the circuit breaker in the case of a fixed 12.6...
  • Page 42 Condition: Applies for 100 kW and 120 kW 806/5-5 ▶ Undo the four screws on the flange connection (3) to the gas valve assembly. Move the gas pipe (4) to the side. 1006/5-5 1206/5-5 Danger! Risk of poisoning and fire caused by es- caping gas! The gas pipe may become damaged.

  • Page 43: Cleaning The Heat Exchanger

    12.12 Checking the burner Remove the plugs (12) and (13) from the fan motor by pushing in the latching lug. Remove the plug from the gas valve assembly (10). Remove the plug from the upper safety cut-out (8). Undo the screws (6) on the burner door. Remove the complete gas-air mixture unit (5) from the heat exchanger (7).

  • Page 44: Cleaning The Condensate Trap

    Insert the new electrodes with new seals. – Torque: 2.8 Nm 12.14 Cleaning the condensate trap 806/5-5 Remove the lower section of the condensate trap(2) by unscrewing it from the condensate trap (1). Flush out the lower section of the condensate trap with water.

  • Page 45: Draining The Product

    You can find an overview of the fault codes in the appendix. Overview of fault codes (→ Page 57) 13.1 Contacting your service partner If you contact your Vaillant service partner, if possible, ▶ Check that the sealing ring in the air intake pipe (2) is please mention positioned correctly in the seal seat.

  • Page 46: Reading Off The Fault Codes

    If you are unable to remedy the fault and the fault recurs ▶ despite several fault clearance attempts, contact Vaillant If you require spare parts for maintenance or repair Service. work, use only the spare parts that are permitted for the product.

  • Page 47: Replacing The Burner

    – Unscrew the screws (2) from the fan and remove the Torque: 4 Nm gas valve assembly from the fan. Use four nuts (1) to secure the insulating mat. Ensure Replace the defective component. that the insulating mat is touching the burner door and the cut-outs for the insulating mat lie above the cut- Install the gas valve assembly and the fan in the same outs for the burner door.

  • Page 48: Completing Repair Work

    13.11.5 Replacing the heat exchanger Note If you are replacing only one component, the set Drain the product. (→ Page 45) parameters are transferred automatically. When Remove the gas-air mixture unit. (→ Page 41) the product is switched on, the new component Unscrew the flow and return line in the front area of the adopts the previously set parameters from the underside of the product.

  • Page 49: Decommissioning

    ▶ Drain the product. (→ Page 45) 15 Recycling and disposal Disposing of the packaging ▶ Dispose of the packaging correctly. ▶ Observe all relevant regulations. ▶ For detailed information refer to www.vaillant.co.uk. 0020134823_09 ecoTEC plus Installation and maintenance instructions...

  • Page 50: Appendix

    Appendix Inspection and maintenance work The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If na- tional regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed. Each time inspection and maintenance work is carried out, carry out the required preparatory and com- pletion work.
  • Page 51 Maintenance work Interval Fill up the product/heating installation to 1.0–4.5 bar (depending on the At least every 2 years static height of the heating installation) and start the purge programme P.00 Completing inspection and maintenance work Annually Starting a test operation after maintenance work Annually Visually check the ignition and burner behaviour Annually...

  • Page 52: B Installer Level Menu Structure - Overview

    Installer level menu structure – Overview Menu Information Reset burner off time Installer level Back Select Enter code Installer level Fault list F.00 F.75 Test programs Interruption Fault Flow sensor Appliance config. Pump water shortage Back Back Select Installer level Test programs Gas type check P.00...
  • Page 53 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...

  • Page 54: C Overview Of Diagnostics Codes

    Overview of diagnostics codes Default Own setting Code Parameter Values or explanations setting D.000 Partial heating load Adjustable partial heating load in kW Auto Auto: Product automatically adjusts max. partial load to current system demand D.001 Overrun time of internal heating 2 to 60 min 5 min pump for heating mode...
  • Page 55 D.046 Pump type 0 = Relay with disable facility 0 = Relay with disable 1 = PWM with disable facility facility D.047 Outdoor temperature (with Vaillant Actual value in °C Not ad- weather-compensated control) justable D.050 Offset for minimum speed...

  • Page 56: D Status Codes - Overview

    Default Own setting Code Parameter Values or explanations setting D.082 Number of burner start-ups in heat- Number of burner start-ups Not ad- ing mode justable D.083 Number of burner starts in domestic Number of burner start-ups Not ad- hot water mode justable D.084 Maintenance indicator: Number of Adjustment range: 0 to 3000 hrs and "---"...

  • Page 57: E Overview Of Fault Codes

    Status code Meaning S.39 "Burner off contact" has triggered (e.g. surface-mounted thermostat or condensate pump) S.40 Comfort protection mode is active: Product running with limited heating comfort S.41 Water pressure > 0.6 MPa (6 bar) S.42 Flue non-return flap response blocks burner operation (only in conjunction with accessory VR40) or condensate pump defective;...
  • Page 58 Code Meaning Cause – F.61 Fault: Gas valve assembly actuation Short circuit/short to earth in cable harness for the gas valve as- sembly – Gas valve assembly defective (coils shorted to earth) – Electronics defective – F.62 Fault: Gas valve assembly switch-off delay Delayed shutdown of gas valve assembly –...

  • Page 59: Wiring Diagram

    Wiring diagram Display Pump PWM signal connection Water pressure sensor white Cylinder sensor (optional) 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 Earth...

  • Page 60: Commissioning Checklist

    Commissioning Checklist Benchmark Commissioning & Warranty Validation Service Record It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation.
  • Page 61 GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s)) Weather compensation...
  • Page 62 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER Date: SERVICE/INTERIM WORK ON BOILER...
  • Page 63 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER Date: SERVICE/INTERIM WORK ON BOILER...

  • Page 64: Commissioning Flow Chart

    Commissioning Flow Chart 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...

  • Page 65: I Initial Start-Up Checklist

    Initial start-up checklist Location Competent person Customer service tech- nician Name Street/house number Postcode Town/city Telephone Start-up date Serial number Basic hydraulic diagram Initial start-up checklist Values Unit Installation, general Building type (house/apartment building, special building) Used for commercial purposes? Year of manufacture Insulation status/renovation System output...
  • Page 66 Values Unit Piping at least 1.5 inches (single unit) Piping at least DN65 (cascade up to 360 kW) Piping at least DN100 (cascade > 360 kW) Expansion relief valve MPa (bar) System separation using a plate heat exchanger Which type? Number of mixers Cylinder –...

  • Page 67: Treating The Heating Water

    Other heat generators Solar system, heat pump, solid fuel boiler? If yes, which type? Control system Vaillant control If yes, which type? Third-party control If yes, which type? Room temperature control, outdoor temperature control If yes, which type?
  • Page 68 80 kW 100/120 kW 80 kW: A 100/120 kW: B 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 x [l] System volume Water treatment required (water softener and inhib- itor) Water hardness [mg/l CaCO₃] Water treatment not required Installation and maintenance instructions ecoTEC plus 0020134823_09...

  • Page 69: Index

    Index Guarantee and Customer Service......... 7 Handing over to the end user ..........38 Heat exchanger ............. 43, 48 Additional relay..............29 Heating flow................. 21 Air ratio setting ..............34 Heating return..............21 Air/flue pipe ................. 25 Heating system..............32 Article number ..............
  • Page 70 Safety devices ..............11 Scale ................... 20 Scale deposition ..............20 Scope of delivery..............13 Self-test ................41 Service message..............45 Service partner ..............45 Side section................. 19 Spare parts..............40, 46 Status codes..............28, 56 Switching on ................ 29 Target feed temperature............
  • Page 72 Supplier Vaillant Ltd. Nottingham Road Belper Derbyshire DE56 1JT Telephone 0330 100 3461 info@vaillant.co.uk www.vaillant.co.uk 0020134823_09 Publisher/manufacturer Vaillant GmbH Berghauser Str. 40 D-42859 Remscheid Tel. +492191 18 0 Fax +492191 18 2810 info@vaillant.de www.vaillant.de © 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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