Vaillant ecoFIT sustain 630 Installation And Maintenance Instructions Manual
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Vaillant ecoFIT sustain 630 Installation And Maintenance Instructions Manual

Vaillant ecoFIT sustain 630 Installation And Maintenance Instructions Manual

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ecoFIT sustain
615 - 630
en Installation and maintenance instructions

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Summary of Contents for Vaillant ecoFIT sustain 630

  • Page 1 ecoFIT sustain 615 - 630 en Installation and maintenance instructions...

  • Page 2: Table Of Contents

    Installation and maintenance Flushing the heating installation for the first time ("cold") ............25 instructions Filling and purging the heating installation ..25 Filling the domestic hot water circuit....26 Contents Checking the gas setting ........26 9.10 Thoroughly flushing the heating installation Safety ..............

  • Page 3: Safety

    Safety Qualification The person carrying out the work described Intended use here must have completed professional train- The product is intended as a heat generator ing. The competent person must demon- for closed heating installations and for do- strably have all of the knowledge, skills and mestic hot water generation.
  • Page 4 ▶ Do not use any electrical switches, mains To prevent electric shocks, proceed as fol- plugs, doorbells, telephones or other com- lows before working on the product: munication systems in the building. ▶ Disconnect the product from the power ▶ Close the emergency control valve or the supply by switching off all power supplies main isolator.

  • Page 5: Regulations (Directives, Laws, Standards)

    List of relevant standards for Great Britain and Ireland ▶ Observe the national regulations, stand- ards, directives, ordinances and laws. You can find a list of relevant standards at: https://www.vaillant.co.uk/standards 0020277252_03 ecoFIT sustain Installation and maintenance instructions...

  • Page 6: 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 7: Technical Data

    Technical data Technical data – General VU 156/6-3 (H-GB) VU 186/6-3 (H-GB) VU 306/6-3 (H-GB) Gas category Diameter of the gas pipe 1/2 inch 1/2 inch 1/2 inch Diameter of the heating connec- 3/4 inch 3/4 inch 3/4 inch tions Expansion relief valve connection 15 mm 15 mm...
  • Page 8 VU 156/6-3 (H-GB) VU 186/6-3 (H-GB) VU 306/6-3 (H-GB) Effective output range (P) 4.5 to 15.2 kW 5.0 to 18.3 kW 7.1 to 30.2 kW at 80/60 °C Domestic hot water heat 4.4 to 18.0 kW 4.9 to 25.2 kW 7.1 to 35.0 kW output (P) Maximum heat input –...

  • Page 9: Notes On The Documentation

    Code (DSN) Specific product code Hot Water Association Read the instructions. Vaillant is a full member of the Hot Water Association and promotes the scheme in association with its cylinder range. GC no. Gas council number Details are available on the web site www.vaillant.co.uk...

  • Page 10: Functional Elements: System Boiler

    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. Installation and maintenance instructions ecoFIT sustain 0020277252_03...

  • Page 11: Set-Up

    Set-up Dimensions Checking the scope of delivery ▶ Check that the scope of delivery is complete and intact. Number Designation Heat generator Unit mounting bracket Flexible condensate discharge pipe 3/4" seals 1/2" seals Service valve Gas stopcock Connection pipe (heating flow and return) Gas pipe Drain pipe for the Pressure relief valve Mounting template...

  • Page 12: Installation Site

    Installation site Minimum fall This boiler is not suitable for outdoor installation. This boiler 44 mm/m may be installed in any room. However if the boiler is being installed in a room containing a bath or shower it must only be installed in zones 2 or 3.
  • Page 13 6.6.2 Position of the air/flue terminal 6.6.2.1 Positioning the terminal of a fan-supported flue system Installation site Dimensions Adjacent to a boundary. 300 mm The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang.

  • Page 14: Horizontal Terminal Positioning

    Installation site Dimensions The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant. Above adjacent ground or balcony.

  • Page 15: Flue Configuration Description

    6.6.3.3 Vertical Concentric Flue ⌀ 60/100 mm or 6.6.3 Flue Configuration Description ⌀ 80/125 mm (C33 type installation) 6.6.3.1 Horizontal Concentric Flue ⌀ 60/100 mm or ⌀ 80/125 mm (C13 type installation) Gasket (fitted) Consult the separate installation manual for air/flue gas sys- Note tems supplied with your appliance for all possibilities and as- If the terminal is at less than 1.80 m from the...

  • Page 16: Removing/Installing The Front Casing

    Removing/installing the front casing 6.9.1 Front casing, removing 6.10.2 Installing the side section ▶ Refit the components in the reverse order. 6.9.2 Installing the front casing ▶ Refit the components in the reverse order. 6.10 Removing/installing the side section 6.10.1 Removing the side section Caution.

  • Page 17: Installation

    Installation Preparing for installation ▶ Make sure that the existing gas meter is capable of passing the rate of gas supply required. ▶ Consider the maximum heat output given in DHW mode. ▶ Install the following components: – Draining cocks at the lowest points in the heating installation (→...

  • Page 18: Connecting The Condensate Discharge Pipe

    Connecting the condensate discharge pipe 7.5.1.1 Direct Connection to internal soil and vent stack Ø22mm ▶ Follow the instructions listed here and observe the legal Preferred option and local regulations on condensate discharge. ▶ Use PVC or any other material that is suitable for drain- 7.5.1.2 Direct connection to external soil and vent ing the non-neutralised condensate.
  • Page 19 7.5.1.7 External termination into rain water down Preferred option for external termination pipe 7.5.1.5 External termination into soakaway Ø32mm ≤ 3 m ≤ 3 m < 500 mm Ø22mm 100 mm Ø 32mm Ø12 NB only combined foul/rainwater drain 7.5.1.8 Additional methods of introducing air breaks Ground (either/or) Bottom of sealed tube Seal...

  • Page 20: Flue Installation

    Flue installation 7.7.2 Cable route 7.6.1 Installing and connecting the air/flue pipe You can find out which air/flue pipes may be used by consulting the enclosed set-up instructions for the air/flue system. Observe the information on positioning the air/flue ter- 230V minal.

  • Page 21: Establishing The Power Supply

    Screw the respective plug to the connection cable. 10. Check whether all conductors are inserted mechanic- ally securely in the terminals of the plug. Remedy this if necessary. 11. Plug the plug into the associated PCB slot. – In doing so, observe the wiring diagram in the ap- pendix.
  • Page 22 Condition: When connecting a control (230 V). 230V~ ▶ Connect the control to the main plug. ▶ Remove the bridge from the 24V=RT plug. Close the electronics box. Installation and maintenance instructions ecoFIT sustain 0020277252_03...

  • Page 23: Operation

    Operation Live Monitor (status codes) Menu → Live monitor Operating concept Status codes in the display provide information on the pro- The operating concept and the display and setting facilities duct's current operating status. of the operator level are described in the operating instruc- Status codes –...

  • Page 24: Start-Up

    Start-up Total Water hardness at specific system volume heating > 20 l/kW output ≤ 20 l/kW Carrying out the initial start-up > 50 l/kW ≤ 50 l/kW Initial start-up must be carried out by a customer service mol/ mol/ mol/ technician or an authorised competent person using the CaCO₃...

  • Page 25: Filling The Condensate Trap

    Additives for frost protection intended to remain Avoiding danger arising from insufficient permanently in the installation water pressure – Adey MC ZERO The filling pressure must be between 0.10 and 0.15 MPa – Fernox Antifreeze Alphi 11 (1.0 and 1.5 bar). –...

  • Page 26: Filling The Domestic Hot Water Circuit

    If you discover unusual levels of CO or CO in the sup- ply air, search for the leak in the flue system or for signs of flue gas recirculation. Eliminate the damage properly. Check again whether the supply air contains any un- usual levels of CO or CO If you cannot eliminate the damage, do not start up the product.

  • Page 27: Checking The Co₂ Content

    ▶ Undo the sealing screw on the test nipple (2). Record the appliance gas inlet working pressure (kPa resp. mbar) in the Benchmark gas boiler commissioning Connect a manometer to the test nipple (2). checklist. Open the gas stopcock (1). Start up the product with check programme P.01 (sys- 9.9.4 Checking the CO₂...

  • Page 28: Adapting The Unit To The Heating Installation

    Note Set maximum burner anti-cycling time [min] Flow (tar- The actual reading on the digital pressure get) gauge should ideally be 0,05 MPa (0,5 bar) [°C] plus an additional pressure corresponding 12.5 16.5 20.5 25.0 to the highest point of the system above the base of the boiler –...

  • Page 29: Setting The Bypass Valve

    1000 1000 1200 Remaining feed head Max. PWM Remaining feed head Max. PWM [mbar] [mbar] Min. PWM Min. PWM Flow rate [l/h] Flow rate [l/h] 15s: 30s: 1000 1400 1000 1200 Remaining feed head Max. PWM Remaining feed head Max. PWM [mbar] [mbar] Min.

  • Page 30: Setting The Domestic Hot Water Temperature

    ▶ Inform the end user that they must not store or use explo- Position of the adjusting Notes/application sive or highly flammable substances (such as petrol, pa- screw per or paint) in the installation room of the product. If the radiators do not heat ▶...

  • Page 31: Observing Inspection And Maintenance Intervals

    12 Inspection and maintenance 12.5 Setting the CO₂ content Condition: The CO₂ content must be adjusted 12.1 Complete Service Interval Record section ▶ After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located on the inside back pages of this document. 12.2 Using original seals If you replace components, use only the enclosed original...

  • Page 32: Cleaning The Heat Exchanger

    10. Remove the burner seals (7) and the burner (8). 11. Check the burner and the heat exchanger for damage and dirt. 12. If necessary, clean or replace the components accord- ing to the following sections. 13. Install the two new burner seals. 12.7 Cleaning the heat exchanger Remove the screw (1).

  • Page 33: Troubleshooting

    – 12.12 Draining the product Clearance for the ignition electrodes: 3.5 to 4.5 mm Make sure that the seal (5) is free from damage. Close the service valves of the product. ▽ If necessary, replace the seal. Start check programme P.05. Overview of the check programmes (→...

  • Page 34: Procuring Spare Parts

    13.2 Calling up and clearing the fault memory 13.5 Replacing defective components 13.5.1 Replacing the burner The last 10 fault messages are stored in the fault memory. ▶ Call up the installer level. (→ Page 23) Remove the gas-air mixture unit. (→ Page 31) ▶...

  • Page 35: Replacing The Pump Head

    13.5.4 Replacing the pump head Remove the upper clip (1). Disconnect the pump cables from the electronics box. Remove the lower clip (3). Undo the four screws (1). 10. Remove the return pipe (2). Remove the pump head (2). Replace the O-ring. Use four screws to secure the new pump head.

  • Page 36: Replacing The Pcb

    13.5.6 Replacing the PCB 13.5.8 Replacing the expansion relief valve Remove the clip (2). Remove the expansion relief valve. Fit the new expansion relief valve with a new O-ring. Reattach the clip (2). 13.5.9 Replace the pressure sensor Open the electronics box. (→ Page 20) Pull all of the plugs out from the PCB.

  • Page 37: 15 Recycling And Disposal

    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. 0020277252_03 ecoFIT sustain Installation and maintenance instructions...

  • Page 38: 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 39: Overview Of Diagnostics Codes

    Maintenance work Interval Checking the pre-charge pressure of the expansion vessel at regular intervals Reassemble the product After each time maintenance work is carried out Open the service valves, carry out the required leak-tightness test Annually Fill the product/heating installation to the filling pressure specified for the Annually system Connect the product to the electrical installation...
  • Page 40 Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. code – – d.15 Pump speed Current value adjustable – – d.16 Status of the 24 V Current value off = Heating off room thermostat adjustable on = Heating on –...
  • Page 41 Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. code – d.28 Function of relay 1 = Circulation pump Adjustable 2 (multi-functional 2 = External pump module) 3 = Cylinder charging pump 4 = Extraction hood 5 = External solenoid valve 6 = Fault display 7 = Solar pump (omitted)
  • Page 42 Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. code – – – d.69 Number of unsuccess- Current value ful ignitions at 2nd at- adjustable tempt – d.70 Operation of the prior- 0 = Normal operating mode Adjustable itising diverter valve (DHW and heating mode)

  • Page 43: Status Codes - Overview

    Status codes – Overview Note Since the code table is used for various products, some codes may not be visible for the product in question. Status code Meaning Displays in heating mode Heating mode: No requirement S.01 Heating mode: Fan prerun S.02 Heating mode: Pump prerun S.03...

  • Page 44: Overview Of Fault Codes

    Status code Meaning S.98 Automatic test programme: Return temperature sensor, heating demands blocked. S.99 Internal automatic test programmes S.108 Purging the combustion chamber, fan in operation S.109 Product's standby mode activated Overview of fault codes Note Since the code table is used for various products, some codes may not be visible for the product in question. Fault code Meaning Possible cause...
  • Page 45 Fault code Meaning Possible cause F.67 Value sent back by ASIC is incorrect Implausible flame signal, electronics defective (flame signal) F.68 Fault: Unstable flame (analogue input) Air in gas, gas flow pressure too low, incorrect air ratio, incorrect gas in- jector, ionisation flow interruption (cable, electrode) F.70 Invalid product code (DSN)

  • Page 46: E Wiring Diagram: System Boiler

    Wiring diagram: system boiler Burner off RT 24V X106 eBUS – Burner 24V= 230V~ RT 230Vac 230Vac Main PCB Pressure sensor Interface PCB External ignition transformer Temperature sensor on the heating flow Heating pump Temperature sensor on the heating return Ionisation and ignition electrode Main power supply and connection for 230 V control Gas valve assembly...

  • Page 47: F Wiring Diagram: System Boiler (30 Kw)

    Wiring diagram: system boiler (30 kW) Burner off X106 eBUS – Burner 24V= 230V~ RT 230Vac 230Vac Main PCB Gas valve assembly Interface PCB Pressure sensor Control system Ionisation electrode Temperature sensor on the heating flow Heating pump Temperature sensor on the heating return Ignition electrode Main power supply and connection for 230 V control 0020277252_03 ecoFIT sustain Installation and maintenance instructions...

  • Page 48: 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 49 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 50 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 SERVICE/INTERIM WORK ON BOILER Date:...
  • Page 51 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 SERVICE/INTERIM WORK ON BOILER Date:...

  • Page 52: 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 53: Index

    Index Installer level ............... 23 Installer level, calling up ............23 Intended use................3 Air intake pipe, removing............. 31 Air/flue pipe, horizontal wall duct......... 15 Kammerbelüftung ..............12 Air/flue pipe, installing ............20 Leak-tightness ............... 28, 36 Air/flue pipe, type C13 ............15 Air/flue pipe, type C33 ............
  • Page 56 Supplier Vaillant Ltd. Nottingham Road Belper Derbyshire DE56 1JT Telephone 0330 100 3461 info@vaillant.co.uk www.vaillant.co.uk 0020277252_03 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.

This manual is also suitable for:

Ecofit sustain 618Ecofit sustain 615Vu 156/6-3 (h-gb)Vu 186/6-3 (h-gb)Vu 306/6-3 (h-gb)

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