Vaillant ecoTEC plus 612 Instructions For Installation And Servicing
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Vaillant ecoTEC plus 612 Instructions For Installation And Servicing

Wall hung room sealed fan assisted condensing boiler
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For the installer
Instructions for installation and servicing
ecoTEC
Wall hung room sealed fan assisted condensing boiler
GB
ecoTEC plus 612
ecoTEC plus 615
ecoTEC plus 618
ecoTEC plus 624
ecoTEC plus 630
ecoTEC plus 637
ecoTEC plus 824
ecoTEC plus 831
ecoTEC plus 837
ecoTEC pro 28
ecoTEC pro 24

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  • 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 637 ecoTEC plus 824 ecoTEC plus 831...

  • Page 2: Table Of Contents

    General instructions for heating system ..20 Vaillant warranty ......36 Gas connection .
  • Page 3 Recycling and disposal ....50 Vaillant service ......50 Appendix .

  • Page 4: Introduction

    1 Introduction Introduction Introduction Notes on the documentation Note The following information is intended to help you This boiler must be installed and serviced by a throughout the entire documentation. competent person in accordance with the Gas Further documents apply in combination with this instal- Safety (Installation and Use) Regulations 1998.

  • 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. At the rear of this guide, you will find a Benchmark gas boiler commissioning checklist.

  • 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 6.7 – 19.0 8.7 – 24.0 12.0 – 28.0 6.7 – 19.0 9.0 – 24.0 60 °C flow/40 °C return 6.9 –...
  • Page 7 Boiler specifications 2 ecoTEC plus Technical data Units CH heat output range 80 °C flow/60 °C return 4.9 – 12.0 4.9 – 15.0 6.7 – 18.0 8.7 – 24.0 10.0 – 30.0 12.0 – 37.0 60 °C flow/40 °C return 5.1 –...

  • Page 8: Dimensions

    2 Boiler specifications Dimensions ecoTEC plus 630: ecoTEC plus 637, ecoTEC plus 837: Fig. 2.1 Dimensions in mm Legend: Heating return pipe Ø 22 mm 2 Cold water connection Ø 15 mm (combination boilers only) 3 Gas connection Ø 15 mm 4 Hot water connection Ø...

  • Page 9: Installation

    Boiler specifications 2 Installation Fig. 2.2 Function elements of combination boilers Fig. 2.3 Function elements of system boilers Legend: Legend: Expansion vessel Expansion vessel 2 Air intake pipe 2 Air intake pipe 3 Burner module 3 Burner module 4 Ignition electrode 4 Ignition electrode 5 Fan 5 Fan...

  • Page 10: General Requirements

    Part 1 Specification for installation of flues. This appliance should only be installed in conjunction with Part 2 Specification for installation and maintenance either a Vaillant flue system or an alternative approved of ventilation for gas appliances. system (details of flue approval categories can be found in the technical section of the installation manual).
  • Page 11 General requirements 3 Fig. 3.1 Contents included with delivery of ecoTEC plus Fig. 3.2 Contents included with delivery of ecoTEC plus system boilers combination boilers DO NOT remove the boiler from the polystyrene base at DO NOT remove the boiler from the polystyrene base at this stage.

  • Page 12: Installation Site

    3 General requirements Note If a room sealed boiler is installed in a room with a bath or shower, electrical switches or boiler controls using the mains power supply must be placed at locations that cannot be reached by the person in the bath or shower. If the boiler is installed in an unusual location, special procedures may be necessary and BS 5546 and BS 6798 give detailed guidance on this aspect.

  • Page 13: Flue Pipe

    Vaillant appliances are certified only for use 25 m. with genuine Vaillant flue pipes. Only use genu- A vertical flue system is also available. Refer to flue sys- ine Vaillant flue pipes. Malfunctions can occur if tem installation instructions for full details.

  • Page 14: Air Supply

    3 General requirements ensure that the condensate plume does not affect adjacent surfaces the terminal should be extended as shown in Fig. 3.9. 2) Dimension F: This clearance may be reduced to 25 mm without affecting the performance of the boiler. However, in order to ensure that the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred.

  • Page 15: Guide To System Requirements

    General requirements 3 3.10 Guide to system requirements 3.10.4 Pressure gauge This is factory fitted to the boiler and indicates the pri- 3.10.1 Water circulation system mary circuit pressure to facilitate filling and testing. Detailed recommendations for the water circulation sys- tem are given in BS 6798 and BS 5449: Part 1 (for small 3.10.5 Expansion vessel bore and micro bore central heating systems).

  • Page 16: System By-Pass

    3 General requirements 3.11.3 Venting The boiler is fitted with an automatic air vent. Additional provision should be made to enable the heating system to be vented during filling and commissioning either by automatic air vents or manually. 1. Step 2.

  • Page 17: Boiler Installation Sequence 4

    Boiler installation sequence 4 Boiler installation sequence do not lean forward/sideways. Clear the route before attempting the lift. If removing boiler from truck strad- Transporting the appliance dle the load and tilt forwards to facilitate secure grip. Ensure safe lifting techniques are used – keep back Caution! straight –...

  • Page 18: Required Minimum Distances/Assembly Clearances

    4 Boiler installation sequence Positioning of Appliance for Final Installation – above grip to protect against sharp edges and ensure good worktop, foreseeable obstructions etc. grip when handling appliance. It is recommended a risk This appliance is deemed to be a one person lift when assessment of the roof space area be carried out before removed from the carton.

  • Page 19: Unpack The Boiler

    Boiler installation sequence 4 4.2.2 Unpack the boiler • Fix the paper template to the wall ensure that the To unpack the boiler, cut both plastic carton straps, template is vertical. open box and lift out the polystyrene top packing. Lift the cardboard box upwards.

  • Page 20: Installing The Flue System

    4 Boiler installation sequence Installing the flue system - The appliance is fitted with an expansion vessel (10 • Install the flue system (refer to the seperate air/flue l/0.75 bar). duct installation instructions). • Before assembling the appliance check if this volume is adequate.

  • Page 21: Cold Water Mains Inlet And Hot Water Outlet (Ecotec Combination Boilers Only)

    Boiler installation sequence 4 • Fit the union nut (2) and the compression olive (3) to • Insert the seal (1) and connect the service valve (2) to the gas connection pipe (1) of the boiler. the appliance cold water connection. •...

  • Page 22: Heating Connection

    4 Boiler installation sequence 4.12 Heating connection Caution! When making final connection to the boiler, if using soldered fittings, extra care should be taken to avoid damage to isolation valves through heat transfer. 4.12.1 Heating flow and return connection Note Before connecting the heating circuit to the boiler, all pipework and radiators must be thor- oughly flushed to remove any installation debris.

  • Page 23: Pressure Relief Valve

    Boiler installation sequence 4 4.12.2 Pressure Relief Valve min. Fig. 4.10 Heating flow and return connection for ecoTEC pro combination boiler ecoTEC plus system boiler • Insert a seal (1) and fit the service valves (2) to the flow and return connection of the appliance. •...

  • Page 24: Connection To The Main Supply

    4 Boiler installation sequence current edition of the ETCI (Electro-Technical Council for • Remove the front case and lower the control panel. Ireland) rules. The boiler is supplied for connection to • Unclip the bottom of the terminal box cover and hinge 230 V, ~ 50 Hz supply fused at 3 A rating.

  • Page 25: Electric Board Layout

    Boiler installation sequence 4 4.14.3 Electric board layout eBUS accessory connection Burner cable harness Accessory module connection Diagnosis via eBUS, vrnetDIALOG outer probe ext. flow or return probe Hydraulic cable harness Connection for external eBUS controller Caution: Do not connect Room thermostat 24 V: supply voltage! Connection 7, 8 and 9...
  • Page 26 4 Boiler installation sequence Ignition electrode flow return 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 27 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 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)

  • Page 28: Controls

    If external controls are used, this link must be removed, and the controls connected 4.15.4 Vaillant optional plug in timer accessories across terminals 3 and 4. Terminal 5 is an additional Refer to the instructions supplied with the optional neutral connection for external neutrals such as from accessories for connection details.

  • Page 29: Frost Protection

    Boiler installation sequence 4 4.17 Frost protection The boiler has an integral frost thermostat which is designed for protection of the boiler. To protect remote or exposed parts of the heating system or property additional frost protection measures must be taken such as the installation of an external frost thermostat.

  • Page 30: Commissioning Part I

    5 Commissioning Part I Commissioning Part I when the system is cold. This corresponds to a filling pressure between 1.0 and 2.0 bar. If the pointer is in the Preliminary electrical checks light grey area, please refill water. Check the electrical installation by carrying out short If the heating system extends over several storeys, the circuit, earth continuity and resistance to earth tests system may require a higher filling pressure.

  • Page 31: Filling The Heating System In Ecotec Pro Combi

    Commissioning Part I 5 The ecoTEC plus combination boiler will be delivered 5.4.4 Filling the heating system for the first time with a filling loop. Note • Insert the double check valve (1) of the filling pipe at the cold water shutoff valve and secure the double As long as there is insufficient water pressure check valve with the spring clip (2).

  • Page 32: Filling The Condensate Siphon

    5 Commissioning Part I Filling the condensate siphon Fig. 5.11 Adjusting the by-pass valve (in combination boilers) Fig. 5.4 Filling the condensate siphon Danger! Note that if the boiler is run with an empty condensate trap there is a danger that fumes might escape into the room and cause poison- ing.

  • Page 33: Gas Inlet Working Pressure

    Maximum net Natural gas in m Propane in kg/h Appliance heat input in kW nominal + 5% - 10% nominal + 5% - 10% ecoTEC plus 612 12.2 1.29 1.36 1.16 0.95 1.00 0.85 ecoTEC plus 615 15.3 1.62 1.70 1.46...

  • Page 34: 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. 00 2001 0641. To reset the appliance from LPG to natural gas mode, you need the Vaillant conversion kit Art.

  • Page 35: Functional Checks (Commissioning Part Ii) 6

    Functional checks (commissioning part II) 6 Functional checks (commissioning part II) plus Functional checks 6.1.1 Procedure After installing and checking the gas supply pressure, perform a function check before commissioning the appliance and handing over to the user. • Commission the appliance according to the relevant operating manual.

  • Page 36: Handing Over To The User

    Danger! Vaillant warranty Electrocution by touching live parts can be fatal! Vaillant provide a full parts and labour warranty for this appli- The supply terminals in the appliance switch ance. The appliance must be installed by a suitably competent box are live even if the main ON/OFF switch is person in accordance with the Gas Safety (Installation and turned off.

  • Page 37: Maintenance

    Inspection and maintenance 7 Always perform the following steps after completing Note any inspection tasks: The boiler is fitted with a combustion analysis • Open the service valves in the heating flow and return test point. A suitable combustion analyser can and in the cold water inlet (combination boilers only).

  • Page 38: Functional Check Of Boiler Operation

    7 Inspection and maintenance 7.1.4 Functional check of boiler operation • Remove screw (2) and remove the air intake pipe (1). • Carry out a functional check of the boiler operation as • Disconnect the gas supply (3) on the gas valve. Ensure previously detailed.

  • Page 39: Checking The Burner

    Inspection and maintenance 7 • After checking/replacing the burner, re-assemble the burner module in the boiler as described in Section 7.2.4. 7.2.4 Refitting the burner module Fig. 7.5 Replacing the burner door seal • Insert a new seal (1) in the burner door. Caution! The burner door seal (1) and the self-locking Fig.

  • Page 40: Cleaning The Condensate Siphon

    7 Inspection and maintenance • Reconnect the HT lead (5) and earth lead (6) to the • Remove the lower part (1) of the condensate siphon by spark electrode. turning the bayonet catch in anticlockwise direction. • Clean the siphon part section by rinsing it out with •...

  • Page 41: Recommissioning The Boiler

    Inspection and maintenance 7 Troubleshooting 8 Troubleshooting • Ensure the boiler CH service valves are closed. • Release the pressure from the boiler. • Remove valve cap from expansion vessel charge point. Logical fault finding procedure • Check that the internal charge pressure of the expan- These checks must be carried out before attempting to sion vessel is between 0.75 and 0.9 bar.

  • Page 42: Diagnostic Codes

    8 Troubleshooting 8.1.2 Diagnostic codes In the diagnostic mode, you can change certain parame- ters or display more information. The diagnostic information is divided into two diagnostic Display Meaning levels. The second diagnostic level can be reached only Heating mode (all models): after entering a password.
  • Page 43 Digitised ionisation potential Display range of 0 to 102, > 80 no flame, < 40 even flame Outside temperature d.47 Actual value in °C (with weather compensating Vaillant controller only) d.67 Remaining burner anti cycling time in min d.76 Appliance variant (device specific number) 00 to 99 d.90...
  • Page 44 8 Troubleshooting Second diagnostic level Scrolling and changing values and exiting the diagnostic • As described above in the first diagnostic level, scroll mode is done as described in the first diagnostic level. through the diagnostic number d.97. • Change the displayed value to 17 (password) and Note press the “i”...

  • Page 45: Fault Codes

    Troubleshooting 8 Display Meaning Display value/adjustable value d.78 Storage charging temperature limit (target flow tem- Adjustment range in °C 55 to 90 (Factory setting: 80) perature in storage mode, system boilers only) d.80 Heating operating hours in h d.81 Water heating operating hours (combination boilers in h only) d.82...
  • Page 46 8 Troubleshooting Code Meaning Cause NTC broken, NTC cable broken, Defective connection at NTC, F. 0 Flow–NTC open circuit Defective connection at electronics Return–NTC open circuit NTC broken, NTC cable broken, Defective connection at NTC, F. 1 Defective connection at electronics F.10 Flow NTC short circuit NTC defective, short circuit in cable harness, cable/casing shortcut...

  • Page 47: Test Programs

    Troubleshooting 8 Parts replacement 9 Test programs • Put the appliance out of operation. Special functions can be triggered on the appliances by activating various test programs. Caution! These programs are given in detail in the Table 8.5. Before starting any maintenance work: •...

  • Page 48: Replacing Expansion Vessel

    9 Parts replacement • Remove the air intake pipe (Fig. 7.1, Pos. 2). Replacing expansion vessel • Loosen the gas supply pipe on the gas fitting (Fig. 7.2, Pos. 3). Fig. 9.2 Dismantling fan with gas fitting • Pull out the plug (4) from the gas valve. •...

  • Page 49: Replacing Primary Heat Exchanger

    Parts replacement 9 Replacing primary heat exchanger • Pull out the clamps (1) and (2) and free the return pipe as well as the flow pipe on the primary heat exchanger. Danger! • Remove the four screws (3) on the primary heat Before replacing the component, comply with exchanger holder.

  • Page 50: Check Co Content And If Necessary Set (Air-Ratio Adjustment)

    < 250 < 250 Table 9.2 Factory gas settings 10 Recycling and disposal Both the Vaillant ecoTEC and the associated transport Fig. 9.7 Carrying out measurement of CO levels, preparing for packaging consist primarily of recyclable raw materials. air-ratio adjustment...

  • Page 51: Appendix

    Appendix Appendix Instructions for installation and servicing ecoTEC / 839592_09...

  • Page 52: Benchmark Gas Boiler Commissioning Checklist

    Benchmark gas boiler commissioning checklist...

This manual is also suitable for:

Ecotec plus 630Ecotec plus 615Ecotec plus 637Ecotec plus 618Ecotec plus 824Ecotec plus 624 ... Show all

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