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 ecoTEC plus 837 ecoTEC pro 28 GB
Contents Contents 1 1.1 1.1.1 1.1.2 1.1.3 1.2 1.3 1.4 1.5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on the documentation . . . . . . . . . . . . . . . . Applicable documents . . . . . . . . . . . . . . . . . . . . . . Retention of documents . . . . . . . . . . . . . . . . . . . . Safety instructions and symbols . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 7 7.1 7.1.1 7.1.2 7.1.3 Inspection and maintenance . . . . . . . . . . . . Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the inspection and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.4 Functional check of boiler operation . . . . . . . . . 7.
1 Introduction 1 Introduction 1.1 Notes on the documentation The following information is intended to help you throughout the entire documentation. Further documents apply in combination with this installation and maintenance manual. We assume no liability for any damage caused by non-observance of these manuals. 1.1.
Introduction 1 The Valliant ecoTEC are state-of-the-art appliances which have been constructed in accordance with recognised safety regulations. Nevertheless, danger to the life and limb of the user or third parties can still occur or the appliance or other material assets be damaged in the event of improper use. The appliance is designed to generate heat for connecting to hot water central heating systems and for instantaneous hot water supply (ecoTEC combination boilers only).
2 Boiler specifications 2 Boiler specifications 2.1 Technical data Technical data CH heat output range 80 °C flow/60 °C return 60 °C flow/40 °C return 50 °C flow/30 °C return 40 °C flow/30 °C return Maximum DHW output 824 ecoTEC plus 831 837 ecoTEC pro 28 6.7 – 19.0 6.9 – 19.6 7.1 – 20.2 7.2 – 20.6 8.7 – 24.0 9.0 – 24.7 9.2 – 25.5 9.4 – 26.0 12.0 – 28.0 12.3 – 28.9 12.7 – 29.7 12.9 – 30.3 9.0 – 24.0 9.3 – 24.7 9.6 – 25.5 9.8 – 26.0 kW kW kW kW kW Units 23.0 31.0 37 28.
Boiler specifications 2 ecoTEC plus Technical data CH heat output range 80 °C flow/60 °C return 60 °C flow/40 °C return 50 °C flow/30 °C return 40 °C flow/30 °C return Category SEDBUK Band SAP Seasonal Efficiency Inlet gas working pressure required (G20, natural gas) Inlet gas working pressure required (G31, Propane) Connected load (if needed, related to stored charge/water heating) at 15 °C and 1013 mbar Exhaust mass rate at minimum thermal load (40 °C flow/30 °C return at maximum thermal load (80 °C flow
2 Boiler specifications 2.2 Dimensions 9 65 8 190 440 175 241 7 6 642 720 883 125 10 11 12 20 5 4 3 2 1 35 100 45 300 75 130 180 ecoTEC plus 630: 334 ecoTEC plus 637, ecoTEC plus 837: 368 35 100 5 4 3 2 1 Fig. 2.
Boiler specifications 2 2.4 Installation 14 14 1 13 1 2 2 3 13 4 3 4 5 5 12 6 12 11 10 10 7 8 9 Fig. 2.2 Function elements of combination boilers Legend: 1 Expansion vessel 2 Air intake pipe 3 Burner module 4 Ignition electrode 5 Fan 6 Diverter valve with by-pass 7 Pump 8 Aqua-Sensor 9 Electronics box 10 Pressure sensor 11 Hot water heat exchanger 12 Gas valve 13 Heat exchanger 14 Flue pipe connection 7 9 Fig. 2.
3 General requirements 3 General requirements 3.1 Preliminary remarks for room sealed appliances This appliance should only be installed in conjunction with either a Vaillant flue system or an alternative approved system (details of flue approval categories can be found in the technical section of the installation manual). Install the flue system as detailed in the separate flue installation instructions supplied with this boiler. 3.
General requirements 3 1 8 1 8 2 7 2 7 3 6 4 5 3 6 4 5 Fig. 3.1 Contents included with delivery of ecoTEC plus system boilers Fig. 3.2 Contents included with delivery of ecoTEC plus combination boilers DO NOT remove the boiler from the polystyrene base at this stage. DO NOT remove the boiler from the polystyrene base at this stage.
3 General requirements 1 7 2 6 i F 3.4 Installation site The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location must also provide adequate space for servicing and air circulation around the boiler.
General requirements 3 10 Flue pipe Danger! Vaillant appliances are certified only for use with genuine Vaillant flue pipes. Only use genuine Vaillant flue pipes. Malfunctions can occur if you use other accessories. These may result in damage and injury. You will find a list of genuine flue pipes in the Vaillant installation manual for flue pipes. The CE mark is valid only if the appliance is operated with Vaillant flue pipes. 40 1435 880 3.6 550 3.
3 General requirements 3.7 Flue termination The following details refer to both flue systems. a. The terminal must be located where the combustible substances can escape freely at all times. b. A plume of water vapour will sometimes be visible from the flue terminal. Positions where this could be a nuisance should be avoided. c.
General requirements 3 3.9 Electrical supply A 230 V, ~ 50 Hz single phase electricity supply fused to 3 Amp. must be provided in accordance with the latest edition of BS 7671 (IEE Wiring Regulations) and any other local regulations that may apply. In IE reference should be made to the current edition of the ETCI rules. The method of connection to the mains electricity supply must provide a means of completely isolating the boiler and its ancillary controls.
Vessel Volume [L] Initial system pressure (bar) 1.0 Pressure relief valve setting (bar) 1.5 3.0 Total water content of system litres 25 50 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 For system volumes other than those given above, multiply the system volume by the factor across 2.7 5.4 10.9 13.6 16.3 19.1 21.8 24.5 27.2 30.0 32.7 35.7 38.1 40.9 43.6 46.3 49.0 51.8 54.5 3.9 7.8 15.6 19.5 23.4 27.3 31.2 35.1 39.0 42.9 46.8 50.7 54.6 58.5 62.4 66.3 70.2 74.1 78.0 0.109 0.
Boiler installation sequence 4 20 – 5 mm either side of the boiler – 180 mm below the boiler – 165 mm* above the boiler when utilising the 100 mm outside diameter flue – 246 mm* above the boiler when utilising the 125 mm outside diameter flue – 500 mm in front of the boiler to enable easy access for servicing (may be provided by an opening door) 165 175 60/100 5 25 A A A 1065 4.1.1 Select position for boiler Refer to section 3.4 ‘Installation site’ for information regarding the appliance location.
4 Boiler installation sequence 4.2 Flue exit • If using rear flue mark the position of the air/flue duct and its circumference. Note Lift the boiler from either side at the bottom edge Other flue options Flue instructions for other flue systems such as vertical RSF flues, flues run to the side of the boiler and the use of additional bends etc. are detailed in the flue installation instructions provided with the boiler.
Boiler installation sequence 4 4.8 Gas connection Note With the spacer frame (Art. No 308 650), the pipes can be fitted vertically upwards behind the appliance. The distance of the appliance from the wall thus increases by 65 mm. Danger! The gas connection may only be made by a competent person. The legal directives and the local regulations for gas supply companies must be observed. • Fit the union nut (6) and the compression olive (5) to the pre-formed tail provided with ecoTEC plus appliances (7).
4 Boiler installation sequence 4.10 Condensate drain pipe bar 1 2 7 4 a 6 d c b 6 1 2 3 Internal stackpipe 3 Internal discharge system 5 7 Gulley Soakaway 3 4 5 Fig. 4.7 Installing the hot and cold water connection (ecoTEC pro combination boiler) Note Flush all foreign matter from the mains supply before connecting to the boiler. • Insert the seal (1) and connect the service valve (2) to the appliance cold water connection.
Boiler installation sequence 4 b)connecting into the internal discharge branch (e.g. sink waste or washing machine) with an external termination, the condensate discharge pipe should have a minimum diameter of 22 mm with no length restriction and should incorporate a trap with a 75 mm (3) (built into the boiler) seal. The connection should preferably be made down stream of the sink waste trap. If the connection is only possible upstream, then an air break is needed between the two traps.
4 Boiler installation sequence Caution! To ensure fumes do not escape through the syphon of the boiler the trap must be filled with water before the boiler is turned on. Therefore the discharge pipework should be installed so as not to interfere with the removal and refitting of the condensate trap, we recommend the outlet pressure release valve pipe supplied is not shortened. You must leave a bottom clearance of at least 180 mm below the condensate trap for removal and refitting.
Boiler installation sequence 4 Danger! This appliance must be earthed. • Feed the power supply flex into the appliance and the control panel through the cable clamps provided and tighten. Danger! Mains connection terminals L and N remain live even when the boiler on/off control is switched off. Note Do not connect any power voltage to the connections 7-8-9 or BUS (+,-). - + 7 89 L N 3 45 Note Ensure that all cords pass through the cable clamps in the rear of the control box and are securely fixed.
4 Boiler installation sequence 4.13.3 Electric board layout eBUS accessory connection Burner cable harness Accessory module connection Diagnosis via eBUS, vrnetDIALOG outer probe ext.
Boiler installation sequence 4 NTC return NTC flow Ignition electrode 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 in 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) X 20/9 blue (earth) X 2/16 black A X 2/7 pink B X 2/15 brown C Water pressure sensor X 2/8 blue D Diverter valve X 2/9 black X 2/11 red X 2/12 green Pump Aqua sensor X 2/4 orange X 2/3
4 Boiler installation sequence NTC return NTC flow Ignition electrode 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 in 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) X 20/9 blue (earth) X 2/10 black Hot water contact C1/C2 X 2/14 brown Pump Water pressure sensor X 2/9 black X 2/11 red X 2/12 green X 2/4 orange tank NTC connection X 2/10 black X2
Boiler installation sequence 4 4.14 Controls 4.14.1 Vaillant controls and accessories Controller Item no.
4 Boiler installation sequence 5 Commissioning Part I 4.16 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. This frost thermostat should be connected across the boiler terminals 3 and 4, in parallel with any external heating controls.
Commissioning Part I 5 5.4.1 Checking the filling pressure of the heating system 4 plus pro 3 i F P bar 1 2 2 1 bar Fig. 5.2 Filling device ecoTEC plus combination boiler Fig. 5.1 Checking the filling pressure of the heating system Note The ecoTEC appliances come with a manometer and a digital pressure indicator. The manometer allows you to quickly check whether the filling pressure is in target range or not even when the appliance is turned off.
5 Commissioning Part I 5.4.3 Filling the heating system in ecoTEC pro combination boilers and ecoTEC plus system boilers The ecoTEC pro combination boilers and the ecoTEC plus system boilers do not come with a filling device. In these appliances, water is filled in the heating system through a filling pipe provided onsite. • Join a hose between a cold water dispensing valve and the filling pipe of the heating system. • To fill, first open the cold water dispensing valve.
Commissioning Part I 5 5.7 Adjusting the pumping capacity 5.9 Checking the gas supply Only in ecoTEC plus boilers: The capacity of the two-stage pump can be adjusted to the requirements of the heating system. If needed, change the setting of the operating mode dependent pump speed under the diagnostic number “d.19” (see section 8.1.2). 5.9.1 Factory settings 5.8 Adjusting the by-pass The appliances have an adjustable by-pass valve. The pressure can be adjusted between 170 and 350 mbar. Approx.
5 Commissioning Part I Natural gas: DO NOT proceed with adjustment or attempt to put the unit into service if the inlet working pressure lies outside the 17–25 mbar range. 5.10 Refitting the case 2 LPG: DO NOT proceed with adjustment or attempt to put the unit into service if the inlet working pressure is lower than 37 mbar. 1 • Turn off the appliance, remove U gauge. • Tighten the test point screw and check for leaks.
Commissioning Part I 5 Functional checks (commissioning part II) 6 5.11 Adjusting the central heating output (range rating) The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the boiler, as follows: • Press the “i” and “+” buttons simultaneously. • Keep the “+” button pressed until “d.0” is displayed. Note The display runs from “d.0” to “d.99” before restarting at “d.0”. • Press the “i” button.
6 Functional checks (commissioning part II) 6.1.2 Heating • Switch on the appliance. • Make sure that there is a heating demand. • Press “i” to activate the status indicator. As soon as a heat demand is received, the appliance runs through the status indicators “S. 1” to “S. 3”, until the appliance is running correctly in normal mode and the display shows “S. 4”. plus pro Fig. 6.2 Display indicator during heating mode 6.1.3 Water heating (combination boilers only) • Switch on the appliance.
Functional checks (commissioning part II) 6 Inspection and maintenance 7 with the heat input (kW) and temperature difference between flow and return. • Leave the user instructions and the installation instructions with the user. 6.3 Vaillant warranty Vaillant provide a full parts and labour warranty for this appliance. The appliance must be installed by a suitably competent person in accordance with the Gas Safety (Installation and Use) Regulations 1998, and the manufacturer’s instructions.
7 Inspection and maintenance 7.1.2 Maintenance Before commencing any servicing or maintenance work, carry out an initial inspection of the system as follows: • Inspect the flue, pipework and electrical connections for indications of damage or deterioration. • Inspect the air supply and ventilation arrangements of the installation. • Check the heating and water system, in particular the condition of radiator valves, evidence of leakage from the heating system and dripping hot water taps. 7.1.
Inspection and maintenance 7 7.2 Servicing the burner module Caution! Damage to corrugated gas pipe! Under no circumstances must the burner module be suspended from the flexible corrugated gas pipe. 7.2.1 Removing the burner module The burner module consists of the burner, fan, gas valve und the gas supply (mixer tube). These four components make up the complete assembly, the burner module. Danger! There is danger of being injured or burnt by the burner module and at all components carrying water.
7 Inspection and maintenance • Check the burner surface for damage, replace the burner if necessary. • After checking/replacing the burner, re-assemble the burner module in the boiler as described in Section 7.2.4. 1 7.2.4 Refitting the burner module 1 2 3 4 Fig. 7.5 Replacing the burner door seal • Insert a new seal (1) in the burner door. Fig. 7.3 Cleaning the integral condensation heat exchanger Caution! The burner door seal (1) and the self-locking nuts on the burner module (Art. No.
Inspection and maintenance 7 • Reconnect the HT lead (5) and earth lead (6) to the spark electrode. • Insert the cables (8) on the fan motor and the cable (7) on the gas fitting. 7.3 Cleaning the condensate siphon 1 2 1 3 Fig. 7.9 Cleaning the condensate siphon Fig. 7.7 Refitting the gas supply • Reconnect the gas supply (3) to the gas valve, ensuring that a new sealing washer is used and correctly located. Use the spanner flat at the flexible gas line to hold the gas fittings.
7 Inspection and maintenance 8 Troubleshooting 7.4 Checking the expansion vessel • Fill out the Benchmark gas boiler commissioning checklist at the rear of this guide. 1 Fig. 7.10 Checking expansion vessel admission pressure Fig. 7.11 Function check Note It is not necessary to perform this check every year – a check every three years is sufficient. • • • • Ensure the boiler CH service valves are closed. Release the pressure from the boiler. Remove valve cap from expansion vessel charge point.
Troubleshooting 8 8.1.1 Status codes The status codes that you can see on the display provides information about the current operating condition of the appliance. The display of the status codes can be called as follows: plus pro Display Meaning Warm start (ecoTEC combination boilers only) / Charge hot water cylinder (ecoTEC system boilers only): S.20 Warmstart demand S.21 Fan running S.22 Pump running S.23 Ignition sequence S.24 Burner ignited S.25 Fan and water pump running S.26 Fan over run S.
8 Troubleshooting First Diagnostic level • Press the “i” and “+” keys simultaneously. The display shows “d.0”. • Use the “+” or “–” keys to scroll through the desired diagnostic numbers of the first diagnostic level (see table 8.2). • Press the “i” key. You can end the diagnostic mode as follows: • Press the “i” and “+” keys simultaneously. or • Do not press any key for approx. 4 minutes. The current heating flow temperature appears in the display again.
Troubleshooting 8 Second diagnostic level • As described above in the first diagnostic level, scroll through the diagnostic number d.97. • Change the displayed value to 17 (password) and press the “i” button. You are now in the second diagnostic level where all information from the first diagnostic level (see table 8.2) and the second diagnostic level (see table 8.3) is displayed. Display Meaning d.17 d.18 d.
8 Troubleshooting Display Meaning d.78 Display value/adjustable value Storage charging temperature limit (target flow temperature in storage mode, system boilers only) Heating operating hours Adjustment range in °C 55 to 90 (Factory setting: 80) in h1) d.
Troubleshooting 8 Code Meaning Cause F.25 Interruption in the compact thermal module cable harness Incorrect sensing of flame Compact thermal module cable harness defective F.27 F.28 Flame detector defective F.
8 Troubleshooting 9 Parts replacement 8.4 Test programs Special functions can be triggered on the appliances by activating various test programs. These programs are given in detail in the Table 8.5. • The test programs P.0 to P.6 will be started when “Power ON” is turned on and the “+” key is pressed for 5 s. The display shows “P.0”. • Press the “+” key to start counting the test number upwards. • Press the “i” to operate the appliance now and to start the test program.
Parts replacement 9 5 1 Fig. 9.1 Replacing burner Fig. 9.3 Gas fitting/fan screwed joint • Loosen the 4 screws (1) on burner, and remove the burner. • Mount the new burner with a new seal. Ensuring that the notch in the burner aligns with the burner viewing window. • Install the burner module as described in Section 7.2.4. • After completing the work, check for gas leaks and perform a function check (see section 7.6)! 9.3 Caution! Mount the gas valve and the fan in the same position as before.
9 Parts replacement 9.5 Replacing primary heat exchanger Danger! Before replacing the component, comply with the safety instructions in Section 9.1. 1 2 • Disconnect the appliance from the mains as described in Section 9.1, and close the service valve in the gas supply pipe. • Close the flow and return service valves and drain the appliance. • Remove the burner module as described under 7.2.1. • Remove the expansion vessel as described under 9.4.
Parts replacement 9 9.6 Replacing electronics and display Danger! Before replacing the component, comply with the safety instructions in Section 9.1. 1 2 3 Fig. 9.6 Primary heat exchanger holder • Disconnect the plug-in connection (2) of the thermal fuse in the primary heat exchanger. • Remove the three screws (3) on the primary heat exchanger holder. • Turn the holder to the side around the rivet (1), pull the primary heat exchanger downwards to the right and remove it from the appliance.
9 Parts replacement 10 Recycling and disposal 11 Vaillant service Settings 1 Natural gas (H) Propane Tolerance Tolerance CO2 after 5 min. full load mode with appliance front closed CO2 after 5 min. full load mode with appliance front removed Set for Wobbe-Index W0 CO value with full load Unit 9.2 ± 1,0 10.2 ± 0,5 Vol.–% 9.0 ± 1,0 10.0 ± 0,5 Vol.–% 15 < 250 22.5 < 250 kWh/m3 ppm Table 9.
Appendix Appendix Instructions for installation and servicing ecoTEC 51
839592_03 GB 03 2006
