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Vaillant EcoTEC Plus

Vaillant EcoTEC Plus

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Published by Pas Sommese
vaillant ecotec plus installation manual
vaillant ecotec plus installation manual

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Published by: Pas Sommese on May 11, 2013
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For the installerecoTEC plus 612ecoTEC plus 615ecoTEC plus 618ecoTEC plus 624ecoTEC plus 630ecoTEC plus 637ecoTEC plus 824ecoTEC plus 831ecoTEC plus 837ecoTEC pro 28ecoTEC pro 24
Instructions for installation and servicing
ecoTEC
Wall hung room sealed fan assisted condensing boiler
GB
 
2
Contents
Instructions for installation and servicing ecoTEC / 839592_09
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notes on the documentation . . . . . . . . . . . . . . . . 41.1.1 Applicable documents . . . . . . . . . . . . . . . . . . . . . . 41.1.2 Retention of documents . . . . . . . . . . . . . . . . . . . . 41.1.3 Safety instructions and symbols . . . . . . . . . . . . . 41.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 Gas council numbers . . . . . . . . . . . . . . . . . . . . . . . 5
2 Boiler specifications . . . . . . . . . . . . . . . . . . . . 6
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 General requirements . . . . . . . . . . . . . . . . . . . 10
3.1 Preliminary remarks for room sealedappliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . . 103.3 Contents included with delivery . . . . . . . . . . . . . 103.4 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.6 Flue pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.6.1 Standard 100 mm flue system . . . . . . . . . . . . . . . 133.6.2 Optional 125 mm flue system . . . . . . . . . . . . . . . . 133.7 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.8 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.9 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.10 Guide to system requirements . . . . . . . . . . . . . . 153.10.1 Water circulation system . . . . . . . . . . . . . . . . . . . 153.10.2 Filling and preparing heating system . . . . . . . . . 153.10.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . 153.10.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.10.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 153.11 Pump specifications . . . . . . . . . . . . . . . . . . . . . . . 153.11.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 153.11.2 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.11.3 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.12 Condensate trap. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Boiler installation sequence . . . . . . . . . . . . . . 17
4.1 Transporting the appliance . . . . . . . . . . . . . . . . . 174.2
Required minimum distances/assembly clearances . 18
4.2.1 Select position for boiler . . . . . . . . . . . . . . . . . . . 184.2.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2.3 Using boiler template . . . . . . . . . . . . . . . . . . . . . . 194.3 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.4 Fitting the boiler hanging bracket . . . . . . . . . . . 194.5 Installing the flue system . . . . . . . . . . . . . . . . . . . 204.6 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 204.7 Removing the front case . . . . . . . . . . . . . . . . . . . 204.8 General instructions for heating system . . . . . . 204.9 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.10 Cold water mains inlet and hot water outlet(ecoTEC combination boilers only) . . . . . . . . . . . 214.11 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . . 214.12 Heating connection . . . . . . . . . . . . . . . . . . . . . . . 224.12.1 Heating flow and return connection . . . . . . . . . 224.12.2 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 234.13 Connecting the flue system to the boiler . . . . . 234.14 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 234.14.1 General requirements . . . . . . . . . . . . . . . . . . . . . . 234.14.2 Connection to the main supply . . . . . . . . . . . . . . 244.14.3 Electric board layout . . . . . . . . . . . . . . . . . . . . . . . 254.15 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.15.1 Vaillant controls and accessories . . . . . . . . . . . . 284.15.2 External electrical controls . . . . . . . . . . . . . . . . . 284.15.3 Connection details for external time switchesand boiler terminal strip . . . . . . . . . . . . . . . . . . . . 284.15.4 Vaillant optional plug in timer accessories . . . . 284.15.5 Connection details using theVR 65 Control Center . . . . . . . . . . . . . . . . . . . . . . 284.16 Thermostatic radiator valves . . . . . . . . . . . . . . . 284.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 294.19 Anticycling ‘economiser’ control . . . . . . . . . . . . 294.20 Automatic pump spin control (APS). . . . . . . . . . 29
5 Commissioning Part I . . . . . . . . . . . . . . . . . . . 30
5.1 Preliminary electrical checks . . . . . . . . . . . . . . . . 305.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.3 Cold water supply (ecoTEC combinationboilers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4 Filling and bleeding the heating system . . . . . . 305.4.1 Checking the filling pressure of the heatingsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.2 ecoTEC plus combination boiler filling loop . . . 305.4.3 Filling the heating system in ecoTEC pro combi-nation boilers and ecoTEC plus system boilers . 315.4.4 Filling the heating system for the first time . . . 315.5 Initial system flush (“cold”) . . . . . . . . . . . . . . . . . 315.6 Filling the condensate siphon . . . . . . . . . . . . . . . 325.7 Adjusting the pumping capacity . . . . . . . . . . . . . 325.8 Adjusting the by-pass . . . . . . . . . . . . . . . . . . . . . . 325.9 Checking the gas supply . . . . . . . . . . . . . . . . . . . . 325.9.1 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.9.2 Gas inlet working pressure . . . . . . . . . . . . . . . . . 335.9.3 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . 335.10 Refitting the case. . . . . . . . . . . . . . . . . . . . . . . . . . 345.11 Adjusting the central heating output(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Functional checks (commissioning part II). . 35
6.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . 356.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.1.2 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.1.3 Water heating (combination boilers only) . . . . . 356.1.4 Final flush of the heating system (“hot”) . . . . . 356.2 Handing over to the user . . . . . . . . . . . . . . . . . . . 366.3 Vaillant warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Inspection and maintenance . . . . . . . . . . . . . 36
7.1 Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 367.1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 367.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
 
3
Instructions for installation and servicing ecoTEC / 839592_09
Contents
7.1.3 Overview of the inspection and maintenancetasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.1.4 Functional check of boiler operation . . . . . . . . . 387.2 Servicing the burner module . . . . . . . . . . . . . . . . 387.2.1 Removing the burner module . . . . . . . . . . . . . . . 387.2.2 Cleaning the integral condensation heatexchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . . 397.2.4 Refitting the burner module . . . . . . . . . . . . . . . . 397.3 Cleaning the condensate siphon . . . . . . . . . . . . . 407.4 Checking the expansion vessel . . . . . . . . . . . . . . 407.5 Recommissioning the boiler. . . . . . . . . . . . . . . . . 417.6 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1 Logical fault finding procedure . . . . . . . . . . . . . . 418.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . 428.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458.4 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478.5 Resetting parameter to factory settings. . . . . . 47
9 Parts replacement . . . . . . . . . . . . . . . . . . . . . 47
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 479.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . . 479.3 Replacing fan or gas valve . . . . . . . . . . . . . . . . . . 479.4 Replacing expansion vessel . . . . . . . . . . . . . . . . . 489.5 Replacing primary heat exchanger . . . . . . . . . . 499.6 Replacing electronics and display . . . . . . . . . . . 499.7 Check CO
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content and if necessary set(air-ratio adjustment) . . . . . . . . . . . . . . . . . . . . . . 50
10 Recycling and disposal . . . . . . . . . . . . . . . . . . 5011 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . . 50Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Benchmark gas boiler commissioning checklist . . . . . 52

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