Vaillant ecoTEC plus VU Series Installation And Maintenance Instructions Manual
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Vaillant ecoTEC plus VU Series Installation And Maintenance Instructions Manual

Vaillant ecoTEC plus VU Series Installation And Maintenance Instructions Manual

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For the competent person
Installation and maintenance instructions
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40   D-42859 Remscheid
Telefon 021 91 18‑0   Telefax 021 91 18‑28 10
[email protected]   www.vaillant.de
Installation and maintenance instructions

ecoTEC plus

VU
GB
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Summary of Contents for Vaillant ecoTEC plus VU Series

  • Page 1: Ecotec Plus

    Installation and maintenance instructions For the competent person Installation and maintenance instructions ecoTEC plus Publisher/manufacturer Vaillant GmbH Berghauser Str. 40   D-42859 Remscheid Telefon 021 91 18‑0   Telefax 021 91 18‑28 10 [email protected]   www.vaillant.de...

  • Page 2: Table Of Contents

    Decommissioning the product ......28 Reading off the filling pressure ......17 Recycling and disposal........28 Preventing low water pressure ......18 Vaillant customer service ......... 29 Filling and purging the heating installation ..18 12.1 Guarantee............29 Flushing the heating installation for the first 12.2...
  • Page 3 Contents Opening of the flue pipe........41 Positioning of the opening of a fan-supported flue gas guiding............ 41 Text from BS 5440-1 on fan-supported flue gas guiding............42 Opening of the flue pipe below eaves and balconies ............42 Technical data............ 42 Index ...................

  • Page 4: Safety

    1 Safety Safety Any other use that is not specified in these instructions, or use beyond that specified in Action-related warnings this document shall be considered improper use. Any direct commercial or industrial use Classification of action-related warnings is also deemed to be improper. The action-related warnings are classified in accordance with the severity of the possible Caution.
  • Page 5 Safety 1 1.3.4 Risk of death due to blocked or 1.3.9 Risk of death due to lack of safety leaking flue gas routes devices Installation errors, damage, tampering, unau- The schematic drawings included in this doc- thorised installation sites or similar can cause ument do not show all safety devices re- flue gas to escape and result in a risk of pois- quired for correct installation.

  • Page 6: Regulations (Directives, Laws, Standards)

    1 Safety ▶ During repair work, do not apply any leak are greater than 60 °C. Young children and elderly persons are particularly at risk, even detection sprays or liquids to the covering at lower temperatures. cap on the filter of the Venturi. ▶...
  • Page 7 Safety 1 – BS 7593 Code of practice for treatment of manual handling assessment charts (MAC) tool. water in domestic hot water central heating systems. In addition where no specific instructions are – BS 12831 Heating systems in buildings. given then reference shall be made, but not Method for calculating design heat load.

  • Page 8: Notes On The Documentation

    Serial number for identification; 7th to 16th digits = Applicability of the instructions product article number These instructions apply only to: VU… Vaillant gas-fired wall-hung boiler for heating Product article number ecoTEC plus Product description VU GB 656/4‑5 0010004140...

  • Page 9: Installation

    Installation 4 Installation Product dimensions and connection dimensions Unpacking the product Remove the product from its box. Ø 80/125 Remove the protective film from all parts of the product. Checking the scope of delivery ▶ Check that the scope of delivery is complete and intact. 4.2.1 Scope of delivery Num-...

  • Page 10: Minimum Clearances And Installation Clearances

    4 Installation Wall-mounting the product Flue gas connection, Expansion relief valve 80/125 diameter connection Hanging bracket Condensate discharge connection Gas pipe, 25 mm dia- Flow drain opening meter, gas connection Filling connection option R1“ Expansion vessel con- (combined filling and nection emptying valve) Heating return connec-...

  • Page 11: Removing Or Installing The Front Casing

    Installation 5 Removing or installing the front casing You must only start up the product if a sufficiently dimen- sioned low loss header has been installed between the heat 4.9.1 Removing the front casing generation circuit and the heating circuit or cylinder charging circuit.

  • Page 12: Gas Installation

    5 Installation 5.1.2 Cylinder priority switching via low loss one cylinder charging circuit) without the need for special ac- cessories. If several circuits are required, special accessor- header ies and/or controllers are required. The product's remain- ing feed head for the low loss header is sufficient. You can individually design the cylinder charging circuit connection downstream of the low loss header (cylinder size, cylinder charging pump size, etc.).

  • Page 13: Hydraulics Installation

    Installation 5 5.3.1 Connecting the heating flow and heating return ▶ Install the gas line without tension in accordance with the recognised rules of technology. ▶ Make sure that the existing gas meter is capable of Install service valves properly at the flow connection (1) passing the rate of gas supply required.

  • Page 14: Installing And Connecting The Flue Pipe

    5 Installation Electrical installation Danger! Risk of death from electric shock as a res- ult of an improper electrical connection! An improper electrical connection may neg- atively affect the operational safety of the product and result in material damage or per- sonal injury.
  • Page 15 Installation 5 5.5.1.2 Closing the electronics box 10. Plug the ProE plug into the associated PCB slot. Close the cover (2) by pushing it downwards onto the 5.5.4 Installing the controller electronics box (3). ▶ Install the controller if necessary. Ensure that all of the clips (1) audibly click into the brackets.

  • Page 16: Start-Up

    6 Start-up 5.5.8.1 Using the auxiliary relay Switching on the product ▶ Connect an additional component directly to the integ- Set the product's main switch to 1. rated auxiliary relay using the grey plug on the PCB. ◁ The basic display appears on the display. Carry out the wiring.

  • Page 17: Checking And Treating The Heating Water/Filling And Supplementary Water

    Start-up 6 Checking and treating the heating Caution. water/filling and supplementary water Risk of material damage if the heating water is treated with unsuitable frost or Caution. corrosion protection agents. Risk of material damage due to poor-qual- Frost and corrosion protection agents may ity heating water cause changes in the seals, noises during ▶...

  • Page 18: Preventing Low Water Pressure

    6 Start-up If the heating installation is full, the indicator on the pressure 13. Fill with water until the required filling pressure is gauge must point to the upper half of the grey area when the reached. heating installation is cold in order to ensure that it operates 14.

  • Page 19: Filling The Condensate Trap

    Start-up 6 Filling the condensate trap Conditions: The product design is compatible with the local gas group ▶ Danger! Proceed as described below. Risk of poisoning due to escaping flue 6.10.2 Checking the leak-tightness of the flue gas gas. system and for flue gas recirculation An empty or insufficiently filled condensate trap may allow flue gas to escape into the Check that the flue gas system is intact, in accordance...
  • Page 20 6 Start-up Conditions: Gas flow rate not in the permissible range Conditions: Gas flow pressure not in the permissible range ▶ Check all of the piping and ensure that the gas flow rates Caution. are correct. Risk of material damage and operating ▶...

  • Page 21: Checking Function And Leak-Tightness

    ▶ If this is the case, inform Vaillant Customer Service. Close the drain valve. ▶ Install the front casing. (→ Page 11) Fill the heating system again with water as de- scribed in "Filling and purging the heating installation"...

  • Page 22: Adapting The Unit To The Heating Installation

    7 Adapting the unit to the heating installation Re-fill the system until the system design pressure of 0,1 MPa (1,0 bar) is attained. Note The actual reading on the digital pressure gauge should ideally be 0,05 MPa (0,5 bar) plus an additional pressure corresponding to the highest point of the system above the base of the boiler –...

  • Page 23: Setting The Maximum Flow Temperature

    Adapting the unit to the heating installation 7 the cylinder charging and heating mode target values. This Setting the maintenance interval prevents the living rooms from overheating. If there is a heat If you set the maintenance interval, the maintenance mes- demand, the pump is switched on every 25 minutes for 5 sage SEr appears in the display after a configurable number minutes once the overrun time has elapsed.

  • Page 24: Inspection And Maintenance

    If you do not use cer- tervals, may impair the operational safety of tified Vaillant original spare parts for maintenance or repair the product and lead to injuries and material work, this voids the conformity of the product. We therefore damage.

  • Page 25: Cleaning The Heat Exchanger

    Inspection and maintenance 8 Cleaning the heat exchanger Use the main switch to switch off the product. Close the gas isolator cock. Protect the folded down electronics box against sprayed Remove the front casing. (→ Page 11) water. Tilt the electronics box forward. Use vinegar (max.

  • Page 26: Checking The Burner

    8 Inspection and maintenance – Checking the burner Tightening torque: 6 Nm Cleaning the air separation system 8.8.1 Cleaning or replacing the filter in the air separator Unscrew the brass cover (1) on the steel casing (3). Pull the filter (2) up and out. Check the surface of the burner for damage.

  • Page 27: Installing The Compact Thermal Module

    Troubleshooting 9 Installing the compact thermal module 8.11 Checking the pre-charge pressure of the external expansion vessel Depressurise the heating installation. Measure the pre-charge pressure of the expansion ves- sel at the vessel valve. Fill the expansion vessel with air at a pre-charge pres- sure of less than 0.075 (0.75 bar) according to the static head of the heating installation.

  • Page 28: Querying The Fault Memory

    10 Decommissioning the product Querying the fault memory Remove the burner. Fit the new burner with a new seal. The product has a fault memory. You can use this to query Make sure that the cutouts in the seal and the burner the last ten faults that occurred in chronological order.

  • Page 29: 12 Vaillant Customer Service

    – Registering with us Registration is simple. Just complete the Guarantee Regis- tration Card and return to Vaillant within 30 days of installa- tion. Your details will then be automatically registered within the Vaillant scheme. –...

  • Page 30: Appendix

    Appendix Appendix Overview of diagnostics codes Default set- Own setting Code Parameter Values or explanations ting Heating partial load, adjustable val- Adjustable heating partial load Approx. 70% ues in kW of the max- imum output Internal heating pump overrun time 2 …...
  • Page 31 Appendix Default set- Own setting Code Parameter Values or explanations ting D.26 Internal accessory relay at X6 (pink 1 = Circulation pump plug) 2 = Second external pump 3 = Cylinder charging pump 4 = Flue non-return flap/extractor hood 5 = External gas valve 6 = External fault message D.27 Switching accessory relay 1 for ac-...

  • Page 32: B Inspection And Maintenance Work - Overview

    Appendix Default set- Own setting Code Parameter Values or explanations ting D.72 Pump overrun after cylinder charging Adjustable from 0 to 600 seconds 80 seconds D.75 Max. charging time for domestic hot 20 - 90 min 45 minutes water cylinder without independent control system D.76 Unit variant: Device-specific number...

  • Page 33: C Status Codes - Overview

    Appendix Mainten- ance Inspection (At least Work (annual) every two years) Check the gas flow pressure at maximum heat input. If the gas flow pressure is not within the correct range, carry out maintenance work. Check the CO₂ content (the air ratio) of the product and, if necessary, adjust it. Keep a record of this.

  • Page 34: D Overview Of Fault Codes

    Appendix Status code Meaning S.21 DHW mode: Fan start-up S.22 DHW mode: Pump pre-run S.23 DHW mode: Ignition S.24 DHW mode: Burner on S.25 DHW mode: Pump/fan overrun S.26 DHW mode: Fan overrun S.27 DHW mode: Pump overrun S.28 Hot water burner anti-cycling time Special cases S.30 Room thermostat (RT) is blocking heating mode...
  • Page 35 Appendix Code Meaning Cause F.22 Safety switch-off: Low water pressure No or insufficient water in the product, water pressure sensor defective, cable to pump or water pressure sensor loose/not connected/defective F.23 Safety switch-off: Temperature difference too Pump blocked, insufficient pump output, air in product, flow and return great NTC connected the wrong way round F.24...

  • Page 36: E Connection Diagram

    Appendix Connection diagram brown Cylinder thermostat (accessory) black "C1/C2" black orange Cylinder sensor violet black Water pressure sensor green green signal Flow sensor black blue 1 Earth black 2 Hall signal grey 4 PWM signal 5 + 24 V natural black Flow sensor blue...
  • Page 37 Appendix 230 V~ Auxiliary relay (can be adjusted under D.26) Internal pump Cylinder charging pump Option: Ext. controller/room thermostat 3-4 (Contact) Mains input Option: Ext. controller/room thermostat 7-8-9 pink (continuous, analogue) Option: Bus connection (controller/digital room therm.) Option: Contact thermostat Earth Earth Plug for controller accessory...

  • Page 38: F Commissioning Checklist

    Appendix Commissioning Checklist Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the completed in full. www.centralheating.co.uk © Heating and Hotwater Industry Council (HHIC) Installation and maintenance instructions ecoTEC plus 0020029173_04...
  • Page 39 Appendix GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
  • Page 40 Appendix SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ²...

  • Page 41: G Opening Of The Flue Pipe

    Appendix Opening of the flue pipe D, E Positioning of the opening of a fan-supported flue gas guiding Minimum dimen- Installation site sions Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm Horizontally to an opening, air bricks, opening windows, etc., that can be opened.

  • Page 42: H Text From Bs 5440-1 On Fan-Supported Flue Gas Guiding

    Appendix Text from BS 5440-1 on fan-supported flue gas guiding BS 5440–1: It is recommended that the fanned flue gas system terminal is positioned as follows: – At least 2 m from an opening in the building directly opposite, and –...
  • Page 43 Appendix Technical data – General VU GB 656/4‑5 Approved unit category Gas connection, boiler side 1″ Flow/return heating connections, inside thread, boiler 1″ side Flow/return heating connections, outside thread, boiler 1,5″ side Air/flue gas connection 80/125 mm Gas connection pressure, G20 natural gas 2.0 kPa (20.0 mbar) Gas flow at 15 °C and 1013 mbar (based on hot water...

  • Page 44: Index

    Index Index Gas connection ..............12 Gas ratio setting ..............19 Air index setting..............20 Handing the product over to the operator......23 Air separator................ 26 Air separator, filter ............... 26 Handling ................9 Heat exchanger ..............25 Air/flue pipe ................. 14 Air/flue pipe, installed ............
  • Page 45 Index Unloading the box ..............9 Voltage .................. 5 Wall-mounting the product ..........10 0020029173_04 ecoTEC plus Installation and maintenance instructions...
  • Page 48 0020029173_04   26.03.2015 Vaillant Ltd Nottingham Road   Belper   Derbyshire   DE56 1JT Telephone 44 84 56 02 29 22   Vaillant Service Solutions 44 807 06 06 07 77 Spares Technical Enquiries 44 17 73 59 66 15 [email protected]   [email protected] www.vaillant.co.uk © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with...

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