Vaillant ecoTEC PLUS SERIES Installation And Maintenance Manual
Wall hung room sealed fan assisted condensing boiler
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- Installation and maintenance instructions manual (92 pages) ,
- Instructions for installation and servicing (52 pages) ,
- Setup instructions (44 pages)
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Summary of Contents for Vaillant ecoTEC PLUS SERIES
- Page 1 For the installer Installation and maintenance manual 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 824 ecoTEC plus 831 ecoTEC pro 828...
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Page 2: Table Of Contents
....4.14.6 Vaillant optional plug in timer accessories . . . General requirements .... - Page 3 Contents 6.1.4 Final rinsing of the heating system (“hot”). . . Handing over to the user ....Inspection and maintenance ... . 38 Initial inspection.
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Page 4: Introduction
1 Introduction Introduction ecoTEC 800 range The ecoTEC 800 range is a fully automatic, wall mount- Notes on the documentation ed, room sealed condensing (high efficiency) combina- The following information is intended to help you tion boiler for central heating and domestic hot water. throughout the entire documentation. -
Page 5: Ce Mark
The appliances satisfy the basic requirements of the effi- ciency directive (92/42/EEC) as condensing appliance. Fig. 1.1 Declaration of conformity Vaillant Ltd. supports the Benchmark initiative. In the information pack, you will find a Benchmark Logbook. It is very important that... -
Page 6: Boiler Specifications
2 Boiler specifications Boiler specifications Technical data ecoTEC plus Technical data Units CH heat output range 80 °C flow/60 °C return 4.0 – 12.0 4.0 – 15.0 6.0 – 18.0 8.7 – 24.0 10.0 – 30.0 60 °C flow/40 °C return 4.1 –... - Page 7 Boiler specifications 2 ecoTEC plus ecoTEC pro Technical data Units CH heat output range 80 °C flow/60 °C return 6.0 – 18.0 8.7 – 24.0 8.7 – 24.0 60 °C flow/40 °C return 6.1 – 18.6 9.0 – 24.7 9.0 – 24.7 50 °C flow/30 °C return 6.3 –...
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Page 8: Dimensions
2 Boiler specifications Dimensions Fig. 2.1 Dimensions in mm Legend: Heating return pipe Ø 22 mm 2 Cold water connection Ø 15 mm (only 800 series) 3 Gas connection Ø 15 mm 4 Hot water connection Ø 15 mm (only 800 series) 5 Heating flow pipe Ø... -
Page 9: Installation
Boiler specifications 2 Installation Fig. 2.3 Function elements of 600 series Legend: Fig. 2.2 Function elements of 800 series Diaphragm expansion tank 2 Air intake pipe Legend: 3 Compact thermal module Diaphragm expansion tank 4 Ignition electrode 2 Air intake pipe 5 Rapid-action fan 3 Compact thermal module 7 Pump... -
Page 10: Type Plate
This appliance shall only be installed in conjunction with gas pipework up to 28 mm (R1) in domestic premises a Vaillant air flue duct. Install the flue system as detailed (2nd family gas). in the separate flue installation instructions supplied BS 7593: Treatment of water in domestic hot water cen- with this boiler. - Page 11 General requirements 3 Fig. 3.1 Scope of delivery for ecoTEC plus 600 series Fig. 3.2 Scope of delivery for ecoTEC plus 800 series DO NOT remove the boiler from the polystyrene base at DO NOT remove the boiler from the polystyrene base at this stage.
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Page 12: Installation Site
3 General requirements Installation site Please note the safety instructions below before choos- ing where to install the heater: Caution! Do not install the appliance in rooms prone to frost. In rooms with aggressive steam or dust, the appliance must be operated independent of the ambient air. -
Page 13: Gas Supply
Danger! Fig. 3.5 Art. No. 303 900 Vaillant appliances are certified only with genu- ine Vaillant flue pipes. Only use genuine Vaillant flue pipes. Malfunctions can occur if you use 3.6.2 Optional 125 mm flue system other accessories. These may result in damage A concentric flue system of 125 mm outside diameter is and injury. -
Page 14: Flue Termination
3 General requirements Flue termination Note The following details refer to both flue systems. In addition, the terminal should not be nearer a. The terminal must be located where the combustible than 150 mm to an opening in the building fab- substances can escape freely at all times. -
Page 15: Electrical Supply
General requirements 3 Electrical supply 3.10.3 Pressure relief valve A 230 V, ~ 50 Hz single phase electricity supply fused to A pressure relief valve is provided with the boiler. This 3 Amp. must be provided in accordance with the latest safety device is required on all sealed C.H. -
Page 16: Pump Specifications
3 General requirements 4 Boiler installation sequence Boiler installation sequence 3.11 Pump specifications 3.11.1 Circulating pump Required minimum distances/assembly clear- only ecoTEC plus: ances The circulating pump is included in the boiler. The resid- ual pump discharge height depending on the overflow valve is shown in Fig. -
Page 17: Select Position Of Boiler
Boiler installation sequence 4 4.1.1 Select position of boiler Flue hole (80/125 mm Minimum Clearances Refer to section ‘Boiler location’ for information regard- flue system) Reqd. ing the appliance location. In general the boiler must be Flue hole positioned such that: (60/100 mm •... -
Page 18: Cutting Through The Wall
4 Boiler installation sequence Cutting through the wall Removing the housing • If needed, cut an opening for the flue pipe through the wall. Installing appliance holder Fig. 4.4 Removing/fixing the housing To disassemble the front housing of the appliance, pro- ceed as follows: Fig. -
Page 19: Gas Connection
Boiler installation sequence 4 Gas connection nuts in this position of the maintenance tap. • The diameter of the conduit (7) is 15 mm. Connect a Note gas supply pipe of not less than 15 mm diameter to the With the balancing frame (Art. No 308 650), copper tail. -
Page 20: Heating Connection
4 Boiler installation sequence ecoTEC plus, 800 series Fig. 4.8 Installing the heating flow and return connection for ecoTEC plus, 800 series Fig. 4.7 Installing the hot and cold water connection (ecoTEC • Insert the packing (1) and screw in the maintenance pro) tap (2) at the return connection of the appliance. -
Page 21: Drain Pipe On The Pressure Control Valve
Boiler installation sequence 4 ecoTEC pro • Insert a union nut (4) and a pinching ring (3) on both conduit elbows (5). The diameter of the conduits is 22 mm. • Insert the conduit elbows until the stopper in the maintenance taps. -
Page 22: Condensate Drain Pipe
4 Boiler installation sequence 4.11 Condensate drain pipe b) connecting into the internal discharge branch (e.g. sink waste or washing machine) with an external termina- tion, 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) seal. -
Page 23: Connection To The Main Supply
Boiler installation sequence 4 Danger! Mains connection terminals L and N remain live even when the boiler on/off control is switched off. - + 7 8 9 3 4 5 Note Do not connect any power voltage to the con- nections 7-8-9. -
Page 24: Electric Board Layout
4 Boiler installation sequence 4.13.3 Electric board layout Fig. 4.15 Connection wiring ecoTEC Installation and maintenance manual ecoTEC... - Page 25 Boiler installation sequence 4 backflow 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 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 26 4 Boiler installation sequence backflow 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)
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Page 27: Connection Of Programmable Thermostats
Smiths Timeguard ProgramaSTAT PRT11, PRT17 Sunvic TLX 6501 Sunvic TLX RFP, TLX RFD Vaillant VRT 230, 220 Fig. 4.18 Connection details for programmable thermostats 4.14 Controls (800 series) 4.14.1 External electrical controls 4.14.2 Connection of external controls The boiler terminals 3, 4 and 5 are for connecting exter- nal electrical controls such as a time switch and/or room 4.14.3 Connection details for programmable room... -
Page 28: Connection Of Time Switches
4 Boiler installation sequence 4.14.4 Connection of time switches ACL Drayton Tempus 1, Tempus 2 Lyfestyle LP111, LP711 ACL Drayton Switchmaster SM300 ACL Drayton Switchmaster 980 Danfoss Randall 103 Series Danfoss Randall Set 1E, TS975 Danfoss Randall TS715 Grässlin Towerchron QE1, QM1 Honeywell ST610A, ST6100C... -
Page 29: Connection Details For External Time Switches
4.20). 4.18 Circulating pump The boiler incorporates a built in circulating pump that is 4.14.6 Vaillant optional plug in timer accessories fully prewired (no additional wiring is necessary). The Refer to the instructions supplied with the optional pump incorporates an automatic overrun period after accessories for connection details. - Page 30 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Cylinder thermostat Room thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC ACL Drayton Digistat 2, 3, 4 Tower CS1 ACL Drayton RTS 1, 2 Honeywell L641...
- Page 31 External wiring centre/junction box* *Do not use pre-wired printed circuit board type not used Cylinder thermostat Room thermostat ACL Drayton HTS3 Vaillant VRT 9090 Danfoss Randall ATC ACL Drayton Digistat 2, 3, 4 Tower CS1 ACL Drayton RTS 1, 2 Honeywell L641...
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Page 32: Commissioning Part I
5 Commissioning Part I Commissioning Part I 5.4.1 Checking the filling pressure of the heating system Preliminary electrical checks plus Check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity. Gas supply The complete gas installation including the gas meter must be inspected, checked for leaks and purged in... -
Page 33: Ecotec Plus Filling Device (800 Series)
Commissioning Part I 5 5.4.2 ecoTEC plus filling device (800 series) The ecoTEC plus appliance from the 800 series will be delivered with a filling device. Fig. 5.3 Double check valve detached while heating 5.4.3 Filling the heating system in ecoTEC pro and ecoTEC plus (600 series) The ecoTEC pro appliances and the ecoTEC plus appli- ances from the 600 series do not come with a filling... -
Page 34: Rinsing The Heating System For The First Time ("Cold")
5 Commissioning Part I system is completely filled with water, all vent valves Filling the condensation water siphon have been shut and the manometer pointer is in the centre of the dark grey area. Ventilate the heating pump by loosening the central screw. Close the filling valve and the cold water dispensing valve. -
Page 35: Adjusting The Pumping Capacity
Commissioning Part I 5 Adjusting the pumping capacity Checking the gas setting Only in ecoTEC plus: 5.9.1 Factory setting The capacity of the two-stage pump can be adjusted to the requirements of the heating system. If needed, Caution! change the setting of the operating mode dependent Before operating the boiler check the data pump speed under the diagnosis point “d.12”... -
Page 36: Checking The Gas Rate
If the measured gas flow volume lies outside the tolerance limits specified in Table 5.1, do not • Press the “i” button. The “=” symbol is displayed. The operate the appliance and inform the Vaillant part load setting is now displayed in kW. Customer Service. -
Page 37: Gas Changeover
Art. No. xxx xxx. To reset the appliance from propane gas to nat- 6.1.2 Heating ural gas mode, you need the Vaillant changeo- • Switch on the appliance. ver set Art. No. yyy yyy. • Make sure that there is a heat request. -
Page 38: Water Heating (Only 800 Series)
Further information can be obtained from Sentinel, Betz Dearborn Ltd., Tel: 0151 4951861, or Only genuine Vaillant spare parts may be used for Fernox, Alpha–Fry technologies. Tel: 0870 6015000. inspections, maintenance and repair work to ensure the • Refit the boiler casing (see Section 5.10). -
Page 39: Safety Instructions
Inspection and maintenance 7 7.1.2 Safety instructions Note Important: The boiler is fitted with a combustion analysis Before starting any maintenance work: test point. A suitable combustion analyser can • Isolate the mains electricity supply by disconnecting be connected to this point to establish the com- the plug at the socket outlet (if there is only an isolat- bustion performance of the boiler. -
Page 40: Overview Of The Maintenance Tasks
7 Inspection and maintenance 7.1.4 Overview of the maintenance tasks carry out for: No. Activity mainte- inspection nance Disconnect the device from the mains supply, close the gas supply and maintenance taps, depressurise the device (observe the manometer) Dismantle compact thermal module Clean integral condensation heat Check whether the burner is dirty Install compact thermal module. -
Page 41: Cleaning The Integral Condensation Heat Exchanger
Inspection and maintenance 7 Fig. 7.1 Dismantle air intake pipe Fig. 7.3 Dismantling compact thermal module • Remove the screw (1) and remove the air intake pipe • Disconnect HT lead (5) and earth lead (6) from spark (2) from the suction nozzle. electrode. -
Page 42: Checking The Burner
7 Inspection and maintenance 7.2.4 Installing the compact thermal module Fig. 7.6 Replacing silicone gaskets • Insert a new silicone gasket (1) in the burner door. Caution! The silicone gasket (1) in the burner door (Art. No.: 981 046) must be always replaced during maintenance and servicing. -
Page 43: Cleaning The Condensation Water Siphon
Inspection and maintenance 7 • Remove the lower section (1) of the condensate water siphon by turning the bayonet catch in anticlockwise direction. • Clean the siphon lower section by rinsing it out with water. • Fill the lower section with water until about 10 mm below the upper edge. -
Page 44: Recommissioning The Boiler
7 Inspection and maintenance 8 Troubleshooting Recommissioning the boiler 3. Check that the gas supply to the boiler is on, that it • Carry out electrical safety checks. has been correctly purged and that an inlet pressure • Turn on the electrical supply. of 20 mbar is available at the gas valve. -
Page 45: Diagnosis Codes
Troubleshooting 8 8.1.2 Diagnosis codes Display Meaning In the diagnosis mode, you can change certain parame- 600 and 800 series (heating mode): ters or display more information. S.00 No heat required The diagnosis information is divided into two diagnosis S.01 Fan start levels. - Page 46 8 Troubleshooting Display Meaning Display value/adjustable value d.00 Heating partial load Adjustable heating partial load in kW (factory setting: max. output) d.01 Water pump return water time for heating mode 1 - 60 min (factory setting: 5 min) d.02 Max. blocking time heating at 20 °C Flow temperature 2 - 60 min (factory setting: 20 min) d.03 Drinking water flow temperature reading (800 series...
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Page 47: Error Codes
Troubleshooting 8 Display Meaning Display value/adjustable value d.61 Number of fuel automatic system faults Number of successful ignitions in the last attempt d.64 Average ignition time in seconds d.65 Maximum ignition time in seconds d.68 Successful ignitions in the first attempt Quantity d.69 Successful ignitions in the second attempt... - Page 48 8 Troubleshooting Code Meaning Cause F.00 Flow–NTC: Flow–NTC cable defective/broken, NTC faulty NTC broken, NTC cable broken, Defective connection at NTC, Defective connection at electronics F.01 Return–NTC: Return–NTC cable defective/broken, NTC faulty NTC broken, NTC cable broken, Defective connection at NTC, Defective connection at electronics F.02 Drinking water outlet probe stopped (<-10 °C)
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Page 49: Test Programs
Troubleshooting 8 Replacing components 9 Test programs Important: Special functions can be triggered on the appliances by Before starting any maintenance work: activating various test programs. Isolate the mains electricity supply by discon- These programs are given in detail in the necting the plug at the socket outlet (if there is Table 8.4. -
Page 50: Replacing Fan Or Gas Fittings
9 Replacing components • Mount the new burner with a new gasket. Make sure that the nose on the burner window grips onto the gasket in the groove in the burner. • Install the compact thermo module as described in Section 7.2.4. -
Page 51: Replacing Primary Heat Exchanger
Replacing components 9 Replacing primary heat exchanger Danger! Before replacing the component, comply with the safety instructions in Section 9.1. • Disconnect the appliance from the mains as described in Section 9.1, and close the maintenance tap in the gas supply pipe. •... -
Page 52: Replacing Electronics And Display
9 Replacing components Replacing electronics and display Danger! Before replacing the component, comply with the safety instructions in Section 9.1. • Comply with the assembly and installation manuals provided with the spare parts. Replacing display or electronics If you are replacing only one of the two components, the parameter adjustment functions automatically. -
Page 53: Check Co 2 Content And If Necessary Set (Air-Ratio Adjustment)
Replacing components 9 Check CO content and if necessary set (air- Note ratio adjustment) Only for natural gas: Adjust only in increments of 1/8 turn and wait approx. 1 minute after each adjustment until the value stabilises. Only for liquid gas: Adjust only in very small increments (approx. -
Page 54: Recycling And Disposal
10.1 Appliance The Vaillant gas wall heater, ecoTEC, consists 92 % of metallic materials which can be melted down again at iron and steel works and therefore can be recycled almost any number of times. - Page 55 Installation and maintenance manual ecoTEC...