Installation and maintenance instructions For the competent person Installation and maintenance instructions ecoTEC plus VU VUW GB, IE
Table of Contents i BEFORE PROCEEDING - ENSURE BOILER IS CORRECT FOR GAS GROUP SUPPLIED! Table of Contents 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Notes on the documentation .....................................4 Storing documents ..........................................................4 Symbols used ....................................................................4 Applicability of the instructions ...................................4 Identification plate.....................................................
Table of Contents 10.7 10.7.1 10.7.2 10.7.3 10.8 10.8.1 10.9 10.10 10.11 10.11.1 10.11.2 Filling and purging the heating installation ............41 Filling the heating installation .................................. 42 Purging the heating system ....................................... 42 Flushing the system for the first time ("cold") ..... 42 Avoiding low water pressure ...................................... 43 Top up VUW boilers using a filling device ...............
1 Notes on the documentation 1 Notes on the documentation Article number Gas Council Number ecoTEC plus 612 (VU GB 126/5-5) 0010011677 41-044-60 ecoTEC plus 615 (VU GB 156/5-5) 0010011678 41-044-61 ecoTEC plus 618 (VU GB 186/5-5) 0010011679 41-044-62 Boiler The following instructions are intended to guide you throughout the entire documentation. Further documents apply in combination with these installation and maintenance instructions.
Notes on the documentation 1 and fully explained at hand over to the operator of the installation. Installers should point out also the service record section for completion following service calls to this appliance. Vaillant Ltd. is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimize safety, efficiency and performance.
a a 2 Safety 2 Safety 2.1 2.2 Safety and warning information > When installing the ecoTEC plus, take account of the general safety instructions and the warning notes that appear before all of the actions. 2.1.
a Safety 2 Installation and settings In the following cases, the boiler must be operated only with the front casing fitted and closed and with a completely mounted air/flue gas duct: – starting up – test purposes – continuous operation, Otherwise, under unfavourable operating conditions, injury, death or material damage may occur.
a a 2 Safety 2.5 General requirements 2.5.1 Related documents To ensure the safe installation and continued satisfactory operation of your appliance, all works shall be carried out by a competent installer fully conversant with the required current and up to date, acts standards, laws and regulations relevant for this range of equipment at the time of installation. In addition any special requirements of Local Authorities, gas undertakings or insurers must be complied with.
a Safety 2 b Caution. Risk of damage caused by aggressive vapours and dust. Aggressive vapours and dust in the installation room may cause corrosion damage to the boiler and to the flue gas installation. > Ensure that the boiler is room sealed if the air in the installation room contains aggressive vapours or dust. > Observe the following when choosing the installation site and operating the boiler, – Do not install the boiler in rooms prone to frost.
a a 2 Safety "Small Bore" and "Micro Bore" central heating installations). Lines which do not form part of the usable heating surface should be insulated to prevent heat losses and possible freezing up, especially where the lines run under rooves and ventilated cellar rooms. The drain connections must be easily-accessible, so that the entire system including the boiler and hot water system can be drained.
Description of the appliance 3 3 Description of the appliance Design 5 4 5 6 6 7 7 4 8 9 3 9 3 10 11 2 1 8 10 11 2 12 1 13 12 13 14 14 15 15 19 18 16 17 3.1 Functional elements of the VU system boiler 3.
4 Installation 4 Installation i i BEFORE PROCEEDING - ENSURE BOILER IS CORRECT FOR GAS GROUP SUPPLIED! 4.2 The work described in this section must only be carried out by a competent person. The pipes can be routed upwards behind the boiler in front of the wall (surface installation) using the spacer frame. Which means the distance between the wall and the boiler increases by 65 mm. Scope of delivery The Vaillant ecoTEC plus is delivered pre-mounted in a packaging unit. 4.1 Accessories 4.1.
Installation 4 Item Qty 1 1 2 1 3 1 4 4 5 3 6 1 7 1 8 3 1 Description Wall bracket Boiler Lower cover Supply pipes (gas, heating, expansion relief valve) Service valves Installation template Enclosure documentation Bags with parts Additional for propane boilers: sticker for tank 4.2.3 Disposing of the packaging > Dispose of the cardboard packaging used on the ecoTEC plus at a cardboard recycling site. > Dispose of the plastic film and plastic filling at an appropriate plastic recycling site.
4 Installation > If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip. > Ensure safe lifting techniques are used – keep back straight – bend using legs. > Do not twist – reposition feet instead. > Take care to avoid trip hazards, slippery or wet surfaces and climbing steps and stairs. > Always use assistance if required. Carriage of carton from point of delivery to point of installation – first or higher floor, cellar.
Installation 4 > Always use assistance if required. > Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance. flooring, lighting and other factors, and appropriate measures taken. 4.4 Requirements for the installation site 4.4.1 Required minimum clearances/installation clearances Positioning of Appliance for Final Installation – within compartment etc. restricting installation.
4 Installation 4.4.2 Using installation templates An installation template is supplied with the boiler to aid wall mounting. The template shows the following: – The position of the fixing holes for the hanging bracket. – The position of the connections. – The position of the wall breakthrough of the air/flue gas duct. Position the installation template vertically over the installation site. > Attach the template to the wall, using tacks for example.
Installation 4 4.5 Dimension drawing and connection measurements 8 440 A 125 1 624 720 2 3 4 5 6 7 11 20 35 100 180 125 B 3 4 5 6 7 35 100 9 10 4.4 Connection measurements in mm Key 1 Wall breakthrough for air/flue gas duct 2 Hanging bracket 3 Heating flow (Æ 22 x 1.5) 4 Hot water connection (Æ 15 x 1.5), only for VUW boilers 5 Gas connection (Æ 15 x 1.5; ecoTEC 837: Æ 22 x 1.5) 6 Cold water connection (Æ 15 x 1.5), only for VUW boilers 7 Heating return (Æ 22 x 1.
4 Installation 4.6 Wall-mounting the boiler a 4.7 Removing/fitting the front casing Danger! Risk of death if the load-bearing capacity of the fixing elements used is insufficient! If the fixing elements or wall do not have sufficient load-bearing capacity, the boiler can come loose and fall down. This may also cause leaks in the gas line, which is potentially fatal. > When fitting the boiler, ensure that the fixing elements and the wall have a sufficient load-bearing capacity.
Installation 4 4.8 Removing/fitting the side panel You can also remove a side panel for installation or maintenance purposes. b Caution. Risk of damage caused by mechanical tension. Removing both side panels may cause mechanical distortion in the boiler, which can cause damage to the piping and potentially result in leaks. > Always only remove one side panel, never both side panels at the same time. > Fold the electronics box (1.) forwards. > Unscrew the two screws (2.
5 Gas installation 5 Gas installation 5.2 Connecting the gas pipe The work described in this section must only be carried out by a competent person. 5.1 Preparing for installation a Danger! Risk of death from incorrectly installed gas system! An incorrect gas installation can result in leaks and an explosion. > During installation, the legal directives and the local regulations for gas supply companies must be observed.
Hydraulic installation 6 6 Hydraulic installation The work described in this section must only be carried out by a competent person. 6.1 b Caution. Risk of damage caused by heat transfer when soldering. Heat that is transferred during soldering can cause damage to the seals in the service valves. > Do not solder the connection pieces if the connection pieces are screwed to the service valves.
6 Hydraulic installation 6.2 Connecting the hot and cold water (VUW boiler) 6.4 Connecting the heating flow and heating return 6.4.1 VUW boiler 6.1 Fitting the hot and cold water connection > Make the domestic hot and cold water connections as shown. > Ensure correct water pressure and flow requirements and that any expansion can be accommodated with the cold supply pipe work (¬ section 2.5.7). 6.2 Fitting the heating flow and heating return (VUW boiler) > Make the water connections as shown. 6.
Hydraulic installation 6 6.5 Low loss header A low loss header disconnects the boiler from the heating system. The system is no longer dependent on the remaining feed head of the boiler. In conjunction with the boiler circulation pump, the low loss header ensures that a sufficiently high minimum quantity of water is always circulating through the boiler. No electrical accessories are required in order to use a low loss header. 6.
6 Hydraulic installation > Insert a seal (1) in the cap nut (2). > Screw the discharge pipe (3) onto the expansion relief valve. > Make the discharge line routing as short as possible and sloping away from the boiler. > Allow the line to terminate in such a way that nobody can be injured and no cable or other electrical components can be damaged if water or steam is ejected. > Note that the end of the line must be visible.
Flue gas installation 7 Air/flue gas duct The CE mark is valid only if the appliance is operated with Vaillant air/flue gas ducts. All ecoTEC plus boilers feature a 60/100 mm diameter air/ flue gas connection as standard. Selecting the most suitable system depends on the individual installation and application conditions.
7 Flue gas installation 7.2 Flue termination The following details refer to all flue systems. a. The terminal must be positioned such that the products of combustion can disperse 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.
Flue gas installation 7 Location A Minimum dimensions Directly below an opening, air brick, opening win300 mm dows, etc. B Above an opening, air brick, opening window, etc. 300 mm C Horizontally to an opening, air brick, opening win300 mm dow, etc. D Below temperature-sensitive building components 75 mm e.g.
8 Electrical installation 8 8.1 Electrical installation Preparing for installation e Danger! Risk of death from electric shock! Touching live connections can cause serious personal injury. > Switch off the power supply. > Secure the power supply against being switched on again. e Danger! Risk of electrocution as a result of an improper electrical connection! An improper electrical connection may negatively affect the operational safety of the boiler and result in material damage or personal injury.
Electrical installation 8 b Caution. Risk of damage caused by incorrect installation. A mains voltage at the incorrect plug terminals on the ProE system can destroy the electronics. > Only connect the mains connection cable to the terminals marked for the purpose. b Caution. Risk of damage caused by incorrect installation. Connecting wires that have been stripped too far can cause short circuits and damage the electronics if a strand accidentally comes loose.
8 Electrical installation > If you connect a weather compensator or room temperature control via eBUS, then bridge input 24 V = RT (X100 or X106) if no bridge exists. > I If using low voltage (24 V) controls connect these in place of the bridge marked RT 24 V (X100 or X106). > Close the electronics box (¬ section 8.1). > In order to achieve pump operating mode "Comfort" (continuously running pump) for multi-circuit controllers, change diagnosis code D.
Electrical installation 8 > Perform the wiring in the same way as in ¬ section 8.4. > To start up the connected components, select the components using diagnosis code "D.026" at installer level (¬ section 11.1). 8.5.2 Connect VR 40 – "2 from 7" multifunctional module You can connect additional components to the ecoTEC plus using the Vaillant multi-functional module 2 in 7 (accessories). > Fit the components in accordance with the corresponding operating and installation instructions.
8 Electrical installation 8.
Electrical installation 8 X51 Display Connection X22 8 7 2 1 5 3 X25 11 white 10 + Holding magnet 1 2 3 4 5 6 4 X2 Pump PWM signal Gas valve + 9 6 12 8 17 7 18 14 13 11 Stepper motor + 1 2 3 4 5 6 Mass flow sensor Diverter valve * M 1 3 4 Water pressure sensor blue 4 12 1 16 5 7 8 7 12 X20 13 pink 2 15 16 4 3 17 X24 3 white 17 white blue J Return sensor DCF 1 0 0 X16 L N X11 L N grey blue X18 L N Circulation pump remote control External temperature sensor Flow sensor (option
8 Electrical installation X22 8 7 2 1 5 3 X25 11 white 10 9 6 12 8 17 7 18 14 13 X2 113 blue 2 6 4 12 5 1 5 7 8 7 12 X20 13 pink 2 15 16 4 3 17 X24 3 white 17 Mass flow sensor Diverter valve M Water pressure sensor Impeller sensor orange J Warm start sensor violet J Hot water sensor red J Flow sensor blue J Return sensor Coding resistor, output range 6FB AF RF DCF 1 0 0 X16 grey X18 Circulation pump remote control External sensor External temperature sensor DCF connection Earth Ea
Electrical installation 8 X22 white X41 Edge connector X100 white 6FB AF RF DCF 1 X11 L N X18 Diverter valve M Water pressure sensor Impeller sensor orange J Warm start sensor violet J Hot water sensor red J Flow sensor blue J Return sensor Coding resistor, gas group L N blue Mass flow sensor Coding resistor, output range X16 grey + Safety fuse + pink Holding magnet 1 3 4 1 2 3 Bus 24 V 230 V~ + Stepper motor 1 2 3 4 5 6 0 0 Burner RT off 24 blue Gas valve
9 Operation 9 Operation The Vaillant ecoTEC plus boiler is fitted with a digital information and analysis system (DIA). If additional settings are required, which have not been configured using the installation assistant, you can view and modify further parameters using the DIA. The operating concept and operation of the boiler is described in the ¬ operating instructions of the boiler. The read-off and setting facilities of the operator level are also described in the ¬ operating instructions.
Operation 9 9.2 Overview of the menu structure Menu Information Reset burner off time Installer level Back Select Installer level Fault list Test programmes Appliance config. Enter code 17 Back Ok Back Select Installer level Fault list Test programmes Appliance config. Back Select F.00 F.
9 Operation Appliance config. Target flow temp. DHW temperature Comfort mode Back Select Appliance config. DHW temperature Comfort mode Auxiliary relay Back Select Appliance config. Comfort mode Auxiliary relay Accessory relay 1 Back Select Appliance config. Auxiliary relay Accessory relay 1 Accessory relay 2 Back Select Appliance config. Accessory relay 1 Accessory relay 2 Heating partial load Back Select Appliance config.
Commissioning 10 10 Commissioning At the time of commissioning, complete all relevant sections of the benchmark checklist found within the back pages of this document. Ensure that the filling and purging programs P.06 and P.00 have been allowed to run fully before the boiler is ignited for the first time.
10 Commissioning 10.2.4 Target feed temperature 10.2.11 Restarting the installation assistant Use the minus button and the plus button to set the target feed temperature. Confirm your setting with OK. You can restart the installation assistant any time by calling it up manually in the menu. Menu ¬ Installer level ¬ Installation assistant 10.2.5 Hot water temperature 10.3 Use the minus button and the plus button to set the hot water temperature. Confirm your setting with OK. 10.2.
Commissioning 10 Display Meaning P.00 1) Purging test program The heating circuit and the hot water circuit are purged using the automatic air vent (the cap of the automatic air vent must be released). 1 x right selection button: Start heating circuit purging 2 x right selection button (" -> "): Start purging hot water circuit 3 x right selection button (" -> "): Restart heating circuit purging 1 x left selection button ("Cancel"): Exit purging program The internal pump is cyclically actuated.
10 Commissioning > Purge the lowest radiator until water flows out of the purging valve without bubbles. > Purge all other radiators until the entire heating system has been filled with water. Close all purging valves. > Use the display to monitor the rising filling pressure in the heating installation. > Top up with water until the pressure gauge display is in the middle of the grey area and the required filling pressure appears on the display.
Commissioning 10 > Refill the heating system with water, as described in (¬ section 10.7). > Check that the expansion relief valve of the heating system is functioning correctly by turning the handle on the valve. > Check the pressure in the heating system and top up with water if necessary. > Close the filling valve and the cold water valve. 10.
10 Commissioning Gas valves with gas pressure regulators (1) are not installed in all boilers. There are also versions without gas pressure regulators. 10.11.1 Factory setting b 1 10.4 Filling the condensate siphon > Remove the lower part (1) of the condensate siphon by turning the bayonet fitting anti-clockwise. > Fill the lower section with water until about 10 mm below the upper edge. > Re-attach the lower section to the condensate siphon.
Commissioning 10 flue gas and air measurements on this boiler - for details see section ¬ section 10.11.2. Proceed to put the boiler into operation as follows: > Check the maximum gas flow rate as detailed in ¬ section 10.11.3. > Check the gas inlet working pressure as detailed in ¬ section 10.11.4. > Note that you must re-measure the gas flow rate or the gas inlet working pressure, if changes were required to correct any issues found. 10.11.
10 Commissioning 1 > > > > > > > > 2 10.7 Measuring the gas inlet working pressure > Undo the sealing screw of the measuring nipple (1) (lower screw) at the gas valve using a screwdriver. > Connect a digital pressure gauge or U-tube manometer (2) to the measuring nipple (1). > Open the gas isolation valve of the boiler. > Start the boiler by activating the test program P.01 as described in ¬ section 13.4.
Commissioning 10 10.12 Carrying out a full function test > After completing the installation and the gas setting, perform a complete function check of the boiler before starting up the boiler and handing it over to the operator. > Start up the boiler in accordance with the relevant operating instructions. If you have still not successfully completed the installation assistant and subsequently confirmed this, it will be restarted when you switch on the boiler.
11 Adapting the boiler to the heating installation 11 also explained by the plain text display "DHW mode: Burner on". S.24 The installation assistant is started when the boiler is switched on for the first time (¬ section 10.2). DHW mode Burner on If you have already filled the heating installation and terminated the installation assistant, but wish to set the most important system parameters again, you can also call up the "Appliance configuration" menu point.
Adapting the boiler to the heating installation 11 Factory setting Auto Your own setting Code Parameters Adjustable values D.000 Heating partial load Adjustable heating partial load in kW Auto: Boiler automatically adjusts max. partial load to current system demand D.001 Overrun time of internal pump for heating mode 1 - 60 min 5 min D.002 Max. burner anti-cycling time heating at 20 °C flow temperature 2 - 60 min 20 min D.003 Outlet temp. actual value In °C Not adjustable D.
11 Adapting the boiler to the heating installation Factory setting External pump Your own setting Code Parameters Adjustable values D.026 Auxiliary relay control Circulation pump External pump Cylinder charging pump Extractor hood External solenoid valve External fault message Solar pump (not active) eBUS remote control (not active) Legionella protection pump (not active) Solar valve (not active) D.
Adapting the boiler to the heating installation 11 Code Parameter Adjustable values D.060 Number of temperature limiter shutdowns Number of shutdowns Your own setting Not adjustable D.061 Number of ignition device cutoffs Number of unsuccessful ignitions in the last attempt Not adjustable D.064 Average ignition time In seconds Not adjustable D.065 Maximum ignition time In seconds Not adjustable D.067 Remaining burner anti-cycling time In minutes Not adjustable D.
11 Adapting the boiler to the heating installation Code Parameter Adjustable values D.091 Status DCF with external sensor connected No reception Reception Synchronised Valid D.093 Setting of device specific number (DSN) Setting range: 0 to 99 D.094 Delete fault history Delete fault list D.095 Software version of PeBUS components PCB (BMU) Display(AI) actoSTOR(APC) HBI/VR34 D.096 Factory setting Reset all adjustable parameters to factory setting D.
Adapting the boiler to the heating installation 11 Eco (intermittently operating pump) 11.1.5 Pump operating mode Eco is the factory setting. This pump operating mode is useful for removing residual heat after hot water generation when the heat demand is extremely low and large temperature spreads exist between the hot water generation and heating mode target values. This prevents living rooms from being under-supplied.
11 Adapting the boiler to the heating installation Reset remaining burner anti-cycling time You have two options to reset the remaining burner anticycling time: 1st option Menu ¬ Reset burner anti-cycling time The current burner anti-cycling time appears in the display. > Confirm the reset of the burner anti-cycling time by ("Select"). pressing the right selection button 2nd option > Press the fault clearance key (¬ Operating instructions). 11.1.
Adapting the boiler to the heating installation 11 Position of the setting screw Pressure in MPa (mbar) Right-hand stop (turned all the way down) If the radiators do not get properly hot in the factory setting. 35.0 (350) Note: In this case, you must set the pump to the maximum stage. Mid-position (5 turns to the left) 5 further turns to the left from the mid-position Notes/application 25.0 (250) Factory setting 17.
12 Inspection and maintenance 12 Inspection and maintenance We recommend the conclusion of an inspection and maintenance contract with an approved company or installer. The inspection serves to determine the actual condition of the respective boiler and compare it with the specified condition. This is done by measuring, checking and observing. Maintenance is required in order to eliminate any deviations of the actual condition from the specified condition.
Inspection and maintenance 12 During any inspection and maintenance or after change of parts of the combustion circuit, the following must be checked: – The boiler has been installed in accordance with the relevant installation instructions. – The integrity of the flue gas installation and flue seals is in accordance with the relevant flue installation instructions enclosed. – Visual, the integrity of the boiler combustion circuit and relevant seals (paying particular attention to the burner door seal).
12 Inspection and maintenance 1 1 2 12.1 Measuring the CO2 concentration i The boiler is fitted with a flue gas analysis point (1). A suitable flue gas analyser can be connected to this point to establish the combustion performance of the boiler. > Remove the front casing (¬ section 4.7). > Start the testing program P.01 (¬ section 10.4). > Wait at least 5 minutes until the boiler reaches its operating temperature. > Measure the CO2 concentration at the flue gas analysis point (1).
Inspection and maintenance 12 Unit Settings Natural gas (H) Result Propane CO2 after 5 minutes full load mode with boiler front casing fitted Vol.–% 7.8 - 10.2 9.7 - 10.7 CO2 after 5 minutes full load mode with boiler front casing removed Vol.–% 7.6 - 10.0 9.5 - 10.5 Set for Wobbe index Ws kWh/m3 15 22.5 CO value with full load CO/CO2 ppm < 250 < 0.0031 < 250 < 0.0026 F.
12 Inspection and maintenance 12.2 Inspection and maintenance work steps No. Activity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Check the air flue gas installation for leaks and for proper fixation and ensure it is not blocked or damaged and is fitted correctly, complying with the relevant installation instructions. Carry out a general inspection of the boiler for dirt and dust and clean as necessary.
Inspection and maintenance 12 12.2.1 Filling the boiler and the heating installation Display Test programs Action T.01 A description of how to fill the boiler and the heating installation is provided in ¬ section 10.7. Check internal pump You can switch the internal pump on and off. T.02 Check 3-way valve You can move the diverter valve to the heating position or to the hot water position. 12.2.2 Draining the boiler T.03 Check fan You can switch the fan on and off.
12 Inspection and maintenance > Close the service valves on the boiler. > Remove the front casing from the boiler (¬ section 4.7). > Fold the electronics box forwards (¬ section 8.2). 8 1 2 1 7 2 6 3 3 4 5 4 12.4 Removing the compact thermal module 12.3 Remove the air intake pipe > Unscrew the retaining screw (2, ¬ fig. 12.3) and detach the air intake pipe (1, ¬ fig. 12.3) from the intake stub. b Caution. Risk of damage to the gas pipe. The corrugated gas pipe may become damaged.
Inspection and maintenance 12 12.4.2 Cleaning the heat exchanger b 12.4.3 Checking the burner Caution. Risk of damage from water spray. If you fail to protect the electronics box adequately, water can penetrate the box during cleaning and may damage the electronics. > Protect the folded down electronics box against sprayed water. 1 > Remove the compact thermal module (¬ section 12.4.1). 2 3 12.6 Checking the burner As the burner (1) is maintenance-free, it does not require cleaning.
12 Inspection and maintenance > Drain the hot water from the boiler. > Undo the nut (1, ¬ fig. 12.8) of the cold water supply line from the casing of the boiler. 1 1 12.7 Cleaning the condensate siphon > Remove the lower part (1) of the condensate siphon by turning the bayonet fitting anti-clockwise. > Clean the bottom of the siphon by flushing it out with water. > Fill the lower section of the siphon with water up to about 10 mm below the upper edge. > Re-fit the lower part of the condensate siphon.
Inspection and maintenance 12 1 9 2 8 3 7 4 5 > Open the gas isolator cock on the boiler and ensure there are no leaks. > Check that the sealing ring in the air intake pipe is positioned correctly in the seal seat. > Insert the air intake pipe (1, ¬ fig. 12.3) back into the intake stub. > Attach the air intake pipe using the retaining screw (2, ¬ fig. 12.3). 12.4.7 Checking the charge pressure of the expansion vessel 6 12.
13 Troubleshooting 13 13.1 Troubleshooting Contact Vaillant Service Solutions (0870 6060 777) > If you contact Vaillant Service Solutions (0870 6060 777) or your Vaillant service partner, if possible, please mention – the fault code displayed (F.xx), – the boiler status that is displayed (S.xx) in the "Live Monitor" (¬ section 13.2.1). 13.2 Performing diagnostics You can use the function menu to control and test individual components of the boiler in the fault diagnosis.
Troubleshooting 13 Display Meaning S.62 Gas family check unsuccessful: CO/CO2 values at limit. Check combustion. S.63 Gas family check unsuccessful: Combustion quality outside permissible range (see also F.93). S.76 S.96 System pressure too low; top up water Return temperature sensor test running, heating demands are blocked S.97 Water pressure sensor test running, heating demands are blocked S.98 Flow/return temperature sensor test running, heating demands are blocked 13.
13 Troubleshooting 13.2.8 Overview of fault codes Code Meaning Cause F.00 Flow temperature sensor interruption NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC defective F.01 Return temperature sensor interruption NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC defective F.
Troubleshooting 13 Code Meaning Cause F.49 eBUS fault Short circuit on eBUS, eBUS overload or two power supplies with different polarities on the eBUS F.52 Mass flow sensor connection fault Mass flow sensor not connected/disconnected, plug not connected or incorrectly connected F.53 Mass flow sensor fault Mass flow sensor faulty, filter below venturi filter cap wet or blocked, gas flow pressure too low F.54 F.56 F.57 F.61 Gas pressure fault (in combination with F.28/F.
13 Troubleshooting Code Meaning Cause F.93 Gas group fault Combustion quality outside the permitted range: Wrong gas restrictor, recirculation, wrong gas group, internal pressure measuring point in venturi blocked (do not use lubricant on O-ring in venturi.). Gas family check prematurely terminated. Communication fault No communication with the PCB Communication fault between display and PCB in the electronics box 13.2 Fault codes (continued) 13.
Replacing components 14 14 Replacing components The work described in this section must only be carried out by an approved competent person. The original components of the product were also certified as part of the CE declaration of conformity. If you do not use certified Vaillant original spare parts for maintenance or repair work, this voids the CE conformity of the product. We therefore strongly recommend that you fit Vaillant genuine spare parts.
14 Replacing components 14.3 Replacing the fan 1 1 2 7 3 3 2 4 5 6 14.3 Removing the gas valve and venturi from fan 14.2 Removing the fan > Remove the air intake pipe (¬ section 12.4.1). > Remove the three plugs from the gas valve (5, ¬ fig. 14.2). i The plugs on the fan motor and the venturi have latching lugs with which they engage in the slot. You have to push in the latching lug to pull off the plug. > Remove the entire fan/venturi/gas valve unit from the boiler.
Replacing components 14 > Replace the defective fan. 14.4 2 1 5 Replacing the gas valve b 3 Caution. Risk of material damage caused by making not permissible setting. Modifications to the gas pressure regulator on the gas valve can destroy the gas valve and cause operating faults on the boiler. > Never modify the factory setting for the gas pressure regulator of the gas valve. 4 1 14.5 Installing the gas valve > Refit the components in the reverse order.
14 Replacing components i The plug on the venturi has latching lugs with which it engages in the slot. You have to release the latching lug by pushing it in to pull off the plug. > Remove the plug from the sensor of the venturi (1, ¬ fig. 14.8). > Unscrew the two cap nuts at the top (5, ¬ fig. 14.8) and bottom (4, ¬ fig. 14.8) of the gas valve. Counterhold at opposite side of gas valve when unscrewing, or unscrew both cap nuts at the same time. > Unscrew the fixing screw of the gas valve (3, ¬ fig. 14.
Replacing components 14 b Caution. Risk of damage to boiler and possible malfunctions. The use of lubricant can block functionrelated channels in the venturi. > Never use lubricant when installing the gas restrictor. > Refit the components in the reverse order. Use new seals. > After installing the new venturi, perform a gas family check (¬ section 12.1.5) and a gas ratio setting (¬ section 10.11). 14.6 14.7 Replacing the heat exchanger b Caution. Risk of damage to the heat exchanger.
14 Replacing components > Fill and purge the boiler and, if necessary, the heating installation (¬ section 10.7). 1 2 3 14.8 Replacing the PCB and/or the display e Danger! Risk of death from electric shock! Mains connection terminals L and N remain live even if the continuous voltage on/off switch is turned off! > Before carrying out repair work on the boiler, switch the boiler off using the on/ off button.
Replacing components 14 Language 02 English 14.8.1 Replacing either the display or the PCB > Replace the PCB or display according to the assembly and installation instructions supplied. Cancel Ok 14.15 Setting the language If you are replacing both components at the same time (spare part case), the boiler switches directly to the menu for selecting the language after switching on. The default language setting is English.
15 Decommissioning 15 Decommissioning 15.1 15.3 Temporarily shutting down the boiler b Caution. Risk of frost damage due to incorrect shutdown. If you switch off the boiler using the on/off switch or disconnect it from the power mains, this can cause frost damage to the heating installation. > Only shutdown the boiler fully if the heating installation is otherwise protected from frost. > Drain the heating installation fully.
Technical data 17 17 Technical data ecoTEC plus Unit 612 (VU GB 126/5-5) 615 (VU GB 156/5-5) 618 (VU GB 186/5-5) 624 (VU 630 (VU GB GB 246/5-5) 306/5-5) 637 (VU GB 376/5-5) Nominal heat output range P at 50/30 °C kW 3.3 - 12.9 3.3 - 16.1 4.2 - 19.3 5.7 - 25.7 6.4 - 32.1 7.1 - 39.6 Nominal heat output range P at 80/60 °C kW 3.0 - 12.2 3.0 - 15.4 3.8 - 18.5 5.2 - 24.4 5.8 - 30.4 6.4 - 37.6 Maximum heat output for hot water generation kW 12.2 15.4 18.5 24.4 30.4 37.
17 Technical data ecoTEC plus Unit 824 (VUW GB 246/5-5) 831 (VUW GB 316/5-5) 837 (VUW GB 376/5-5) Nominal heat output range P at 50/30 °C kW 4.2 - 20.4 5.7 - 25.7 7.1 - 30.1 Nominal heat output range P at 80/60 °C kW 3.8 - 19.3 5.2 - 24.4 6.4 - 28.6 Maximum heat output for hot water generation kW 24.4 30.8 38.7 Maximum heat input for hot water generation kW 24.7 31.2 39.2 Maximum heat input at the heating side kW 19.6 24.7 28.9 Minimum heat input G20 kW 4.0 5.5 6.
Glossary 18 18 Glossary required, which have not been configured using the installation assistant, then you can view and modify these using the DIA. Air/flue gas duct An air/flue gas duct is a line system with two separate flow channels. The flue gas is routed into separate chambers at the same time as the required combustion air is pumped to the boiler. The air/flue gas duct can be designed as a concentric or adjacent double flue gas line (the exhaust gas channel is sealed from the air channel).
Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the PDQXIDFWXUHUV LQVWUXFWLRQV DQG WKH GDWD ¿HOGV RQ WKH FRPPLVVLRQLQJ FKHFNOLVW completed in full.
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.
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
PRIOR TO CO AND COMBUSTION RATIO CHECK The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas supply pressure/rate checked as required prior to commissioning. As part of the installation process, especially where a flue has been fitted by persons other than the boiler installer, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that manufacturer’s max.
Index Index A D Accessories.................................................................................... 12 Air/flue gas duct ................................................................... 25, 81 Air/flue system ............................................................................ 25 Article numbers ............................................................................ 4 Auxiliary relay............................................................... 30, 40, 50 Diagnosis codes...
Index H R Heating mode .............................................................................. 47 Heating partial load ................................................................... 40 Heating water Preparation ............................................................................... 9 Removing Burner ....................................................................................... 71 Compact thermal module ..................................................... 61 Display ........
Manufacturer 0020116700_06 GBIE 012014 – Subject to change Supplier
