Ecotec Installation and Servicing1

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
ecoTEC pro 24
GB, IE
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.7 Removing the front case . . . . . . . . . . . . . . . . . . . 21

1.1 Notes on the documentation . . . . . . . . . . . . . . . . 4 4.8 General instructions for heating system . . . . . . 21
1.1.1 Applicable documents . . . . . . . . . . . . . . . . . . . . . . 4 4.9 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1.2 Retention of documents . . . . . . . . . . . . . . . . . . . . 4 4.10 Cold water mains inlet and hot water outlet
1.1.3 Safety instructions and symbols. . . . . . . . . . . . . 4 (ecoTEC combination boilers only). . . . . . . . . . . 22
1.2 Validity of the manual. . . . . . . . . . . . . . . . . . . . . . 4 4.11 Condensate drain pipe . . . . . . . . . . . . . . . . . . . . . 23
1.3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.12 Heating connection . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.12.1 Heating flow and return connection . . . . . . . . . 24
1.5 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.12.2 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 25
1.6 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.13 Connecting the flue system to the boiler . . . . . 25
1.7 Gas council numbers . . . . . . . . . . . . . . . . . . . . . . . 5 4.14 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 25
4.14.1 General requirements . . . . . . . . . . . . . . . . . . . . . . 25
2 Boiler specifications . . . . . . . . . . . . . . . . . . . . 6 4.14.2 Connection to the main supply . . . . . . . . . . . . . . 26
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.14.3 Electric board layout . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.15 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.15.1 Vaillant controls and accessories . . . . . . . . . . . . 30
2.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.15.2 External electrical controls . . . . . . . . . . . . . . . . . 30
4.15.3 Connection details for external time
3 General requirements . . . . . . . . . . . . . . . . . . . 10 switches and boiler terminal strip . . . . . . . . . . . 30
3.1 Preliminary remarks for room sealed 4.15.4 Vaillant optional plug in timer accessories . . . . 30
appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.15.5 Connection details using the VR 65 Control
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . . 10 Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Contents included with delivery . . . . . . . . . . . . . 10 4.16 Thermostatic radiator valves . . . . . . . . . . . . . . . 31
3.4 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.17 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.18 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Flue pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.19 Anticycling ‘economiser’ control . . . . . . . . . . . . 31
3.6.1 Standard 100 mm flue system . . . . . . . . . . . . . . . 13 4.20 Automatic pump spin control (APS). . . . . . . . . . 31
3.6.2 Optional 125 mm flue system . . . . . . . . . . . . . . . . 13
3.7 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5 Commissioning Part I . . . . . . . . . . . . . . . . . . . 32
3.8 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.1 Preliminary electrical checks. . . . . . . . . . . . . . . . 32
3.9 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.10 Guide to system requirements . . . . . . . . . . . . . . 15 5.3 Cold water supply (ecoTEC combination
3.10.1 Water circulation system . . . . . . . . . . . . . . . . . . . 15 boilers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.10.2 Filling and preparing heating system. . . . . . . . . 15 5.4 Filling and bleeding the heating system . . . . . . 32
3.10.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . 16 5.4.1 Checking the filling pressure of the heating
3.10.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.10.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.4.2 ecoTEC plus combination boiler filling loop . . . 32
3.11 Pump specifications . . . . . . . . . . . . . . . . . . . . . . . 17 5.4.3 Filling the heating system in ecoTEC pro
3.11.1 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . . . 17 combination boilers and ecoTEC plus system
3.11.2 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.11.3 Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.4.4 Filling the heating system for the first time . . . 33
3.12 Condensate trap. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.5 Initial system flush (“cold”) . . . . . . . . . . . . . . . . . 33
5.6 Filling the condensate siphon . . . . . . . . . . . . . . . 34
4 Boiler installation sequence . . . . . . . . . . . . . . 18 5.7 Adjusting the pumping capacity . . . . . . . . . . . . . 34
4.1 Transporting the appliance . . . . . . . . . . . . . . . . . 18 5.8 Adjusting the by-pass . . . . . . . . . . . . . . . . . . . . . . 34
4.2 Required minimum distances/assembly 5.9 Checking the gas setting . . . . . . . . . . . . . . . . . . . 34
clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.9.1 Checking for tightness of the flue gas
4.2.1 Select position for boiler . . . . . . . . . . . . . . . . . . . 19 installation and flue gas recirculation . . . . . . . . 35
4.2.2 Unpack the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.9.2 Checking the gas flow rate . . . . . . . . . . . . . . . . . 35
4.2.3 Using boiler template . . . . . . . . . . . . . . . . . . . . . . 20 5.9.3 Checking the gas inlet working pressure . . . . . 36
4.3 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.10 Refitting the case. . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4 Fitting the boiler hanging bracket . . . . . . . . . . . 20 5.11 Adjusting the central heating output
4.5 Installing the flue system . . . . . . . . . . . . . . . . . . . 21 (range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5.12 Gas changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Instructions for installation and servicing ecoTEC 839592_12

Contents
6 Functional checks (commissioning part II). . 39

6.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.2 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.3 Water heating (combination boilers only). . . . . 39
6.1.4 Final flush of the heating system (“hot”) . . . . . 39
6.2 Handing over to the user . . . . . . . . . . . . . . . . . . . 40
6.3 Factory guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 40
7 Inspection and maintenance . . . . . . . . . . . . . 41

7.1 Inspection and maintenance intervals . . . . . . . . 41
7.1.1 General inspection and maintenance
instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.3 Checking the CO2 concentration . . . . . . . . . . . . . 42
7.1.4 Adjusting the CO2 concentration
(or the air ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1.5 Inspection and maintenance work steps . . . . . . 44
7.2 Servicing the burner module . . . . . . . . . . . . . . . . 45
7.2.1 Removing the burner module . . . . . . . . . . . . . . . 45
7.2.2 Cleaning the integral condensation heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.3 Checking the burner . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.4 Refitting the burner module . . . . . . . . . . . . . . . . 46
7.3 Cleaning the condensate siphon . . . . . . . . . . . . . 47
7.4 Checking the expansion vessel . . . . . . . . . . . . . . 48
7.5 Recommissioning the boiler. . . . . . . . . . . . . . . . . 48
7.6 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Logical fault finding procedure . . . . . . . . . . . . . . 49
8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.3 Resetting parameter to factory settings. . . . . . 54
9 Parts replacement . . . . . . . . . . . . . . . . . . . . . 54
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 54
9.2 Replacing burner . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.3 Replacing fan or gas valve . . . . . . . . . . . . . . . . . . 55
9.4 Replacing expansion vessel . . . . . . . . . . . . . . . . . 56
9.5 Replacing primary heat exchanger . . . . . . . . . . 56
9.6 Replacing electronics and display . . . . . . . . . . . 57
10 Recycling and disposal . . . . . . . . . . . . . . . . . . 58
11 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . . 58
Appendix
EG declaration of conformity . . . . . . . . . . . . . . . . . . . . . 59
Benchmark gas boiler commissioning checklist . . . . . 60
Instructions for installation and servicing ecoTEC 839592_12 3

1 Introduction
1 Introduction 1.2 Validity of the manual

This installation manual applies exclusively to units with
1.1 Notes on the documentation the following part numbers:
The following information is intended to help you - 0010004108 - 308525
throughout the entire documentation.
- 308511 - 308526
Further documents apply in combination with this
installation and maintenance manual. - 308520 - 308527
We assume no liability for any damage caused by - 308521 - 308528
non-observance of these manuals. - 308522 - 308531
- 308523 - 308534
1.1.1 Applicable documents
- 308524 - 308536
• Always observe all installation instructions for struc-
tural parts and components of the system when
installing the ecoTEC plus 937. These installation The part number of the unit can be obtained from the
instructions are enclosed with the various system com- identification plate.
ponents as well as additional components.
• Also observe all the operating instructions included 1.3 Introduction
with the system components.
Note
1.1.2 Retention of documents This boiler must be installed and serviced by a
Pass on this installation manual to the owner of the sys- competent person approved at the time by the
tem. The owner should retain the manuals so that they Health and Safety executive and in accordance
are available when required. with the Gas Safety (Installation and Use)
Regulations 1998.
1.1.3 Safety instructions and symbols
Observe the safety instructions in this manual for the ecoTEC combination boiler
installation of the appliance! The ecoTEC combination boiler is a fully automatic, wall
Symbols used in the manual are explained below: mounted, room sealed condensing (high efficiency)
boiler for central heating and domestic hot water.
Danger! Domestic hot water is supplied directly from the boiler,
Immediate danger to life and limb! without requiring a copper cylinder, cold water tank,
feed and expansion vessel and associated pipework.
Danger! Domestic hot water has priority over central heating.
Risk of death from electric shock! The ecoTEC plus combination boiler consists of 3 models
with outputs of 23 kW, 31 kW and 37 kW for domestic hot
Danger! water and two pro versions with outputs of 24 kW and
Risk of burns or scalding! 28 kW for domestic hot water.
All versions are available in natural gas. The ecoTEC plus
Caution! 831 is also available in LPG.
Potentially dangerous situation for the product ecoTEC combination boilers incorporate a warm start
and environment! facility that keeps the domestic hot water heat
exchanger hot, providing an instantaneous delivery of
Note domestic hot water. The temperature in the domestic
Useful information and instructions. hot water heat exchanger is limited by the boiler control
system and it is not necessary to install a scale reducer
• Symbol for a necessary task on the cold mains to the boiler. However, in areas that
get exceptionally hard water, a scale reducer may be
fitted to prevent scale formation in the hot water
system pipes. The heating system on ecoTEC plus
combination boilers can be filled using the built–in filling
loop contained within the boiler.
ecoTEC system boiler

The ecoTEC system boiler is a fully automatic, wall
mounted, room sealed condensing (high efficiency)
boiler for central heating and domestic hot water
(where a separate indirect hot water storage cylinder is
also incorporated in the system).

Introduction 1
The ecoTEC system boiler consists of models with Caution!

outputs of 12, 15, 18, 24, 30 and 37 kW. Any incorrect use is forbidden.
All ecoTEC system boilers are available in Natural Gas.
The ecoTEC plus 618 and 630 are also available in LPG. The appliances must be installed by a competent person
approved at the time by the Health and Safety execu-
1.4 General Notes tive, who is responsible for adhering to the existing reg-
The boilers have been designed for use with a sealed ulations, rules and guidelines.
central heating system, and come fully tested and
assembled with a built in circulating pump, expansion 1.6 CE marking
vessel and diverter valve (ecoTEC combination boilers). The CE marking shows that the appliances
The boilers are easily mounted on any internal wall and comply with the basic requirements of the
can be installed with either a horizontal or vertical RSF following directives:
(room sealed fan assisted) flue. - Gas appliances directive (90/396/EEC)
The boilers use a standard flue system (100 mm or - Electromagnetic compatibility directive with threshold
125 mm outside diameter). Flue extensions and class B (89/336/EEC)
additional bends and elbows are available for the flue - Low voltage directive (73/23/EEC)
system to increase the flexibility. If desired, an inhibitor The appliances satisfy the basic requirements of the
may be used in the system. Guidance on the use of efficiency directive (92/42/EEC) as condensing
inhibitors is contained in these instructions. appliance.
All boilers have a built in diagnostic system which - The Gas Applaince (Safety) Regulations 1992
indicates the operational status of the boiler. This - The boiler (Efficiency) Regulations 1993
feature provides key information to aid commissioning
and fault finding. The data badge is fitted to the
underside of the boiler. See text of General
Requirements for installation requirements or notes.
1.5 Intended use

The Valliant ecoTEC are state-of-the-art appliances
which have been constructed in accordance with Vaillant Ltd. supports the Benchmark initiative.
recognised safety regulations. Nevertheless, danger to At the rear of this guide, you will find a
the life and limb of the user or third parties can still Benchmark gas boiler commissioning checklist.
occur or the appliance or other material assets be It is very important that this is completed cor-
impaired in the event of improper use. rectly at the time of installation, commission-
The unit is not intended for use by persons (including ing and hand over to the user.
children) with reduced physical, sensory or mental
capabilities, or lack of experience and/or knowledge,
unless they have been given supervision or instruction 1.7 Gas council numbers
concerning use of the unit by a person responsible for
their safety. Applaince Gas council numbers
Children must be watched to ensure that they do not ecoTEC pro 24 47-044-36
play with the unit. ecoTEC pro 28 47-044-30
The appliance is designed to generate heat for ecoTEC plus 824 47-044-31
connecting to hot water central heating systems and for
ecoTEC plus 831 47-044-32
instantaneous hot water supply (ecoTEC combination
boilers only). Any other use or extended use is ecoTEC plus 831 Propane 47-044-34
considered to be improper. The manufacturer or ecoTEC plus 837 47-044-33
supplier is not liable for any resulting damage. The user ecoTEC plus 612 41-044-44
alone bears the risk. ecoTEC plus 615 41-044-45
Intended use includes the observance of the operating ecoTEC plus 618 41-044-46
and installation manual and the adherence to the ecoTEC plus 618 Propane 41-044-51
inspection and maintenance conditions. ecoTEC plus 624 41-044-47
ecoTEC plus 630 Propane 41-044-50
Table 1.1 Gas council numbers

2 Boiler specifications
2.1 Technical data
ecoTEC plus ecoTEC pro

Technical data Units
824 831 837 24 28
CH heat output range
80 °C flow/60 °C return 6.7 – 19.0 8.7 – 24.0 12.0 – 28.0 6.7 – 19.0 9.0 – 24.0 kW
60 °C flow/40 °C return 6.9 – 19.6 9.0 – 24.7 12.3 – 28.9 6.9 – 19.6 9.3 – 24.7 kW
50 °C flow/30 °C return 7.1 – 20.2 9.2 – 25.5 12.7 – 29.7 7.1 – 20.2 9.6 – 25.5 kW
40 °C flow/30 °C return 7.2 – 20.6 9.4 – 26.0 12.9 – 30.3 7.2 – 20.6 9.8 – 26.0 kW
Maximum DHW output 23.0 31.0 37 23.0 28.0 kW
Maximum output for heating 19 24 28 19 24 kW
Minimum output 6.7 8.7 12 6.7 9.0 kW
Category II2H3P
SEDBUK Band A A A A A Band
SAP Seasonal Efficiency 91.1 %
Inlet gas working pressure required (G20, natural gas) 20 mbar
Inlet gas working pressure required (G31, Propane) 37 mbar
Connected load (if needed, related to stored charge/ G20: 2.5 G20: 3.3 G20: 4.0 G20: 2.5 G20: 3.0 m3/h
water heating) at 15 °C and 1013 mbar G31: 1.82 G31: 2.46 G31: 2.94 G31: 1.82 G31: 2.22 kg/h
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C return) 3.2 4.2 5.7 3.2 4.4 g/s
at maximum thermal load (80 °C flow/60 °C return) 10.7 14.4 17.1 10.7 13.0 g/s
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C return) 40 40 40 40 40 °C
at maximum thermal load (80 °C flow/60 °C return) 74 83 70 74 74 °C
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature 30 – 85 40 – 85 30 – 85 °C
Default setting: max. 75 °C
Maximum CH system pressure 3.0 bar
Circulation water volume ( T=20 K) 817 1032 1204 817 1032 l/h
Approx. condensation volume 1.8 2.2 2.9 1.8 2.2 l/h
at 50 °C flow/30 °C return heating
Pump delivery height 250 mbar
Minimum DHW flow rate 1.5 l/min
DHW flow rate T=35 K rise 9.4 12.7 15.2 9.4 11.5 l/min
Appr. DHW flow rate at factory set temp. rise ( T=42 7.9 10.6 12.6 7.9 9.6 l/min
K)
Permitted DHW overpressure 10 bar
Mains water pressure required for max. flow rate 0.5 0.75 0.75 0.5 0.5 bar
Mains water pressure required for min. flow rate 0.15 bar
Hot water discharge temperature range 35 – 65 °C
Exhaust flue 60/100 mm
Flue categories C13, C33, C43, C53, C83, B23, B33
10 l expansion vessel pre-charge pressure 0.75 bar
Connections heating flow/return 22 mm
Gas inlet 15 22 15 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
720 x 440 x 720 x 440 x 720 x 440 x 720 x 440 x 720 x 440 x mm
Dimensions (H x W x D) 335 335 403 335 335
Weight (boiler only) 35 38 44,5 34 37 kg
Primary water content 1.9 2.3 2.5 1.9 2.1 l
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input 110 125 140 110 115 W
Table 2.1 Technical data ecoTEC combination boiler

Boiler specifications 2
ecoTEC plus
Technical data Units
612 615 618 624 630 637
CH heat output range
80 °C flow/60 °C return 4.9 – 12.0 4.9 – 15.0 6.7 – 18.0 8.7 – 24.0 10.0 – 30.0 12.0 – 37.0 kW
60 °C flow/40 °C return 5.1 – 12.3 5.1 – 15.5 6.9 – 18.6 9.0 – 24.7 10.3 – 30.9 12.3 – 38.2 kW
50 °C flow/30 °C return 5.2 – 12.7 5.2 – 15.9 7.1 – 19.1 9.2 – 25.5 10.6 –31.8 12.7 – 39.3 kW
40 °C flow/30 °C return 5.3 – 12.9 5.3 – 16.2 7.2 – 19.5 9.4 – 26.0 10.8 – 32.4 12.9 – 40.1 kW
Category II2H3P
SEDBUK Band A A A A A A Band
SAP Seasonal Efficiency 91.2 %
Inlet gas working pressure required (G20,
20 mbar
natural gas)
Inlet gas working pressure required (G31,
37 mbar
Propane)
Connected load (if needed, related to stored G20: 1.3 G20: 1.6 G20: 1.9 G20: 2.6 G20: 3.2 G20: 4.0 m3/h
charge/water heating) at 15 °C and 1013 mbar G31: 0.95 G31: 1.19 G31: 1.43 G31: 1.90 G31: 2.38 G31: 2.94 kg/h
Exhaust mass rate
at minimum thermal load (40 °C flow/30 °C 2.3 2.3 3.2 4.2 4.8 5.7 g/s
return
at maximum thermal load (80 °C flow/60 °C 5.6 7.0 8.3 11.2 13.9 17.1 g/s
return)
Exhaust temperature
at minimum thermal load (40 °C flow/30 °C 40 40 40 40 °C
return)
at maximum thermal load (80 °C flow/60 °C 70 75 83 70 °C
return)
NOx class 5
Protection class IP X4D
max. flow temperature 85 °C
Adjustable flow temperature
30 – 85 °C
Default setting: max. 75 °C
Maximum CH system pressure 3.0 bar
Circulating water volume ( T=20 K) 516 645 774 1032 1290 1591 l/h
Approx. condensation volume
1.1 1.4 1.7 2.2 2.7 3.8 l/h
at 50 °C flow/30 °C return heating
Pump delivery height 250 150 mbar
Adjustable storage target value (15 °C at left
15 – 70 °C
stop, spare adjusting range 40 – 70 °C
Exhaust flue 60/100 mm
Flue categories C13, C33, C43, C53, C83, B23, B33
10 l expansion vessel pre-charge pressure 0.75 bar
Connections heating flow/return 22 mm
Gas inlet 15 22 mm
Pressure relief discharge pipework (min.) 15 mm
Condensate drain (min. internal drain) 19 mm
720 x 440 x 720 x 440 x
Dimensions (H x W x D) 720 x 440 x 335 mm
369 403
Weight (boiler only) 35 35 35 37 38 40 kg
Primary water content 1.9 1.9 1.9 2.1 2.3 2.5 l
Electrical supply voltage 230/50 V ~/Hz
Internal fuse (slow) main voltage 2 A
Power input 100 110 100 110 110 140 W
Table 2.2 Technical data ecoTEC system boiler

2.2 Dimensions
9
440
190
65
8
7
241
175
10
125
883
720
642
11
12
5
4 45
3
75 300
2
130
1 180
ecoTEC plus 630:
334
20
ecoTEC plus 637,

35 35 ecoTEC plus 837:
368
100 100
5 4 3 2 1
Fig. 2.1 Dimensions in mm
Legend:
1 Heating return pipe Ø 22 mm
2 Cold water connection Ø 15 mm (combination boilers only)
3 Gas connection Ø 15 mm
4 Hot water connection Ø 15 mm (combination boilers only)
5 Heating flow pipe Ø 22 mm
6 Hanging bracket
7 Flue hole - flue system 60/100
8 Flue hole - flue system 80/125
9 Spacer frame accessory (Art. No.: 308 650)
10 Flue pipe connection
11 Condensate drain connection (Ø 19 mm)
12 Heating system expansion relief valve connection (Ø 15 mm)
Note
With the spacer frame (Art. No 308 650), the
pipes can be run behind the boiler. The distance
of the appliance from the wall thus increases
by 65 mm.

Boiler specifications 2
2.3 Installation
14 14
1 1
13 13
2 2
3 3
4 4
5
12 5
12
6
11 11
10
7 7
9 9
Fig. 2.2 Function elements of combination boilers Fig. 2.3 Function elements of system boilers
Legend: Legend:
1 Expansion vessel 1 Expansion vessel
2 Air intake pipe 2 Air intake pipe
3 Burner module 3 Burner module
4 Ignition electrode 4 Ignition electrode
5 Fan 5 Fan
6 Diverter valve with by-pass 7 Pump
7 Pump 9 Electronics box
8 Aqua-Sensor 11 Gas valve
9 Electronics box 12 Pressure sensor
10 Hot water heat exchanger 13 Heat exchanger
11 Gas valve 14 Flue pipe connection
12 Pressure sensor
13 Heat exchanger
14 Flue pipe connection
2.4 Type plate

The type plate of the Valliant ecoTEC is attached to the
bottom of the appliance at the factory.

3 General requirements
3 General requirements BS. 5440: Installation and maintenance of flues and

ventilation for gas appliances of rated input not
3.1 Preliminary remarks for room sealed exceeding 70 kW net (1st, 2nd and 3rd family gases).
appliances Part 1 Specification for installation of flues.
This appliance should only be installed in conjunction with Part 2 Specification for installation and maintenance
either a Vaillant flue system or an alternative approved of ventilation for gas appliances.
system (details of flue approval categories can be found
in the technical section of the installation manual). European installation directive
Install the flue system as detailed in the separate flue
installation instructions supplied with this boiler. Caution!
The appliance must be installed and serviced by
3.2 Related documents a competent person approved at the time by
The installation of the appliance and any associated hot the Health and Safety Executive und in
water system must be in accordance with (but not accordance with the Gas Safety (Installation
limited to) the following; COSHH regulations, Gas Safety and Use) Regulations 1998. In IE, the
(Installation and Use) Regulations 1998, Health and installation must be in accordance with the
Safety Document No. 635 (The Electricity at Work current edition of I.S.813 ‘Domestic Gas
Regulations 1989), BS7671 (IEE Wiring Regulations) and Installations’, the current Building Regulations
the Water Supply (Water Fitting) Regulations 1999, or and reference should be made to the current
The Water Bylaws 2000 (Scotland). It should also be in ETCI rules for electrical installation.
accordance with the relevant requirements of the Local
Authority, Building Regulations, The Building Caution!
Regulations (Scotland), The Building Regulations When tightening or slackening screwed
(Northern Ireland) and the relevant recommendations of connections always use suitable open-ended
the following British Standards: spanners (not pipe wrench, or extensions, etc.).
BS 6700: Services supplying water for domestic use Incorrect use and/or unsuitable tools can lead
within buildings and their curtilages. to damage being caused (e.g. gas or water
BS 6798: Specification for installation of gas fired leakage)!
boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises 3.3 Contents included with delivery
(2nd family gas). The Vaillant ecoTEC is delivered pre-mounted in a
BS 7593: Treatment of water in domestic hot water package unit. Check that all the parts have been
central heating systems. delivered intact (see Fig. 3.1 and Table 3.1, Fig. 3.2 and
Institute of Gas Engineers Publication IGE/UP/7/1998: Table 3.2 and Fig. 3.3 and Table 3.3).
”Guide for gas installations in timber framed housing”
BS. 5482 Pt. 1 Domestic butane and propane gas
burning installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2 Gas installation pipework, boosters and
compressors on industrial and commercial premises.
IGE/UP10 Installation of gas appliances in industrial and
commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating
systems.

General requirements 3
8 1 8 1
2 2
7 7
3 3
6 6
4 4
5 5
Fig. 3.1 Contents included with delivery of ecoTEC plus Fig. 3.2 Contents included with delivery of ecoTEC plus
system boilers combination boilers
DO NOT remove the boiler from the polystyrene base at DO NOT remove the boiler from the polystyrene base at
this stage. this stage.
Item Quantity Description Item Quantity Description
1 1 Hanging bracket 1 1 Hanging bracket

2 1 Boiler 2 1 Boiler
3 1 Bottom cover 3 1 Bottom cover
Connecting pipes (gas, heating, water, safety
4 4 Connecting pipes (gas, heating, safety valve) 4 6
valve)
5 3 Isolating valves 5 4 Isolating valves and filling loop
6 1 Template 6 1 Template
User, installation and service and flue instal- User, installation and service and flue installa-
7 3 7 3
lation manuals tion manuals
8 2 Installation and connection accessories 8 2 Installation and connection accessories
For LPG appliances, extra: 1 sticker each for For LPG appliances, extra: 1 sticker each for
2 2
tank and ventilation (above Fig.) tank and ventilation (above Fig.)
Table 3.1 Contents included with delivery of ecoTEC plus Table 3.2 Contents included with delivery of ecoTEC plus
system boilers combination boilers

Note
1
7
If a room sealed boiler is installed in a room
with a bath or shower, electrical switches or
boiler controls using the mains power supply
2 must be placed at locations that cannot be
reached by the person in the bath or shower.
Note
6 If the boiler is to be installed in an airing cup-
board it is not required to separate the boiler
i F P
bar
with a non-combustible partition. However
installation and servicing clearances must be
maintained, and the appliance kept clear of any
clothing.
If the boiler is installed in an unusual location, special

5 procedures may be necessary and BS 5546 and BS 6798
3
give detailed guidance on this aspect. The boiler must
be mounted on a flat, vertical wall, which must be
sufficiently robust to take the weight of the boiler. The
boiler may be installed on a combustible wall, subject to
4 the requirements of the Local Authorities and Building
Regulations. A compartment used to enclose the boiler
must be designed and constructed specifically for this
purpose. (An existing cupboard or compartment may be
used provided that it is modified for the purpose).
Details of essential features of cupboard/compartment
design including airing cupboard installations are given
Fig. 3.3 Contents included with delivery of ecoTEC pro combi- in BS 6798. If the boiler is to be fitted in a timber
nation boilers framed building, it should be fitted in accordance with
Institute of Gas Engineers Publication „IGE/UP/7 Edition
DO NOT remove the boiler from the polystyrene base at 2 Gas installations in timber framed and ligh steel
this stage. framed buildings“. Note the safety instructions below
before deciding where to install the boiler:
Item Quantity Description
1 1 Hanging bracket Caution!
2 1 Boiler Do not install the appliance in rooms prone to
Connecting pipes (hot water, heating safety frost. In rooms with aggressive steam or dust,
3 2
valve) the appliance must be operated independent of
4 4 Isolating valves the ambient air.
5 1 Template
6 1
User, installation and service and flue installa- When choosing the place of installation and while
tion manuals operating the appliance, make sure that the air supply is
7 2 Installation and connection accessories free of chemical substances containing fluorine, chlorine,
Table 3.3 Contents included with delivery of ecoTEC pro combi- sulphur etc. Sprays, solvents and cleaning agents, paints,
nation boilers adhesives etc. contain the kind of substances that can
lead to corrosion even in the exhaust system when the
appliance is operated depending on the ambient air in the
3.4 Installation site worst case scenario. Particularly in hair-cutting salons,
The location chosen for the boiler must permit the pro- lacquering and finishing, cleaning facilities, the appliance
vision of a satisfactory flue termination. The location must be operated independent of the ambient air!
must also provide adequate space for servicing and air Otherwise, a separate installation room is required to
circulation around the boiler. The boiler may be installed guarantee that the air supply is free of the above
in any room, although particular attention is drawn to mentioned substances.
the requirements of BS 7671 (IEE Regulations), the elec-
trical provisions of the Building Standards (Scotland) 3.5 Gas supply
Regulations, and in IE the current edition of IS 813 and The gas supplier should ensure the availability of an
the current ETCI rules, in respect of the installation of a adequate supply of gas. A gas meter may only be
boiler in a room containing a bath or shower. connected to the service pipe by the supplier of gas or

their contractor. An existing meter should be checked to 3.6.2 Optional 125 mm flue system
ensure that it is capable of passing the rate of gas A concentric flue system of 125 mm outside diameter is
supply required. Installation pipes should be fitted in available and can be used to achieve flue lengths up to
accordance with BS 6891. In IE the current edition of IS 25 m.
813. Pipework from the meter to the boiler must be of A vertical flue system is also available. Refer to flue
an adequate size. Do not use pipes of a smaller size system installation instructions for full details.
than the boiler gas connection (15 mm). The complete
installation must be checked for leaks and purged as
1103
described in BS 6891.
3.6 Flue pipe
Danger!
Vaillant appliances are certified only for use 70
with genuine Vaillant flue pipes. Only use
70
genuine Vaillant flue pipes. Malfunctions can
occur if you use other accessories. These may
15
result in damage and injury. You will find a list
of genuine flue pipes in the Vaillant installation
manual for flue pipes. Fig. 3.6 Art. No. 303 209
The CE mark is valid only if the appliance is
operated with Vaillant flue pipes.
3.6.1 Standard 100 mm flue system 650
48
667 87 65
1530
74
880
70
30
Fig. 3.4 Art. No. 303 933 Fig. 3.7 Art. No. 303 200
A standard 100 mm flue system (Art. No. 303 933) is

available. Refer to flue system installation instructions 3.7 Flue termination
for full details. The following details refer to both flue systems.
Flue extensions are available to extend this length up to a. The terminal must be located where the combustible
8 m. Both 90° bends and 45° elbows are also available substances can escape freely at all times.
to increase siting flexibility. 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. If the terminal is fitted less than 2 m above a
balcony, above ground or above a flat roof to which
people have access then a suitable terminal guard
542
must be provided and fitted (made by Tower Flue

Components, Tonbridge, TN9 1TB, Model K3, plastic
1456
coated).
48
901
Fig. 3.5 Art. No. 0020060570

In order to ensure that the condensate plume does

not affect adjacent surfaces the terminal should be
extended as shown in Fig. 3.9.
A 2) Dimension F:
G This clearance may be reduced to 25 mm without
BCD B F
M affecting the performance of the boiler. However, in
G
F order to ensure that the condensate plume does not
J A L
I affect adjacent surfaces a clearance of 300 mm is
H, A F F
K
LK preferred. For IE, recommendations are given in the
E A
G current edition of IS 813.
Fig. 3.8 Flue termination
Note
Vertical flues must not terminate within
600 mm of an openable window, air vent or any
other ventilation opening.
The flue assembly shall be so placed or shielded as to

prevent ignition or damage to any part of the building.
Terminal position mm
Directly below an opening, above an opening or hori-
A 300
zontal to an opening, air brick, opening window, etc. Fig. 3.9 Flue termination under balcony/eaves
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200 3.8 Air supply
E From vertical drain pipes and soil pipes 25 Detailed recommendations for air supply are given in
F From internal or external corners 300 BS 5440: Part 2.
G Above ground, roof or balcony 300 It is not necessary to have an air vent in the room or
H From a surface facing a terminal 600 internal space in which the boiler is installed.
I From a terminal facing a terminal 1200
From an opening in the car port (e.g. door, window)
Cupboard or compartment ventilation
J 1200 The boilers are very high efficiency appliances. As a
into the dwelling
K Vertically from a terminal on the same wall 1500 consequence the heat loss from the appliance casing
during operation is very low. For cupboard or
L Horizontally from a terminal on the same wall 300
compartment installations it is therefore not necessary
M Distance from adjacent for vertical Flue 500
to provide any high or low level permanent air vents for
Table 3.4 Terminal position for a fan assisted concentric flue cooling purposes.
3.9 Electrical supply

Note A 230 V, ~ 50 Hz single phase electricity supply fused to
In addition, the terminal should not be nearer 3 Amp. must be provided in accordance with the latest
than 150 mm to an opening in the building fab- edition of BS 7671 (IEE Wiring Regulations) and any
ric formed for the purpose of accommodating a other local regulations that may apply. In IE reference
built-in element such as a window. should be made to the current edition of the ETCI rules.
The method of connection to the mains electricity
BS 5440–1: It is recommended that the fanned flue supply must provide a means of completely isolating the
terminal should be positioned as follows: boiler and its ancillary controls. Isolation is preferably
a) at least 2 m from an opening in the building directly by the use of a fused three pin plug and unswitched
opposite, and shuttered socket outlet, both complying with the
b) so that the products of combustion are not directed requirements of BS 1363. Alternatively, a 3 Amp. fused
to discharge across a boundary. double pole switch with a 3 mm contact separation on
both poles may be used.
1) Dimensions B, C and D:
These clearances may be reduced to 25 mm without Danger!
affecting the performance of the boiler. This appliance must be earthed.

3.10 Guide to system requirements Vaillant accepts no liability for the compatibility of any
additive or its effectiveness in the entire heating
3.10.1 Water circulation system system.
Detailed recommendations for the water circulation
system are given in BS 6798 and BS 5449: Part 1 (for Additives for cleaning purposes
small bore and micro bore central heating systems). (subsequent flushing required)
Pipework not forming part of the useful heating surface - Fernox F3
should be insulated to help prevent heat loss and - Jenaqua 200
possible freezing, particularly where pipes are run - Jenaqua 300
through roof spaces and ventilated underfloor spaces. - Jenaqua 400
Draining taps must be located in accessible positions - Sentinel X 300
which permit the draining of the whole system including - Sentinel X 400
the boiler and the hot water system. Draining taps
should be at least 1/2 in. BSP nominal size and be in Additives intended to remain permanently in the
accordance with BS 2879. system
The boiler is suitable for use with minibore or microbore - Fernox F1
systems. Copper tubing to BS 2871: Part 1 should be - Fernox F2
used for water carrying pipework. All capillary joints in - Jenaqua 100
all DHW pipework must be made with lead free solder. - Jenaqua 110
Particularly where a new boiler is to be fitted to an - Sentinel X 100
existing system, it is good practice that the system is - Sentinel X 200
thoroughly cleansed.
Additives for frost protection intended to remain
Caution! permanently in the system
To prevent the formation of deposits and pre- - Fernox Antifreeze Alphi 11
vent serious damage to the appliance and sys- - Sentinel X 500
tem, cleansers must be used carefully and must
be completely removed by thoroughly flushing • Inform the operator of the necessary measures in
the system. Cleansers should only be left in case you have used any of these additives.
systems for a maximum of 24 hours. • Inform the operator of the required procedures for
frost protection.
This cleansing must take place prior to the fitting of the • Observe the applicable national regulations and
new boiler and be in accordance with BS 7593. For technical standards for the treatment of filling and
advice on the application of system cleansers contact top-up water.
Sentinel, Betz Dearborn Ltd. Widnes, Cheshire, WA8 Provided the national regulations and technical
8UD. Tel: 0151 420 9595, or Fernox, Alpha Fry standards do not specify any higher requirements, the
Technologies, Tandem House, Marlow Way, Croydon, following applies:
CR0 4XS. Tel 0870 8700362. • You must treat the heating water
- if the total volume of filling and top-up water
3.10.2 Filling and preparing heating system exceeds thrice the nominal volume of the heating
The system can be filled using the built in filling loop system over the service life of the system
(ecoTEC plus combination boilers only) or via a separate or
filling point fitted at a convenient position on the - if the limits given in the following tables are not
heating circuit. The connection must be removed when adhered to.
filling is completed. Where local Water Authority
regulation does not allow temporary connection, a
sealed system filler pump with break tank must be used.
The heating system will not be filled automatically from
the domestic hot water side. (Alternative methods of
filling sealed systems are given in BS 5449).
Mixing additives with the heating water can result in

material damage. However, up to now, no
incompatibility with Vaillant appliances has been
detected with proper use of the following products.
• When using additives, follow the additive
manufacturer‘s instructions without exception.

Total heating Total hardness at 20 l/kW Total hardness at > 20 l/kW Total hardness at > 50 l/kW
output for the smallest boiler heating < 50 l/kW for the smallest boiler for the smallest boiler heating
surface2) heating surface2) surface2)
kW mol/m3 mol/m3 mol/m3
< 50 No requirement or < 3 1)
2 0,02
> 50 to ≤ 200 2 1,5 0,02
> 200 to ≤ 600 1,5 0,02 0,02
> 600 0,02 0,02 0,02
1) with systems equipped with wall-hung boiler and systems with electric heating elements
2) of the specific system volume (nominal capacity in litres/heating output; in case of multiple boiler systems the lowest individual
heating output should be used)
These data only apply up to 3x the system volume for filling and top-up water. Once this triple system volume is exceeded, the
water will have to be treated exactly the same as in case of exceeding the limit values given in Table 3.6 (softening, desalination,
hardness stabilisation and desludging).
Table 3.5 Guidelines for the heating water: Water hardness
Heating water
3.10.3 Pressure relief valve
Unit Low-salt saline A pressure relief valve is provided with the boiler. This
qualities
safety device is required on all sealed C.H. systems and
Electric conductivity
µS/cm < 100 100-1500 is preset at 3 bar and provided with a 15 mm
at 25 °C
compression connection for a discharge pipe, which
Appearance Free of sedimentary substances
must be of no less than 15 mm in diameter. The pressure
pH-value at 25 °C 8,2-10,01) 8,2-10,01) relief valve must not be used for draining purposes.
Oxygen mg/L < 0,1 < 0,02
3.10.4 Pressure gauge
1) With aluminium and aluminium alloys, the ph value range is
This is factory fitted to the boiler and indicates the
restricted from 6.5 to 8.5.
primary circuit pressure to facilitate filling and testing.
Table 3.6 Guidelines for heating water: Salinity
3.10.5 Expansion vessel
ecoTEC boilers incorporate a 10 litre expansion vessel
Caution! which is suitable for a sealed heating system with a
Aluminium corrosion resulting in leakages maximum water content of 100 litres.
caused by unsuitable heating water! If the nominal capacity of the built in expansion vessel is
Unlike materials such as steel, cast iron or cop- not sufficient for the heating system (for instance in
per, aluminium is reactive to alkalised heating case of modernisation of old open systems) an
water (pH-value > 8,5) which results in signifi- additional expansion vessel can be installed external to
cant corrosion. the boiler. It should be fitted in the return pipe as close
With aluminium, ensure that the pH value of as possible to the boiler in accordance with BS 5449:
the heating water ranges between 6.5 up to a Part 1.
maximum of 8.5. Guidance on the sizing of an additional expansion vessel
is given in Table 3.7.
Caution!
Risk of material damage if the heating water is
treated with unsuitable frost or corrosion pro-
tection agents!
Frost and corrosion protection agents may
cause changes in the seals, noises during heat-
ing and possibly subsequent damage.
Do not use any unsuitable frost or corrosion
protection agents.

Vessel Volume [L]

400
Lift [mbar]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0 300
Total water content of system litres
25 2.7 3.9 200
50 5.4 7.8
1. Step 2. Step
100 10.9 15.6 100
125 13.6 19.5
150 16.3 23.4 0
175 19.1 27.3 0 200 400 600 800 1000 1200 1400 1600 1800 2000
200 21.8 31.2 Volumeflow [l/h]
225 24.5 35.1
250 27.2 39.0 Fig. 3.10.2 Pump specifications only ecoTEC 637 and 837
275 30.0 42.9
300 32.7 46.8 only ecoTEC pro:
325 35.7 50.7 The circulating pump is included in the boiler. The
350 38.1 54.6 ecoTEC pro appliances are fitted with a single-stage
375 40.9 58.5 pump. The residual pump discharge height depending on
400 43.6 62.4 the by-pass valve is shown in Fig. 3.11.
425 46.3 66.3 Lift [mbar]
450 49.0 70.2 400

475 51.8 74.1
500 54.5 78.0 300
For system volumes other than those given
above, multiply the system volume by the 0.109 0.156 200
factor across
Table 3.7 Sizing of additional expansion vessel 100
0
3.11 Pump specifications 0 200 400 600 800 1000 1200 1400 1600 1800
Volumeflow [l/h]
3.11.1 Circulating pump
Fig. 3.11 Pump specifications ecoTEC pro
only ecoTEC plus:
The circulating pump is included in the boiler. The residual
pump discharge height depending on the by-pass valve is 3.11.2 System by-pass
shown in Fig. 3.10.1 (ecoTEC plus) and 3.10.2 (ecoTEC plus An automatic system by-pass is provided in the boiler.
637 / 837). The boiler is suitable for use in systems with
The operating mode of the 2-step pump can be adjusted thermostatic radiator valves and no additional by-pass
below the diagnosis number “d.19”, see section 8.1.2. is required. The by-pass valve is adjustable, see section
5.3.
Lift [mbar]
400
3.11.3 Venting
300
The boiler is fitted with an automatic air vent. Additional
provision should be made to enable the heating system
200 to be vented during filling and commissioning either by
automatic air vents or manually.
1. Step 2. Step
100
3.12 Condensate trap
0 The boiler is fitted with a siphonic condensate discharge
0 200 400 600 800 1000 1200 1400 1600 1800 (ecoTEC plus) or a condensate trap (ecoTEC pro)
Volumeflow [l/h]
incorporating a water trap of 140 mm.
Fig. 3.10.1 Pump specifications ecoTEC plus

(except ecoTEC 637 and 837)

4 Boiler installation sequence
4 Boiler installation sequence movements during lift. Avoid upper body/top heavy
bending - do not lean forward/sideways. Clear the route
4.1 Transporting the appliance before attempting the lift. If removing boiler from truck
straddle the load and tilt forwards to facilitate secure
Caution! grip. Ensure safe lifting techniques are used – keep back
With regards to the Manual Handling straight – bend using legs. Do not twist – reposition feet
Operations, 1992 Regulations, the following lift instead. Take care to avoid trip hazards, slippery or wet
operation exceeds the recommended weight for surfaces and when climbing steps and stairs. Always use
a one man lift. assistance if required.
General recommendations when handling Carriage of carton from point of delivery to point of
Clear the route before attempting the lift. Ensure safe installation – roofspace.
lifting techniques are used – keep back straight – bend Recommend 2-person lift. Ensure co-ordinated move-
using legs. Keep load as close to body as possible. Do ments during lift. Avoid upper body/top heavy bending -
not twist – reposition feet instead. If 2 persons do not lean forward/sideways. Clear the route before
performing lift, ensure co-ordinated movements during attempting the lift. Take care to avoid trip hazards, slip-
lift. Avoid upper body/top heavy bending - do not lean pery or wet surfaces and when climbing steps and
forward/sideways. Recommend wear suitable cut stairs. When transferring appliance into roofspace, rec-
resistant gloves with good grip to protect against sharp ommend 1 person to be in roofspace to receive the
edges and ensure good grip. Always use assistance if appliance and other person to be below to pass up and
required. support appliance. Ensure safe lifting techniques are
used – keep back straight – bend using legs. Keep load
Removal of carton from delivery van as close to body as possible. Always use assistance if
Recommend 2 person lift or 1 person with use of sack required. It is assumed safe access, flooring and ade-
truck. If 1 person is performing lift, straddle the load, tilt quate lighting are provided in the roof space. It is rec-
and place carton into position on truck. Recommend ommended a risk assessment of the roof space area be
secure appliance onto truck with suitable straps. Ensure carried out before moving the appliance into the area to
safe lifting techniques are used – keep back straight – take into account access, stability of flooring, lighting
bend using legs. Keep load as close to body as possible. and other factors, and appropriate measures taken.
If 2 persons performing lift, ensure co-ordinated move-
ments during lift. Always use assistance if required. Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton.
Carriage of carton from point of delivery to point of Always keep working area clear. Recommend cut base
installation – ground floor. end of carton and open carton flaps, then tilt boiler for-
Recommend 2 person lift or 1 person with use of sack wards from its side onto its base and remove carton by
truck. If 1 person is performing lift, straddle the load, tilt sliding up over the boiler. Ensure safe lifting techniques
and place carton into position on truck. Recommend are used – keep back straight – bend using legs. Keep
secure appliance onto truck with suitable straps. Ensure load as close to body as possible. Always use assistance
safe lifting techniques are used – keep back straight – if required. Dispose of packaging in a responsible man-
bend using legs. Keep load as close to body as possible. ner. Recommend wear suitable cut resistant gloves with
If 2 persons performing lift, ensure co-ordinated move- good grip to protect against sharp edges and ensure
ments during lift. Clear the route before attempting the good grip when handling appliance outside packaging.
lift. If removing boiler from truck straddle the load and
tilt forwards to facilitate secure grip. Ensure safe lifting Positioning of Appliance for Final Installation –
techniques are used – keep back straight – bend using no obstructions.
legs. Do not twist – reposition feet instead. Take care to This appliance is deemed to be a one person lift when
avoid trip hazards, slippery or wet surfaces and when removed from the carton. Fit bracket securely onto wall
climbing steps and stairs. Always use assistance if before lifting appliance into position. Obtain firm grip on
required. front and sides of appliance, lift upwards, ensure stable
balance achieved and lift upwards to position in place on
Carriage of carton from point of delivery to point of bracket. Ensure safe lifting techniques are used – keep
installation – first or higher floor, cellar. back straight – bend using legs - when lifting load from
Recommend 2-person lift or 1 person with use of sack floor level. Do not twist – reposition feet instead. Keep
truck. If 1 person is performing lift, straddle the load, tilt boiler as close as possible to body throughout lift to
and place carton into position on truck. Recommend minimise strain on back. Ensure co-ordinated move-
secure appliance onto truck with suitable straps. Ensure ments to ensure equal spread of weight of load. Always
safe lifting techniques are used – keep back straight – use assistance if required. Recommend wear suitable
bend using legs. Keep load as close to body as possible. cut resistant gloves with good grip to protect against
If 2 persons performing lift, ensure co-ordinated sharp edges and ensure good grip when handling appliance.

Boiler installation sequence 4
Positioning of Appliance for Final Installation – above with good grip to protect against sharp edges and
worktop, foreseeable obstructions etc. ensure good grip when handling appliance. It is recom-
This appliance is deemed to be a one person lift when mended a risk assessment of the roof space area be
removed from the carton. Fit bracket securely onto wall carried out before moving the appliance into the area to
before lifting appliance into position. Obtain firm grip on take into account access, stability of flooring, lighting
front and sides of appliance, lift upwards, onto worktop and other factors, and appropriate measures taken.
if practicable. Ensure stable balance achieved and lift
upwards to position in place on bracket. If 2 persons 4.2 Required minimum distances/assembly clearances
positioning onto bracket obtain firm grip at front and
sides/base of boiler. Ensure coordinated movements
165/246*
during 2 person lifts to ensure equal spread of weight of
min
load. Ensure safe lifting techniques are used – keep back
straight – bend using legs - when lifting load from floor
level. Do not twist – reposition feet instead. Keep boiler min 500**
min 5 min 5
as close as possible to body throughout lift to minimise
strain on back. Avoid upper body/top heavy bending -
do not lean forward/sideways. 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.
min 180
Positioning of Appliance for Final Installation – within
compartment etc. restricting installation.
This appliance is deemed to be a one person lift when
removed from the carton. Fit bracket securely onto wall Fig. 4.1 Distances during installation (dimensions in mm)
before lifting appliance into position. Obtain firm grip on
front and sides of appliance, lift upwards, onto worktop if The boiler should be mounted on a flat and vertical area
practicable. Ensure stable balance achieved and lift of wall of sufficient area for the boiler plus the required
upwards to drop into place onto bracket. If 2 persons posi- clearances for installation and servicing (Fig. 4.1). These
tioning onto bracket obtain firm grip at front and sides/ are shown on the installation template supplied with the
base of boiler. Ensure coordinated movements during 2 boiler and are:
person lifts to ensure equal spread of weight of load. If 1 – 5 mm either side of the boiler
person positioning onto bracket recommend obtain firm – 180 mm below the boiler
grip supporting base of boiler. Ensure safe lifting tech- – 165 mm* above the boiler when utilising the 100 mm
niques are used – keep back straight – bend using legs - outside diameter flue
when lifting load from floor level. Do not twist – reposition – 246 mm* above the boiler when utilising the 125 mm
feet instead. Keep boiler as close as possible to body outside diameter flue
throughout lift to minimise strain on back. Always use – 500 mm in front of the boiler to enable easy access
assistance if required. Recommend wear suitable cut for servicing (may be provided by an opening door)
resistant gloves with good grip to protect against sharp
edges and ensure good grip when handling appliance. Note
If the boiler is to be installed in a timber framed
Positioning of Appliance for Final Installation – in building, it should be fitted in accordance with
roof space restricting installation. „IGE/UP/7 Edition 2 Gas installations in timber
This appliance is deemed to be a one person lift when framed and ligh steel framed buildings“.
removed from the carton. Obtain firm grip on front and
sides of appliance, lift upwards, ensure stable balance
achieved and lift upwards to drop into place onto 4.2.1 Select position for boiler
bracket. If 2 persons positioning onto bracket obtain Refer to section 3.4 ‘Installation site’ for information
firm grip at front and sides/base of boiler. Ensure co- regarding the appliance location. In general the boiler
ordinated movements during 2 person lifts to ensure must be positioned such that:
equal spread of weight of load. If 1 person positioning • There is adequate space around the boiler for service
onto bracket recommend obtain firm grip supporting and maintenance
base of boiler. Ensure safe lifting techniques are used - • The boiler can be correctly flued, i.e. the flue terminal
keep back straight – bend using legs - when lifting load position is located in accordance with these instruc-
from floor level. Do not twist – reposition feet instead. tions and the air/flue duct can be installed in accord-
Keep boiler as close as possible to body throughout lift ance with the flue installation instructions supplied.
to minimise strain on back. Always use assistance if • All necessary pipework can be connected, including
required. Recommend wear suitable cut resistant gloves the pressure relief valve and condensate drain.

4.2.2 Unpack the boiler • Fix the paper template to the wall ensure that the
To unpack the boiler, cut both plastic carton straps, template is vertical.
open box and lift out the polystyrene top packing. Lift
the cardboard box upwards. The template shows:
– The position of the fixing holes for the boiler
Note mounting bracket.
Care should be taken not to scratch the white – The position of the connections.
surface of the boiler casing. – The position of the flue exit hole.
• Mark the position of the hanging bracket fixing holes.

4.2.3 Using boiler template • Drill 2 holes Ø 10 mm for the hanging bracket.
Note
Use alternative fixing holes where necessary.
20
4.3 Flue exit

• If using rear flue mark the position of the air/flue duct
and its circumference.
165
5
95
Other flue options

175
60/100 5
Flue instructions for other flue systems such as vertical
RSF flues, flues run to the side of the boiler and the use
25
of additional bends etc. are detailed in the flue
installation instructions provided with the boiler.
• Remove the template from the wall and plug the
drilled holes using the wallplugs supplied.
A A
4.4 Fitting the boiler hanging bracket
A
1065
Fig. 4.3 Appliance with hanging bracket
• Fix the hanging bracket to the wall using the plugs

A A
and screws provided with the appliance.
Note
Use alternative fixing holes where necessary.
180
Note
01 2005
45
If the boiler is to be fitted in a timber framed

256723_01
building ensure that the bracket is secured to a

450
substantial part of the timber frame capable of
taking the weight of the boiler.
Fig. 4.2 Assembly template

4.5 Installing the flue system - The appliance is fitted with an expansion vessel
• Install the flue system (refer to the seperate air/flue (10 l/0.75 bar).
duct installation instructions). • Before assembling the appliance check if this volume
is adequate. If not, an extra expansion vessel must be
4.6 Fitting the boiler installed, see section 3.10.5.
• Lift the boiler (3) up to the wall so that it is slightly
above the hanging bracket (1). 4.9 Gas connection
Note Note
Lift the boiler from either side at the bottom With the spacer frame (Art. No 308 650), the
edge pipes can be fitted vertically upwards behind
the appliance. The distance of the appliance
• Lower the boiler slowly onto the hanging bracket so from the wall thus increases by 65 mm.
that the cross member at the rear of the boiler fully
engages onto the hanging bracket. Danger!
The gas connection may only be made by a
competent person approved at the time by the
4.7 Removing the front case Health and Safety Executive and in accordance
with the gas safety (installation and use)
regulations 1998.
2 The legal directives and the local regulations
for gas supply companies must be observed.
Caution!
Ensure a stress-relief assembly of the gas
pipes to avoid leakages!
1
Caution!
The gas regulating block may be tested for
leakage only with a maximum pressure of
150 mbar!
Higher testing pressures can damage the gas
fitting.
Caution!
When making final connection to the boiler, if
using soldered fittings, extra care should be
taken to avoid damage to isolation valves
through heat transfer.
Fig. 4.4 Removing/fixing the front case
To remove the front section of the case, proceed as

follows:
• Loosen the screw (1) on the bottom of the unit.
• Push in the two retaining clips (2) on the bottom of
the appliance until the case is released.
• Grasp the front case by its bottom edge, pull it towards
the front and remove it by lifting it off the unit.
4.8 General instructions for heating system
Caution!
Thoroughly cleanse the heating system before
connecting the appliance!
By doing that, residue such as welds, cinder,
hemp, putty, rust, rough dust and similar
substances are removed from the pipes.
Otherwise such substances can be deposited in
the appliance and cause damage.

4.10 Cold water mains inlet and hot water outlet

(ecoTEC combination boilers only)
7
2
3
6
4
5
6
7 1
2
3
Fig. 4.5 Fitting the gas connection (example ecoTEC plus com-
4
bination boiler)
5
• Fit the union nut (2) and the compression olive (3) to
the gas connection pipe (1) of the boiler. Fig. 4.6 Installing the hot and cold water connection
• Fit the union nut (6) and the compression olive (5) to (ecoTEC plus combination boiler)
the pre-formed tail provided with ecoTEC plus
appliances (7).
• Fully insert the service valve (4) onto the gas
connection pipe and the pre-formed tail into the
service valve. Tighten both union nuts of the service bar
valve.
• The diameter of the pipework (7) is 15 mm (22 mm for
37kW models). Connect a gas supply pipe of not less
than 15 mm diameter to the copper tail.
Note
7
Ensure the gas supply pipework is adequately
sized so that a 20 mbar gas pressure is 6
available at the boiler inlet at full flow rate.
1
• Tighten all connections.
• Check the gas connection with leak indicator spray for 2
leakage. 3
4
5
Fig. 4.7 Installing the hot and cold water connection

(ecoTEC pro combination boiler)
Caution!
taken to avoid damage to isolation valves

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.
• Fit the union nut (4) and the compression olive (3) to 1
the pre-formed tail provided with ecoTEC plus
2
appliances (5). The diameter of the pipe is 15 mm.
• Fully insert the pre-formed tail into the service valve.
Tighten the union nuts. 4
a b c d
• Insert the seal (7) and connect in the pipe (6) to the
6
appliance hot water connection. The diameter of the
pipe is 15 mm. 3 3 5 7
• Mount the handle for the filling loop with a counter- Internal Internal Gulley Soakaway
sunk screw to the service valve (2). stackpipe discharge system
4.11 Condensate drain pipe Fig. 4.8 Installing the condensate drain pipe (picture shows
The ecoTEC plus appliances are fitted with a siphonic ecoTEC plus combination boiler)
trap (The filling height is 145 mm). The siphon collects
the accumulated condensate in a container of approx. The condensate discharge pipe must terminate in a
200 ml capacity and directs the entire content into the suitable position, e.g.:
drain pipe. The risk of the condensate drain pipe a)preferably the discharge pipe should run and
freezing is thus minimised. terminate internally to the house soil and vent stack
The ecoTEC pro appliances are equipped with a normal (at least 450 mm above the invert of the stack). A trap
condensing water trap where the condensate is giving a water seal of at least 75 mm (3) (built into the
constantly emptied into the drain pipe. boiler) should be incorporated into the pipe run, and
• Connect the boiler condensate drain (1) to a there must be an air break (4) in the discharge pipe
condensate discharge pipe (2) which should be upstream of the trap. The connection to the stack
minimum of 19 mm internal diameter (22 mm external should not be made in a way that could cause cross
diameter for any pipework installed external to the flow into any other branch pipe, or from that branch
property) and be made of an acid resistant material pipe into the condensate drainpipe. This can be
(e.g. plastic overflow pipe). achieved by maintaining an offset between branch
pipes of at least 110 mm on a 100 mm diameter stack
Note and 250 mm on a 150 mm diameter stack.
If a boiler does not include a siphon then any b)connecting into the internal discharge branch
external condensate drainage pipe shall be (e.g. sink waste or washing machine) with an external
increased to a minimum diameter of 32 mm termination, the condensate discharge pipe should
nominal diameter to reduce the risk of freezing. have a minimum diameter of 22 mm with no length
In exposed locations, the condensate drainage restriction and should incorporate a trap with a 75 mm
pipework shall be protected with waterproof (3) (built into the boiler) seal. The connection should
pipe insulation. Additionally when a boiler is preferably be made down stream of the sink waste
installed in an unheated location such as a trap. If the connection is only possible upstream, then
garage all condensate drainage pipes should be an air break is needed between the two traps. This is
considered as external. normally provided by the sink waste.
c) terminating in a gully (5) below grid level (6) and
Note above the water level. The external pipe length should
The discharge pipe from the boiler condensate be kept as short as possible to minimise the risk of
drain must have a continuous fall (45 mm per freezing and should not be more than 3 m.
meter) and preferably be installed and d)at a condensate absorption point (soakaway) (7). The
terminated within the building to prevent external pipe length should not be more than 3 m.
possible freezing.
Refer to ‘BS 6798 Specification for installation of
gasfired boilers of rated input not exceeding 70 kW net’
for further information. Before operating the boiler the
condensate trap (1) must be filled with water as
described in relevant section.

4.12 Heating connection ecoTEC pro combination boiler
Caution!
taken to avoid damage to isolation valves bar
4.12.1 Heating flow and return connection
Note
Before connecting the heating circuit to the 1
2
boiler, all pipework and radiators must be
thoroughly flushed to remove any installation 3
4
debris. 5
ecoTEC plus combination boiler
13 Fig. 4.10 Heating flow and return connection for ecoTEC pro
12
combination boiler
11
10 • Insert a seal (1) and fit the service valves (2) to the
9 flow and return connection of the appliance.
8 • Fit a union nut (4) and a compression olive (3) to the
7 22 mm pre-bended copper tail (5).
6
1 • Fully insert pipe (5) into the service valve. Tighten the
2 union nuts in this position.
3
4 ecoTEC plus system boiler
5
Fig. 4.9 Installing the heating flow and return connection for
ecoTEC plus combination boiler
• Insert the seal (1) and fit the service valve (2) to the
return connection of the appliance.
• Insert the seal (10) and fit the service valve (9) to the
flow connection of the appliance.
• Install the O-ring seal (12) on the return valve (11).
Note 1
2
Lay the filling loop hose (13) above the
pipework elbows. 3
4
5
• Fit the union nuts (4) and (7) as well as the
compression olives (3) and (8) to the pre-bended
22 mm copper tails (5) and (6). Fig. 4.11 Heating-side flow and return connection for
• Fully insert pipes (5) and (6) into the service valves. ecoTEC plus system boiler
Tighten the union nuts in this position.
• Fit the handle for the filling loop with a countersunk • Insert a seal (1) and fit the service valves (2) to the
screw to the service valve (9). flow and return connection of the appliance.
• Fit a union nut (4) and a compression olive (3) to the
22 mm pre-bended copper tail (5).
• Fully insert pipe (5) into the service valve. Tighten the
union nuts in this position.

Caution! 4.14 Electrical connection

To ensure fumes do not escape through the syphon
of the boiler the trap must be filled with water be- 4.14.1 General requirements
fore the boiler is turned on. Therefore the discharge
pipework should be installed so as not to interfere Danger!
with the removal and refitting of the condensate Electrocution caused by touching live parts can
trap, we recommend the outlet pressure release be fatal.
valve pipe supplied is not shortened. You must Before working on the appliance, turn off the
leave a bottom clearance of at least 180 mm below power supply and secure against restart.
the condensate trap for removal and refitting.
All electrical work shall be carried out by a competent
person and shall comply with BS 7671 (IEE Regulations). In
4.12.2 Pressure Relief Valve the Republic of Ireland, reference should be made to the
current edition of the ETCI (Electro-Technical Council for
Ireland) rules. The boiler is supplied for connection to
230 V, ~ 50 Hz supply fused at 3 A rating. Connection to
the mains supply shall be made via a fused 3 pin plug to
an unswitched shuttered socket, both complying with the
requirements of BS 1363. (Alternatively, connection may
be made via a 3 A fused double pole isolator having a
contact separation of at least 3 mm in all poles and
supplying the boiler and controls only). The point of
connection to the mains supply must allow complete
electrical isolation of the boiler and its ancillary controls.
It should be readily accessible and adjacent to the boiler.
A 3 core flexible cord according to BS 6500 Tables 6, 8
or 16 (3 x 0.75 to 3 x 1.5 mm2) should be used.
1 Danger!
min.
180 2 This appliance must be earthed.
Danger!
3 Mains connection terminals L and N remain live
even when the boiler on/off control is switched
off.
Fig. 4.12 Installing the drain pipe on the pressure release valve Note
of the heating system (picture shows ecoTEC plus Do not connect any power voltage to the
combination boiler) connections 7-8-9 or BUS (+,-).
The pressure release valve for the heating system is Note

integrated in the appliance. Ensure that all cords pass through the cable
• Position the seal (1) and screw the drain pipe (2) on to clamps in the rear of the control box and are
the pressure release valve. securely fixed. Ensure that the power supply is
connected such that the current carrying
The discharge pipework should be as short as possible conductors become taut before the earth
and installed with a continuous fall away from the boiler. conductor should the supply cord slip from the
The pipe should terminate in a position which ensures cable clamp.
that any discharge of water or steam from the valve
cannot create a hazard to persons in or around the
premises, or cause damage to any electrical compo-
nents or external wiring, and the point of discharge
should be clearly visible.
4.13 Connecting the flue system to the boiler

• Refer to separate air/flue duct installation instructions
included with the boiler.

4.14.2 Connection to the main supply
- + 7 89 L N 3 45
- + 7 89 L N 3 45
Fig. 4.14 Wiring system
• Connect the flex to the L, N and earth plug to the

terminal block.
Green/yellow (earth) wire – boiler terminal Earth sign
Blue (neutral) wire – boiler terminal N
Brown (live) wire – boiler terminal L
Note
Do not connect any power voltage to the
Fig. 4.13 Opening the electronics box connections 7-8-9 or BUS (+,-).
• Remove the front case and lower the control panel. Note
• Unclip the bottom of the terminal box cover and hinge Ensure that the wires are securely fixed in the
back to reveal the connection plugs. terminal block.
• Feed the power supply flex into the appliance and the
control panel through the cable clamps provided and • Refit the terminal box cover by pushing into place
tighten. until it clips back into position.
• Raise the control panel.

4.14.3 Electric board layout
eBUS accessory connection
Burner cable harness
Accessory module connection
Diagnosis via eBUS,

vrnetDIALOG
outer probe
ext. flow or return probe
Hydraulic cable harness

Connection for external
eBUS controller Caution:
Do not connect
Room thermostat 24 V: supply voltage!
Connection 7, 8 and 9 Risk of damage
No bi-directional to electronics!
interface (analogue only)
Mains supply: 230 V/50 Hz
Room thermostat 230 V/50 Hz

(remove bridge on connection)
Heating pump
With ecoTEC pro: 1-step pump (plug with 3-pin)
With ecoTEC plus: 2-step pump (plug with 5-pin)
2A fuse, slow
Igniter
Connection: 230 V
Supply for accessory module
Fig. 4.15 Connection wiring ecoTEC

NTC NTC
flow return 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
X 2/8 blue D
Water pressure sensor
X 2/9 black Diverter valve
X 2/11 red
X 2/12 green
Pump
Aqua sensor
X 2/4 orange
X 2/3 red (+ 5V)
X 2/10 black
X 2/2 black (earth) NTC
X 2/6 green (signal) Plate heat
X 2/5 violet (signal) exchanger
X 2/1 black
ecoTEC plus only:
NTC
Hot water
outlet
X40 X41
X 20 X2 — + 7 8 9 L N 3 4 5
BUS 24V 230V
X12
X31
Electronic control box
Fig. 4.16 Connection wiring ecoTEC combination boiler

NTC NTC
flow return 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
X 2/14 brown contact C1/C2
Pump
Water pressure sensor
X 2/9 black
X 2/11 red
X 2/12 green
X 2/4 orange
tank NTC
X 2/10 black connection
X40 X41
X 20 X2 — + 7 8 9 L N 3 4 5
BUS 24V 230V
X12
X31
Electronic control box
Fig. 4.17 Connection wiring ecoTEC system boiler

4.15 Controls
4.15.1 Vaillant controls and accessories
Controller Item no. Connection

VRC 400 (1-circuit controller, weather-controlled) 00 2001 0843 Installation in electronics box (plug-and-play)
VRT 360 (room temperature controller) 00 2001 0842 Wall-mounted, 2-wire bus
Available from 10-01-2006
VRT 360f (room temperature controller) 00 2001 8258 Wireless controller, receiver wall-mounted
VRT 230 (room temperature controller) 00 2001 0841 Wall-mounted, 3-wire connection to terminals 3-4-5
timeSWITCH 140 (timer) 306 760 Installation in electronics box (plug-and-play)
timeSWITCH 130 (timer) 306 759 Installation in electronics box (plug-and-play)
VRT 30 (room thermostat) 300 637 Wall-mounted, 3-wire connection to terminals 3-4-5
VRT 50 (room thermostat) 00 2001 8265 Wall-mounted, 2-wire bus
Telecommunication Item no. Connection
vrnetDIALOG 830 (Int) 00 2000 3988 GSM/GPRS, installation in electronics box (plug-and-play)
vrnetDIALOG 860/2 (Int) 00 2000 3984 Wall-mounted, GSM/GPRS, up to 16 appliances
Accessories Item no. Connection
VR 65 control centre for UK cylinder installation (eBUS) 307 215 System solution for UK cylinder connection
vrDIALOG 810/2 00 2002 3370 Diagnostic software
Table 4.1 Vaillant controls and accessories
4.15.2 External electrical controls If a room thermostat is to be connected in addition to a

The boiler terminals 3, 4 and 5 are for connecting time switch the wire between the time switch “ON”
external electrical controls such as a time switch and/or terminal and boiler terminal 4 should be broken by the
room thermostat. Terminals 3 and 4 are linked together contacts of the room thermostat (see schematic layout,
when the boiler is supplied. If external controls are used, Fig. 4.18).
this link must be removed, and the controls connected
across terminals 3 and 4. Terminal 5 is an additional 4.15.4 Vaillant optional plug in timer accessories
neutral connection for external neutrals such as from Refer to the instructions supplied with the optional
the anticipator of a room thermostat. accessories for connection details. Upon completion of
all electrical connections refit the terminal box cover by
4.15.3 Connection details for external time switches pushing into place. The cover is secured by two locking
and boiler terminal strip clips.
20 VDC (DO NOT USE 7, 8, 9 IN UK!) 4.15.5 Connection details using the VR 65 Control
Center
7 8 9 L N 3 4 5
The VR 65 Control Center is an eBUS system component.
In a storage unit installation, it is responsible for the
communication between the storage unit, the
ecoTEC plus system boilers and external 2- or 3-way-
N valves. Connect the VR 65 Controll Center as described
L in the enclosed manual.
SWITCH ROOM
3 A FUSE
CONTACTS THERMOSTAT
MAINS
SUPPLY
230 V L
50 Hz N CLOCK
N
Fig. 4.18 Connection details for time switches

4.16 Thermostatic radiator valves

The boiler has a built in automatic by-pass valve making
it ideal for use in systems with thermostatic radiator
valves (no separate system by-pass is required). For
optimum fuel economy where TRV’s are used they must
be used in conjunction with a boiler control interlock. A
programmable room thermostat or separate timer and
room thermostat will ensure complete boiler shut down
when the heating demand is satisfied. (The radiator in
the room containing the room thermostat should not be
fitted with a TRV).
4.17 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.
Note
External frost protection cannot be used when
plug in timers are utilised.
4.18 Circulating pump

The boiler incorporates a built in circulating pump that
is fully prewired (no additional wiring is necessary). The
pump incorporates an automatic overrun period after
the boiler switches off.
4.19 Anticycling ‘economiser’ control

The boiler incorporates a built in anticycling control to
ensure that energy wasteful short cycling of the boiler
cannot occur. This control prevents the boiler from
reigniting for a preset period after central heating
operation (the hot water operation is unaffected by this
control and hot water can be drawn at any time).
Note
To temporarily override the anticycling control
turn the main boiler on/off switch to the off
position “0” and then back to the on position
“I” after a few seconds.
4.20 Automatic pump spin control (APS)

The boiler incorporates a built in control which will spin
the built in circulating pump and operate the diverter
valve (ecoTEC combination boilers only) once in a
23 hour period. This control helps to prevent seizure
when the boiler is not operated for a period of time.
This control is not active when the power supply to the
appliance is turned off.

5 Commissioning Part I
5 Commissioning Part I This corresponds to a filling pressure between 1.0 and

2.0 bar. If the pointer is in the light grey area, refill
5.1 Preliminary electrical checks water.
Check the electrical installation by carrying out short If the heating system extends over several storeys, the
circuit, earth continuity and resistance to earth tests system may require a higher filling pressure.
and a check for correct polarity.
5.4.1 Checking the filling pressure of the heating
5.2 Gas supply system
The complete gas installation including the gas meter
must be inspected, checked for leaks and purged in
accordance with BS 6891. In IE the current edition of
plus pro
IS 813. The gas supply to the boiler can be purged by
slackening the gas service valve beneath the boiler.
Ensure that there is adequate ventilation, extinguish all
naked flames and do not smoke whilst purging. After
purging, the gas service valve connection must be
retightened and checked for leaks (the boiler itself does
not require purging as this will be done by the automatic
burner sequence control).
5.3 Cold water supply (ecoTEC combination boilers

only)
Open all domestic hot water taps supplied by the boiler, bar
turn on the mains water supply to the boiler and open

2
the mains water isolating valve below the boiler. Water
1
will now flow through the boiler to the hot taps. Starting
bar
with the lowest tap supplied, turn the hot taps off one at
a time until the hot water pipework is purged of air.
Check all hot and cold water pipework for leaks.
5.4 Filling and bleeding the heating system Fig. 5.1 Checking the filling pressure of the heating system
Note
The P.6 test program is for filling the heating 5.4.2 ecoTEC plus combination boiler filling loop
system: The diverter valve (combination boilers
only) moves to the centre position, the pump
does not run and the appliance does not go into
heating mode. Use the test program as 4
described in Section 8.2.
The P.0 test program is for bleeding the hot
water circuit (as well as the DHW circuit on
combination boilers): The appliance does not go
into heating mode; the pump runs
inttermittently and bleeds the two circuits in
succession. Use the test program as described
in Section 8.2.
3
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.
If the appliance is in operation, you can display 1
2
the exact pressure by pressing the “-” (2).
For the heating system to operate properly, the

indicator on the manometer (1) must be in the dark grey Fig. 5.2 Filling device ecoTEC plus combination boiler
area when the system is cold.

Commissioning Part I 5
The ecoTEC plus combination boiler will be delivered 5.4.4 Filling the heating system for the first time
with a filling loop.
• Insert the double check valve (1) of the filling pipe at Note
the cold water shutoff valve and secure the double As long as there is insufficient water pressure
check valve with the spring clip (2). in the heating system, the display indicator
• To fill, first open the stop valve (3). changes between the error message F.22 and
• Open the stop valve (4), so that water flows into the the actual pressure indicator when the
heating system. Fill the heating system as described in appliance is on.
Section 5.4.4.
• Close both stop valves after filling and detach the Fill the heating system as follows:
filling device by pulling the double check valve from • Open all heating element thermostat valves.
the cold water stop valve. • Check if both stop valves on the heater are open.
• Only in ecoTEC plus combination boilers: Connect the
Note filling pipe as described in Section 5.4.2.
Both stop valves must be closed while • Only in ecoTEC plus system boilers and in ecoTEC pro
operating the heating system and the filling combination boilers: As described in Section 5.4.3 join
pipe must be again detached at the double a hose between the cold water dispensing valve and
check valve. the filling pipe of the heating system.
• Open the cold water dispensing valve.
• Slowly open the filling valve and let the water flow
into the heating system. Bleed the lowest radiator
until the water flows out at the bleed valve without
bubbles.
• Bleed all other radiators until the heating system is
completely filled with water, all bleed valves have
been shut and the manometer pointer is in the centre
of the dark grey area. Bleed the heating pump by
loosening the central screw. Close the filling valve and
the cold water dispensing valve.
• Loosen the cap of the pump A.A.V. (automatic air
vent) (the appliance is ventilated independently by the
pump A.A.V. during continuous operation).
• Check all connections and the entire system for leaks.
5.5 Initial system flush (“cold”)
Fig. 5.3 Double check valve detached while heating Note

The complete heating system must be flushed
out at least twice: once cold, and once hot as
5.4.3 Filling the heating system in ecoTEC pro com- instructed below.
bination boilers and ecoTEC plus system boilers
The ecoTEC pro combination boilers and the • Check if all radiator thermostatic valves and both
ecoTEC plus system boilers do not come with a filling service valves on the boiler are open.
device. In these appliances, water is filled in the heating • Connect a hose to the drain valve located at the
system through a filling pipe provided onsite. lowest position of the heating system.
• Join a hose between a cold water dispensing valve • Open the 1/2” BSP drain taps and all vent valves on
and the filling pipe of the heating system. the heating elements and allow the water to flow out
• To fill, first open the cold water dispensing valve. of the heating system and the boiler quickly and
• Open the stop valve on the filling pipe, so that water completely to remove all installation residue from the
flows into the heating system. Fill the heating system heating system before commissioning the boiler.
as described in Section 5.4.4. • Close the 1/2” BSP drain taps.
• After filling, close the stop valve on the filling pipe and • Fill the heating system again with water as described
the cold water dispensing valve and remove the filling in Section 5.4.4.
hose. • Check that the pressure relief valve of the heating
system is working by turning the handle on the valve.
• Check the pressure in the heating system and fill
water if needed.
• Close the filling valve and the cold water dispensing
valve.

5.6 Filling the condensate siphon

1
Fig. 5.5 Adjusting the by-pass valve (in combination boilers)

1
Fig. 5.4 Filling the condensate siphon
Danger!
Note that if the boiler is run with an empty
condensate trap there is a danger that fumes
might escape into the room and cause
poisoning. For this reason, it is important to
ensure that the trap is topped up each time the
unit is cleaned.
• Remove the lower part (1) of the condensate siphon by

turning the bayonet catch in anticlockwise direction.
• Fill the lower part with water until about 10 mm below
the upper edge.
• Refit the lower part of the condensate siphon. Fig. 5.6 Adjusting the by-pass valve (in system boilers)
5.7 Adjusting the pumping capacity • Regulating the by-pass on the adjusting screw (1).
Only in ecoTEC plus boilers: 5.9 Checking the gas 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 Malfunctions or reduction in working life of the
pump speed under the diagnostic number “d.19” (see boiler!
section 8.1.2). If the boiler version does not correspond to the
local gas family, there will be malfunctions or
5.8 Adjusting the by-pass you have to change components of the boiler
The appliances have an adjustable by-pass valve. ahead of schedule, e. g. do not use a LPG boiler
The pressure can be adjusted between 170 and on natural gas.
350 mbar. Approx. 250 mbar is preset (mid-position). • Before starting up the boiler compare the
The pressure changes by approx. 10 mbar each time the details of the type of gas specified on the
adjusting screw is rotated. By turning right, the pressure identification plate with the type of gas
increases and turning left decreases it. supplied at the installation site.

If the boiler version corresponds to the local gas family:

1
• Proceed as described below.
If the boiler version does not correspond to the local

gas family:
• Perform the gas conversion in accordance with the
gas conversion kit 0020010641. 2
• Adjust the gas setting as described below
(see sections 5.9.1 to 5.9.3).
The combustion of this boiler has been checked,

adjusted and preset at the factory for operation on the
type of gas defined on the identification plate. No
measurement of the combustion is necessary to set up Fig. 5.7 Flue gas and air measure points
the boiler.
• Do not adjust the multifunctional automatic gas valve. Legend:
• Ensure 1 Flue gas measure point
2 Air measure point
- that the boiler has been installed in accordance with
these instructions,
- the integrity of the flue system and the flue seals, • For checking the system for recirculation use the air
as described in the flue installation instructions measure point (2).
enclosed with this boiler, and as described below, • Use the flue gas analyser.
- a visual check is carried out on the boiler • If you detect any CO or CO2 in the fresh air, search for
combustion circuit and the relevant seals, the flue gas leakage or recirculation.
- that any defects have been corrected at this stage. • Correct the defects.
• Check again as described before, if there is any CO or
To further validate the integrity of the flue system and CO2 in the fresh air.
confirm correct operation of the boiler it is possible to • If you cannot correct the defects you must not start
conduct flue gas and air measurements on this boiler - up the boiler.
for details see section 5.9.1.
5.9.2 Checking the gas flow rate
Proceed to put the boiler into operation as follows: The boiler is fitted with a multifunctional automatic gas
valve which ensures that the precise air/gas ratio is
• Check the maximum gas flow rate as detailed in provided under all operating conditions. The gas flow
section 5.9.2. rate has been set during production and does not
• Check the gas inlet working pressure as detailed in require adjustment. With the front casing fitted check
section 5.9.3. the gas flow rate of the boiler as follows:
• Note that you must re-measure the gas flow rate or • Start the boiler by activating the test program P.1 as
the gas inlet working pressure, if changes were described in section 8.2.
required to correct any issues found. • In addition, ensure that maximum heat can be
dissipated into the heating system by turning up the
5.9.1 Checking for tightness of the flue gas room thermostat.
installation and flue gas recirculation • Alternatively, for ecoTEC combination boilers fully
• Check the integrity off the flue gas installation open the hot water taps to ensure full flow rate
according to TB 200. through the boiler.
• Should the flue gas installation be longer than 2 m we • Wait at least 5 minutes until the boiler has reached its
strongly recommend to check the system for flue gas operating temperature.
recirculation as described below. • Ensure that all other gas appliances in the property
are turned off.
• Measure the gas flow rate at the gas meter.
• Check that the gas flow rate is as stated in Table 5.1.

Gas flow rate

Nominal net heat
Boiler input in kW Natural gas in m3/h Propane in kg/h
as per BS EN 483 nominal + 5% - 10% nominal + 5% - 10%
ecoTEC plus 612 12.2 1.29 1.36 1.16 0.95 1.00 0.85
ecoTEC plus 615 15.3 1.62 1.70 1.46 1.19 1.25 1.07
ecoTEC plus 618 18.4 1.95 2.04 1.75 1.43 1.50 1.29
ecoTEC plus 624 24.5 2.59 2.72 2.33 1.90 2.00 1.71
ecoTEC plus 630 30.6 3.24 3.40 2.91 2.38 2.50 2.14
ecoTEC plus 637 37.8 4.00 4.20 3.60 2.94 3.08 2.64
ecoTEC plus 824 23.5 2.49 2.61 2.24 1.83 1.92 1.64
ecoTEC plus 831 31.6 3.34 3.51 3.01 2.45 2.58 2.21
ecoTEC plus 837 37.8 4.00 4.20 3.60 2.94 3.08 2.64
ecoTEC pro 24 23.5 2.49 2.61 2.24 1.83 1.92 1.64
ecoTEC pro 28 28.6 3.03 3.18 2.72 2.22 2.33 2.00
Table 5.1 Gas flow rates
• If the measured gas flow rate lies outside the toler- 5.9.3 Checking the gas inlet working pressure
ance limits specified in Table 5.1, do not operate the • Ensure that the gas inlet working pressure can be
boiler and inform the Vaillant Service Solutions obtained with all other gas appliances in the property
(0870 6060 777). working.
• Remove the front casing from the boiler.
If the measured gas flow rate is within the tolerance • Close the gas isolation valve of the boiler.
limits shown in Table 5.1, then proceed as follows:
• Take the boiler out of operation by 1
- Pressing the + and i buttons simultaneously and
turn down both thermostat control knobs.
- Only for combination boilers: Allow the boiler to cool
down by turning off water taps and allow pump
overrun to operate for a minimum of two minutes.
• Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
Fig. 5.8 Measuring the gas inlet working pressure
• Loosen the sealing screw marked “in” (1) on the gas

valve.

• Connect a digital pressure gauge or U-tube

manometer (2).
• Open the gas isolation valve of the boiler.
• Start the boiler by activating the test program P.1 as
described in section 8.2.
• In addition, ensure that maximum heat can be
dissipated into the heating system by turning up the
room thermostat.
• Alternatively, for ecoTEC combination boilers fully
open the hot water taps to ensure full flow rate
through the boiler.
• With the boiler operating at full load check that the
gas inlet working pressure at the reference test
point (1) complies with the requirements of Table 5.2.
Natural gas (G20) LPG (G31)
ecoTEC appliance
Minimum pressure at Maximum pressure at Minimum pressure at Maximum pressure at
reference test point in reference test point in reference test point in reference test point in
mbar mbar mbar mbar
ecoTEC plus
612/615/618/624/630
824/831
16 23 23 43
ecoTEC pro
24/28
ecoTEC plus
15 23 23 43
637/837
Table 5.2 Gas inlet working pressures at the reference test
point
• Should the pressure recorded at the reference test • Put the front casing back on.
point in the boiler be lower than indicated (Table 5.2) • Turn off electrical supply to the boiler.
check if there is any blockage in the pipework or if the • You must not start up the boiler.
pipework is undersized.
• If the supply pressure is out of tolerance contact your If the gas inlet working pressure is within the
Emergency Service Provider. permissible range, proceed as follows:
• Take the boiler out of operation by
If the gas inlet working pressure at the reference test - Pressing the + and i buttons simultaneously and
point (1) is not within the permissible range and you turn down both thermostat control knobs.
cannot correct the failure, notify the gas supply - Only for combination boilers: Allow the boiler to cool
company or the Vaillant Service Solutions team and down by turning off water taps and allow pump
proceed as follows: overrun to operate for a minimum of two minutes.
• Take the boiler out of operation by • Close gas isolation valve of the boiler.
- Pressing the + and i buttons simultaneously and • Remove the pressure gauge and re-tighten the sealing
turn down both thermostat control knobs. screw (1).
- Only for combination boilers: Allow the boiler to cool • Open the gas isolation valve of the boiler.
down by turning off water taps and allow pump • Make sure that there is no leakage at the sealing
overrun to operate for a minimum of two minutes. screw.
• Close the gas isolation valve of the boiler. • Put the front casing back on.
• Remove the pressure gauge and re-tighten the sealing • Reset boiler controls for normal operation.
screw (1). • Record the appliance gas inlet working pressure
• Turn on gas at the gas isolation valve. (mbar) in the Benchmark gas boiler commissioning
• Make sure that there is no leakage at the sealing checklist.
screw.
• Turn off gas at the gas isolation valve.

5.10 Refitting the case Appliance Heating output in kW

ecoTEC plus 612 5 – 12
2 ecoTEC plus 618 7 – 18
1 ecoTEC plus 837 12 – 28
ecoTEC pro 24 7 – 19
ecoTEC pro 28 9 – 24
Table 5.3 Heating system part load adjustment ranges
5.12 Gas changeover
Note
To reset the appliance from natural gas to LPG
mode, you need the Vaillant conversion kit
Art. No. 00 2001 0641.
To reset the appliance from LPG to natural gas
Fig. 5.9 Refitting the case mode, you need the Vaillant conversion kit
Art. No. 00 2001 0642.
• Hook the top of the front casing over the lip on the Convert the appliance as described in the
top of the boiler chassis and push the bottom of the conversion kit.
front casing into place.
• Ensure the spring retaining clips (2) engage correctly.
• Tighten case securing screw (1).
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. The “=” symbol is displayed.

The part load setting is now displayed in kW.
• Use the “+” and “–” buttons to increase or decrease
the value in steps of 1 kW. The displayed value will
flash while the adjustment procedure is being carried
out. The available ranges of settings are given in
Table 5.3.
• Push the “i” button for about five seconds, or until the
display stops flashing. The value is now saved to
memory. The display will now return to its normal
state (current heating system flow temperature, e.g.
45 °C).
• Press the “i” and “+” buttons simultaneously to cancel
adjustment mode.
Adjustment mode is also cancelled if no button is
operated for a period of 4 minutes.

Functional checks (commissioning part II) 6
6 Functional checks
(commissioning part II) plus pro
6.1 Functional checks
6.1.1 Procedure
After installing and checking the gas supply pressure,
perform a function check before commissioning the
appliance and handing over to the user.
• Commission the appliance according to the relevant
operating manual.
• Check the gas supply pipe, exhaust system, heating
system and the hot water lines (combination boilers
only) for leaks.
• Check that the flue system has been installed properly
according to the flue system assembly manual. Fig. 6.2 Display indicator during heating mode
• Check for ignition and an even flame on the burner.
• Perform a function check on the heating system (see
section 6.1.2) and the water heating (combination 6.1.3 Water heating (combination boilers only)
boilers only, see section 6.1.3). • Switch on the appliance.
• Hand over the appliance to the user (see section 6.2). • Fully open the hot water tap.
• Press “i” to activate the status indicator.
If the water heating is working correctly, the display
shows the following: “S.14”.
plus pro
Fig. 6.3 Display indicator during water heating

Fig. 6.1 Function check
6.1.2 Heating 6.1.4 Final flush of the heating system (“hot”)

• Switch on the appliance. • Operate the appliance until the appliance and the
• Make sure that there is a heating demand. heating system are up to temperature.
• Press “i” to activate the status indicator. • Check the heating system for leaks.
As soon as a heat demand is received, the appliance • Connect a hose to the drain valve located at the
runs through the status indicators “S. 1” to “S. 3”, until lowest position of the heating system.
the appliance is running correctly in normal mode and • Shut off the appliance, open the drain valve and all
the display shows “S. 4”. bleed valves on the radiators and allow the water to
flow out of the heating system and the boiler quickly
and fully.
• Close the drain valve.
• Fill the heating system again with water as described
in Section 5.4.4.

6 Functional checks (commissioning part II)
• Release water from the system until the system design • Instruct the user about the methods used for
pressure of 1.0 bar is attained. (The actual reading on the combustion air supply and flue conducting. In
digital pressure gauge should ideally be 0.5 bar plus an particular, point out that these measures must not be
additional pressure corresponding to the highest point of altered.
the system above the base of the boiler – 10 m head equals • Inform the user that the instruction manuals should
an additional 1 bar reading on the pressure gauge. The be kept near the appliance.
minimum pressure should not be less than 1 bar in any
installation.) If the system is to be treated with an inhibitor it 6.3 Factory guarantee
should be applied at this stage in accordance with the
manufacturer’s instructions. Two year guarantee for ecoTEC plus appliances
Further information can be obtained from Sentinel, Vaillant undertakes to rectify any manufacturing defect
Betz Dearborn Ltd., Tel: 0151 420 9595, or Fernox, that occurs within twenty-four months of the installation
Alpha–Fry technologies. Tel: 0870 8700362. date.
• Refit the boiler casing (see section 5.10). For the 2nd year of the guarantee to be valid an annual
• Only in ecoTEC plus appliances: Attach the bottom cover service must be carried out by a competent person
to the boiler by sliding the front edge of the cover into approved at the time by the Health and Safety
the lip at the bottom front edge of the appliance chassis. Executive one year after installation.
• Carefully push the rear of the bottom cover upwards The cost of this annual service is not included in the
until the spring retaining clips engage at the side of guarantee.
the appliance. It may be necessary to adapt the bot-
tom cover by removing the easy break sections. One year guarantee for ecoTEC pro appliances
Vaillant undertakes to rectify any manufacturing defect
6.2 Handing over to the user that occurs within twelve months of the installation
date.
Note
When you have finished the installation, attach Registering with us
the sticker supplied (835593) to the appliance Registration is simple. Just complete the Guarantee
in the user’s language. Registration Card and return to Vaillant within 30 days
of installation. Your details will then be automatically
• Set the maximum radiator temperature control to the registered within the Vaillant scheme.
desired setting. Note: No receipt will be issued.
• Set the maximum hot water temperature control to
the desired setting. Immediate help
• Instruct the user in the safe and efficient operation of If your Vaillant boiler develops a fault your first action
the boiler, in particular the function of should be to contact your installer, as his professional
– the boiler on/off control assessment is needed under the terms of our
– the maximum radiator temperature control Guarantee.
– the maximum hot water temperature control If you are unable to contact your installer, phone
(combination boilers only) Vaillant Service Solutions: 0870 6060 777.
– the pressure gauge.
• Show the user how to operate any external controls.
• Explain to the user the importance of having the boiler
regularly serviced by a competent servicing company.
To ensure regular servicing, it is strongly
recommended that arrangements are made for a
Maintenance Agreement. Contact Vaillant Service
Solutions (0870 6060 777) for further details.
• Record central heating operating pressure in the
Benchmark gas boiler commissioning checklist along
with the heat input (kW) and temperature difference
between flow and return.
• Leave the user instructions and the installation
instructions with the user.
• Go through the operating manual with the user and
answer any questions.
• Draw special attention to the safety instructions,
which the user must follow.

Inspection and maintenance 7
7 Inspection and maintenance mally is done by cleaning, adjustment and, if necessary,

replacing individual components that are subject to wear.
7.1 Inspection and maintenance intervals
You must carry out an annual inspection of the
Danger! Vaillant ecoTEC.
Risk of injury and risk of damage to property It is possible to perform a quick, accurate inspection without
due to neglected inspection and maintenance! removing components by requesting data from the DIA
Neglected inspection and maintenance works or system, carrying out the simple visual checks indicated in
not observing the stated inspection and main- Table 7.2 and performing a flue gas measurement.
tenance intervals can interfere with the opera- The maintenance intervals (at least once every 5 years) and
tional safety of the boiler and can result in their scope are determined by the heating engineer based on
damage to property and to persons. the condition of the boiler found during the inspection.
• Point out to the operator that he must All inspection and maintenance work should be performed in
observe the demanded inspection and the order specified in Table 7.2.
maintenance intervals as a minimum.
• Carry out proper regular inspections once a
year. d Danger!
Possible poisoning and burning by escaping hot
• Carry out regular maintenance as dictated by flue gases!
findings during the inspection process. It is possible that hot flue gases escape and
The frequency of maintenance must not be could result in poisoning or burning, if the boiler
longer than every 5 years. is operated
- without a completely installed air/flue gas
Danger! duct
Danger of life and limb due to improper - with an opened air/flue gas duct
inspection/maintenance! - with internal leakages and an opened front
Inspections/Maintenance work carried out casing.
improperly can result in leakages and explosion. • Operate the boiler
• The boiler may only be inspected/maintained - for commissioning
by a competent person. - for testing purposes
- in continuous mode
All service work must be carried out by a competent only with closed front casing and completely
person in accordance with the Gas safety, installation mounted and closed air/flue gas duct.
and use regulations. In the UK this is considered to be a
person approved at the time by the Health and Safety 7.1.1 General inspection and maintenance
Executive. instructions
To ensure the faultless operation, long term availability
In addition BS 6798: 2009 “Specification for installation and of all functions and long working life of your Vaillant
maintenance of gas-fired boilers of rated input not exceeding boiler and to prevent modifications to the approved
70 kW net” advises that: series status only genuine Vaillant spare parts must be
- The person carrying out a combustion measurement used when carrying out inspection, maintenance and
must be assessed as competent in the use of a flue repair work.
gas analyser and the interpretation of the results. For an overview of the available original Vaillant spare
- The flue gas analyser used must be one meeting the parts, contact the Vaillant sales office on
requirements of BS7927 or BS-EN50379-3 and be cali- 01634 292310.
brated in accordance with the analyser manufactur-
ers’ requirements. During any inspection and maintenance or after change
- Competence can be demonstrated by satisfactory of parts of the combustion circuit, the following must be
completion of the relevant ACS standard assessment, checked:
which covers the use of electronic portable flue gas
analysers’ in accordance with BS 7967, parts 1 to 4. - The appliance has been installed in accordance with
- The flue gas analyser is set to the correct fuel setting. the relevant installation instructions.
- The integrity of the flue gas installation and flue seals
We recommend the conclusion of an inspection and is in accordance with the relevant flue installation
maintenance contract with an approved company or installer. instructions enclosed.
The inspection serves to determine the actual condition of - Visual, the integrity of the boiler combustion circuit
the respective boiler and compare it with the specified condi- and relevant seals.
tion. This is done by measuring, checking and observing. - The gas inlet working pressure at maximum rate as
Maintenance is required in order to eliminate any deviations described in section 5.9.3.
of the actual condition from the specified condition. This nor- - The gas flow rates as described in section 5.9.2.

7 Inspection and maintenance
- Correctness of electrical, water and gas connections. • Check the boiler for gas and water leaks.
- Correctness of the water pressure. • If necessary, refill and re-bleed the heating
- The condition of the whole system, in particular the installation.
condition of radiator valves, evidence of leakage from • Replace the front casing to the boiler.
the heating system and dripping taps. • Carry out a functional check of the boiler
(see section 6).
• Correct any faults before proceeding. • Always check earth continuity, polarity and resistance
to earth with a multimeter after any service work and
after replacing any electrical component.
7.1.2 Safety instructions
7.1.3 Checking the CO2 concentration
Danger!
Danger of life and limb by electric shock! Note
The supply terminals of the boiler are under Checking/adjustment of the CO2 concentration
mains voltage even if the boiler main switch is is required in the following instances:
off. - replacement of gas valve,
• Don’t touch the supply terminals. - conversion to or from Natural Gas/LPG
• Protect the electronic box from any water or - or if an incorrect combustion is suspected.
spray.
• Before working on the boiler, turn off the
power and secure against restart.
4
Note
If it is necessary to keep the electricity to the 1
boiler switched on for certain inspection and
maintenance, this is indicated in the description 3
of the maintenance task.
Always perform the following steps prior to inspection 2

or maintenance work:
• Switch off the main switch.
• Disconnect the boiler from the power mains by
- disconnecting the mains plug or
- de-energising the boiler via an isolating device with a
contact opening of at least 3 mm (e. g. fuses or
power switches).
• Further check for electrical isolation of the appliance
by use of a test meter.
• Close the gas isolator cock.
• Close the service valves in the heating flow and
return.
• Remove the front casing from the boiler.
• When removing any water carrying components
ensure that water is kept away from all electrical
components.
Always perform the following steps after performing Fig. 7.1 Measuring the CO2 concentration, specifying the air
any inspection or maintenance work: ratio (gas setting)
• Always use new seals and O-rings when parts are
replaced. Legend:
• Open the service valves in the heating flow and 1 Main throttle
2 Screw
return.
3 Air intake pipe
• Reconnect the boiler to the power mains. 4 Flue gas analysis point
• Switch the main switch on.
• Fill the heating circuit of the boiler to a pressure of
between 1.0 and 2.0 bar if required.
• Bleed the heating installation (see section 5.4, Filling
and bleeding the heating system).
• Open the gas isolator cock.

Note • After performing the adjustments, fold the air intake

The boiler is fitted with a flue gas analysis pipe back up.
point (4). A suitable flue gas analyser can be • Check the CO2 concentration once again.
connected to this point to establish the • If necessary, repeat the setting process.
combustion performance of the boiler. • Push the „i“ button to deactivate the full load mode.
The full load mode is also deactivated if no button is
• Remove the front casing. pushed for 15 minutes.
• Start the testing program P.1. • The adjusting screw shall be sealed after the
• Wait at least 5 minutes until the boiler reaches its adjustment.
operating temperature. • Re-secure the air intake pipe with the screw (2).
• Measure the CO2 concentration at the flue gas • Put the front casing back on.
analysis point (4). Compare the measured value with
the corresponding value in Table 7.1. Settings Natural gas (H) Propane Unit
• If all these points are as required, proceed as Tolerance Tolerance
described in section 7.1.5. CO2 after 5 min. full load 9.2 1,0 10.2 0,5 Vol.–%
mode with appliance
• If one of the flue gas values is greater than the front closed
acceptable values in Table 7.1, then proceed as CO2 after 5 min. full load 9.0 1,0 10.0 0,5 Vol.–%
described in the following section 7.1.4. mode with appliance
front removed
7.1.4 Adjusting the CO2 concentration Set for Wobbe-Index W0 15 22.5 kWh/m3
(or the air ratio) CO value with full load < 250 < 250 ppm
CO/CO2 < 0,0031 < 0,0026
d Danger!
Increased risk of poisoning due to incorrect
Table 7.1 Factory gas setting
settings!
Incorrect setting may increase the risk of Danger!
poisoning. d Risk to life due to poisoning!
• If one of the flue gas values is greater than CO is an extremely toxic gas. Risk to life due to
the acceptable values in Table 7.1 then check excessive CO concentrations.
- the integrity of the complete flue gas • If you are not able to adjust the boiler
installation correctly and the flue gas values remain
- the integrity of the combustion circuit seals higher than allowed in Table 7.1, call the
- the gas inlet working pressure Vaillant Service Solutions.
- the gas flow rate. • Do not start up the boiler!
If the flue gas value needs to be adjusted,

• unfasten the screw (Fig. 7.1, 2) and
• fold the air intake pipe (Fig. 7.1, 3) forwards through
90°. Do not remove the air intake pipe.
• Specify the required flue gas value if necessary (value
with front casing of boiler removed, see Table 7.1) by
turning the screw of the main throttle (Fig. 7.1, 1).
h Note
Use a 4 mm hexagon socket spanner to turn
the screw.
• Turn to the left: higher CO2 concentration,

• Turn to the right: lower CO2 concentration.
h Note
Natural gas: Only perform the adjustment in
increments of 1/8 turn and wait approximately
1 minute after each adjustment until the value
stabilises.
Liquid gas: Only perform the adjustment in very
small increments (approximately 1/16 turns),
and wait approximately 1 minute after each
adjustment until the value stabilises.

7.1.5 Inspection and maintenance work steps
Column 2
Maintenance
Column 1
must be carried
Inspection must
No. Activity out at regular
be carried out
intervals – but
each year
no longer than
5 years
Check the air flue gas installation for leaks and for proper fixation and ensure it is not blocked
1 x x
or damaged and is fitted correctly, complying with the relevant installation instructions.
2 Carry out a general inspection of the boiler for dirt and dust and clean as necessary. x x
Visually inspect the complete heat engine for its general condition and for signs of corrosion,
3 x x
sooting or other forms of damage. If damage is evident proceed to column 2.
Measure the gas flow rate during operation with maximum load (Kap. 5.9.2). If the gas flow
4 x x
rate complies to the Table 5.1 continue with column 1, if not proceed to column 2.
Check the gas inlet working pressure (Kap. 5.9.3) operation with maximum load. If the gas
5 inlet working pressure complies to the Table 5.2 continue with column 1, if not proceed to x x
column 2.
Check combustion by measuring CO, CO2 and CO/CO2. If the values are outside the
6 tolerances of Table 7.1 proceed to maintenance column 2. You must not proceed with the x
maintenance if a new burner door seal kit is not available.
Isolate the boiler from the power mains. Check whether the electrical plug connections and
7 x x
the other electrical connections are fitted tightly and correct them if necessary.
8 Close the gas isolator cock and the service valves. x
Dump the pressure in the boiler on the water side (observe pressure gauge) and check the
9 x
charge pressure of the expansion vessel. Top up if necessary.
10 Remove the compact thermal module. x
Check the integrity of all combustion circuit seals, especially the burner door seal. If there are
11 x
any damages repair them before proceeding.
12 Clean the heat exchanger. x
13 Check whether the burner is dirty and clean it if necessary. x
14 Check the condensate siphon in the boiler, clean and fill if necessary. x x
15 Check the condensate ducts in the boiler and clean if necessary. x x
16 Install the compact thermal module. Caution: Use new seals and nuts! x
Open the service valves and fill up the boiler/appliance to approximately 1.0 - 2.0 bar
17 x
(depending on the static height of the system). Start the bleeding program P.0.
Open the gas isolator cock, reconnect the boiler with the power mains and switch on the
18 x x
boiler.
Perform a test operation of the boiler and heating installation, including water heating and
19 x x
bleed again if necessary.
20 Check visually the ignition and burner performance. x x
Check the boiler for leaks of any kind (gas, flue gas, water, condensate) and rectify as
21 x x
necessary.
If you had problems with the CO, CO2, CO/CO2-values in Step 6 before the maintenance, check
22 them again now (see Table 7.1). If they are outside of the tolerances of Table 7.1 make an x
adjustment, see section 7.1.4.
23 Complete the gas commission checklist (benchmark book). x x
Table 7.2 Inspection and maintenance steps

7.2 Servicing the burner module • Disconnect the gas supply (3) on the gas valve. Ensure
the corrugated gas pipe does not twist by holding the
7.2.1 Removing the burner module flattened section of the pipe, with an open ended
The burner module consists of the burner, fan, gas valve spanner, whilst loosening the union nut.
und the gas supply (mixer tube). These four components
make up the complete assembly, the burner module. Caution!
Damage to corrugated gas pipe!
Danger! Under no circumstances must the burner
There is danger of being injured or burnt by the module be suspended from the flexible
burner module and at all components carrying corrugated gas pipe.
water. Only carry out work on these
components once they have cooled down.
Proceed as follows to remove it:

• Turn off the boiler
• Isolate the electrical supply to the boiler.
4 11
• Remove boiler bottom cover by releasing the two
spring retaining lugs and lowering the rear of the
10
bottom cover.
• Gently pull the bottom cover backwards to remove
from the appliance. 9
• Turn off the gas service valve. 5
• Turn off the boiler CH service valves.
• Loosen screw, release the front case spring retaining
clips located beneath the front edge of the appliance.
• Remove the front casing by easing forward the
bottom edge and gently lifting.
• Lower electronic control box.
6
7
1
Fig. 7.3 Dismantling burner module
2 • Disconnect HT lead (5) and earth lead (6) from spark

electrode.
• Remove four nuts (4) from burner manifold.
• Disconnect two electrical connections (7 and 8) from
fan and gas valve.
• Pull forward and remove burner, gas valve and fan
assembly (9) from integral condensation heat
exchanger (10).
Note
You can suspend the burner module on the
hook (11) while carrying out maintenance tasks.
3
• After removing the thermal compact module, clean
the components as described below.
Fig. 7.2 Dismantling air intake pipe
• Remove screw (2) and remove the air intake pipe (1).

7.2.2 Cleaning the integral condensation heat 7.2.3 Checking the burner
exchanger
Caution!
Protect the electronics box against sprayed
1
water.
Fig. 7.5 Checking burner
The burner (1) is maintenance-free and needs no cleaning.

• 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.
2
7.2.4 Refitting the burner module
3
1
Fig. 7.4 Cleaning the integral condensation heat exchanger
• Dismantle the burner module as described under 7.2.1.
Caution! Fig. 7.6 Replacing the burner door seal

Risk of damaging the primary heat exchanger!
• Do not attempt to loosen nor retighten the • Insert a new seal (1) in the burner door.
four screws (1).
Caution!
With the burner and fan assembly removed it is now The burner door seal (1) and the self-locking
possible to inspect the main heat exchanger (4). nuts on the burner module must be replaced
• Remove any loose deposits from the heating spirals each time the module is removed (for example
(3) using a soft brush and jet of water (ensure that during maintenance, see Table 7.1).
water is kept away from all electrical components. If the burner flange insulation on the burner
Any water used to clean the main heat exchanger will module shows any signs of damage other small
drain through the condensate trap). Avoid pointing cracks it must also be replaced.
the water jet directly at the insulating surface (2) on
the back of the heat exchanger.
If required the heat exchanger can be cleaned using
regular vinegar.

• Reconnect the gas supply (3) to the gas valve,

ensuring that a new sealing washer is used and
4 correctly located. Use the spanner flat at the flexible
gas line to hold the gas fittings.
10
9
5
6 11
Fig. 7.9 Testing the gas supply for soundness
• Turn on the gas supply and test for soundness. Check

7 8 especially the screwed connections (3) and (11).
• Refit the air inlet pipe, ensuring that the blue seal in
the air intake pipe is correctly located.
Fig. 7.7 Refitting the burner module
7.3 Cleaning the condensate siphon
• Insert the burner module (9) in the integral
condensation heat exchanger (10). Danger!
• Tighten the four nuts (4) on the alternate left and Note that if the boiler is run with an empty
right sides until the burner door fits closely and condensate trap there is a danger that fumes
uniformly to the stop surfaces. might escape into the room and cause
• Reconnect the HT lead (5) and earth lead (6) to the poisoning. For this reason, it is important to
spark electrode. ensure that the trap is topped up each time the
• Insert the cables (8) on the fan motor and the cable unit is cleaned.
(7) on the gas fitting.
1
3
Fig. 7.10 Cleaning the condensate siphon

Fig. 7.8 Refitting the gas supply
• Remove the lower part (1) of the condensate siphon by
turning the bayonet catch in anticlockwise direction.

• Clean the siphon part section by rinsing it out with 7.6 Test operation
water. Always perform the following checks after completing
• Fill the lower part with water until about 10 mm below any maintenance task:
the upper edge. • Commission the appliance according to the relevant
• Fasten the lower part again on the condensate siphon. operating manual.
• Check the appliance for gas and water leaks.
7.4 Checking the expansion vessel • Check the air/flue gas installation for leaks, check its
fastening.
• Check for ignition and an even flame on the burner.
• Check that the heating system and the water heating
is working (combination boilers only).
• Fill out the Benchmark gas boiler commissioning
checklist at the rear of this guide.
Fig. 7.11 Checking expansion vessel admission pressure
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. Fig. 7.12 Function check
• Release the pressure from the boiler.
• Remove valve cap from expansion vessel charge point.
• Check that the internal charge pressure of the
expansion vessel is between 0.75 and 0.9 bar.
If the pressure is lower than this the vessel should be
repressurised using an air pump.
• Refit the valve cap.
• Repressurise boiler and heating system.
7.5 Recommissioning the boiler

• Carry out electrical safety checks.
• Turn on the electrical supply.
• Open the boiler CH service valves.
• Carry out function checks of boiler operation as
previously detailed.
• Check gas flow rate as previously detailed.
• Check for water leaks.
• Refit case, ensuring that a good seal is obtained.

Troubleshooting 8
8 Troubleshooting 8.1.2 Diagnostic codes
8.1 Logical fault finding procedure Display Meaning

These checks must be carried out before attempting to Heating mode (all models):
use the fault finding guide.
S. 0 No heat demand
1. Carry out electrical safety checks (see section
S. 1 Fan running
‘Preliminary Electrical Checks’).
S. 2 Water pump running
2. Check that the external electricity supply to the boiler
is on, and a supply of 230 V~ is present between S. 3 Ignition sequence
boiler terminals ‘L’ and ‘N’. S. 4 Burner ignited
3. Check that the gas supply to the boiler is on, that it has been S. 5 Fan and pump running
correctly purged and that an inlet pressure of 20 mbar is S. 6 Fan over run
available at the gas valve. (See section ‘Gas Supply’). S. 7 Pump over run
4. Ensure the heating system is full of water and charged S. 8 Anti cycling mode
to between 1 and 1.5 bar. If not, refill and vent the Domestic hot water mode (ecoTEC combination boilers only):
system. (See section ‘Filling the heating system’).
S.10 Hot water demand
Ensure boiler flow and return service valves are open.
S.11 Fan running
5. Check that the main on/off control is set to the ‘on’ position.
S.13 Ignition sequence
6. Set the central heating temperature to maximum.
S.14 Burner ignited
7. Set the domestic hot water temperature to maximum
(combination boilers only). S.15 Fan and pump running
8.Check that all external controls are on and calling for S.16 Fan over run
heat (if no external controls are fitted, boiler terminals S.17 Pump over run
3 and 4 must be linked). Check that the boiler anti– Warm start (ecoTEC combination boilers only) / Charge hot
cycling economiser is not engaged. water cylinder (ecoTEC system boilers only):
S.20 Warmstart demand
8.1.1 Status codes S.21 Fan running
The status codes that you can see on the display S.22 Pump running
provides information about the current operating
S.23 Ignition sequence
condition of the appliance. The display of the status
S.24 Burner ignited
codes can be called as follows:
S.25 Fan and water pump running
S.26 Fan over run
S.27 Pump over run
plus pro S.28 Anti cycling mode
All boilers:
S.30 No heating demand from external controls (clamp 3-4 open)
Central heating thermostat knob turned off or no heat
S.31
demand by the eBUS control unit
Heat exchanger antifreeze active, as fan speed
S.32 variation is too high. Appliance is within the waiting
time of the operation block function
S.34 Antifrost mode active
S.36 No heating demand from low voltage controls (clamp 7-8-9)
S.41 Water pressure > 2,9 bar
Response from accessory modul or defective
S.42
condensate pump is blocking burner operation
S.52 Water pressure > 2,9 bar
Appliance is within the waiting period of the operation
Fig. 8.1 Display of status codes S.53 block function due to water shortage (VL-RL spread
too big)
• Press the “i” key. Appliance is within the waiting period of the operation
The display shows the status code, e.g. S.4 for “Burner S.54 block function due to water shortage (temperature
gradient)
mode - Heating”.
Return-sensor check is running, demand (DHW or
S.96
heating) is blocked
The display of the status codes can be cancelled as follows: Water pressure sensor check is running, demand (DHW
S.97
• Press the “i” key or or heating) is blocked
• Do not press any key for about 4 minutes. Flow-/Return-sensor check is running, demand (DHW
S.98
The current heating flow temperature appears in the or heating) is blocked
display again. Table 8.1 Status codes (continued)

8 Troubleshooting
In the diagnostic mode, you can change certain The display shows the relevant diagnostic information.
parameters or display more information. • If necessary, use the “+” or “–” keys to change the
The diagnostic information is divided into two diagnostic value (display flashes).
levels. The second diagnostic level can be reached only • Save the new value by holding down the “i” key for
after entering a password. approx. 5 seconds until the display no longer flashes.
Caution! You can end the diagnostic mode as follows:

Access to the second diagnostic level must be • Press the “i” and “+” keys simultaneously.
used exclusively by a qualified technician. or
• Do not press any key for approx. 4 minutes.
First Diagnostic level
• Press the “i” and “+” keys simultaneously. The current heating flow temperature appears in the
The display shows “d.0”. display again.
• Use the “+” or “–” keys to scroll through the desired
diagnostic numbers of the first diagnostic level (see
Table 8.2).
• Press the “i” key.
Display Meaning Display value/adjustable value
d. 0 Heating part load Adjustable heating part load in kW (factory setting: max. output)
d. 1 Water pump over run time for heating mode 2 - 60 min (factory setting: 5 min)
Max. burner anti cycling period at 20 °C Flow
d. 2 2 - 60 min (factory setting: 20 min)
temperature
Hot water flow temperature reading (combination boiler
d. 3 in °C
only)
Current temperature for warm start sensor
d. 4 (combination boilers only) in °C
Current storage tank sensor (system boilers only)
Flow temperature target value or return target value in °C, max. the value set in d.71
d. 5
when return regulation is set. Limited by the eBUS controller (if an eBUS controller is connected)
d. 6 Hot water temperature target value in °C, 35 to 65 °C
Warm start temperature target value in °C, 40 to 65 °C
d. 7 (ecoTEC plus combination boiler only)
Storage temperature target value (system boiler only) in °C, 15 °C for left stop, then 40 to 70 °C
0 = open (no heat request)
d. 8 External controls heat demand (Clamp 3-4)
1 = closed (heat request)
Flow target temperature from external analogue in °C, minimum from ext. eBUS target value and target value terminal
d. 9
regulator to terminal 7-8-9/eBUS 7
d.10 Status internal heating pump 1 = on, 0 = off
d.11 Status external heating pump 1 to 100 = on, 0 = off
d.12 Cylinder charging pump (via accessory module) 1 to 100 = on, 0 = off
d.13 Hot water circulation pump (via accessory module) 1 to 100 = on, 0 = off
d.22 Hot water demand 1 = on, 0 = off
d.23 Summer/Winter function 1 = Winter, 0 = Summer
d.25 Hot water activation via eBUS Control 1 = yes, 0 = no
d.30 Control signal for both gas valves 1 = on, 0 = off
d.33 Fan speed target value in rpm/10
d.34 Fan speed actual value in rpm/10
d.35 Position of diverter valve (combination boilers only) 0 = Heating; 100 = Hot water; 40 = Centre position
Table 8.2 Diagnostic codes of the first diagnostic level

Troubleshooting 8
d.36 Hot water flow sensor in l/min
d.40 Flow temperature Actual value in °C
d.41 Return temperature Actual value in °C
d.44 Digitised ionisation potential Display range of 0 to 102, > 80 no flame, < 40 even flame
Outside temperature
d.47 Actual value in °C
(with weather compensating Vaillant controller only)
d.67 Remaining burner anti cycling time in min
d.76 Appliance variant (device specific number) 00 to 99
d.90 Digital regulator status 1 = identified, 0 = unidentified (eBUS Address <=10)

DCF status with connected external probe with DCF77
d.91 0 = no reception, 1 = reception, 2 = synchronised, 3 = valid
receiver
d.97 Activation of the second diagnostic level Password: 17
Table 8.2 Diagnostic codes of the first diagnostic level

(continued)
Second diagnostic level Scrolling and changing values and exiting the diagnostic
• As described above in the first diagnostic level, scroll mode is done as described in the first diagnostic level.
through the diagnostic number d.97.
• Change the displayed value to 17 (password) and Note
press the “i” button. After exiting the second diagnostic level, if you
press “i” and “+” within 4 minutes, you will
You are now in the second diagnostic level where all directly reach the second diagnostic level
information from the first diagnostic level (see Table without having to enter the password again.
8.2) and the second diagnostic level (see Table 8.3) is
displayed.

d.17 Heating flow/return regulation changeover 0 = flow, 1 = return (factory setting: 0)
d.18 Pump mode (return) 0 = return, 1 = nonstop, 2 = winter (factory setting: 0)
d.19 Only in ecoTEC plus: 0 = pre ignition speed 1, hot water or heating speed 2, overrun speed
Operating modes of the two-speed heating pump 1
1 = pre ignition speed 1, hot water speed 2, heating speed 1, overrun
speed 1
2 = like 1, but speed in heating mode dependent on heating part
load d. 0 (if d.0 is below 60% of full load, then pump speed 1,
otherwise speed 2)
3 = always speed 2
(factory setting: 2)
d.20 Maximum set value for target cylinder temperature Setting range: 50 to 70 °C (factory setting: 65 °C)
(system boilers only)
d.27 Switching accessory relay 1 in the accessory module 1 = Circulation pump (default)
2 = Ext. pump
3 = Storage charging pump
4 = Flue gas flap/extractor hood
5 = External gas valve
6 = External error message
d.28 Switching accessory relay 2 in the accessory module 1 = Circulation pump
2 = Ext. pump (default)
3 = Storage charging pump
4 = Flue gas flap/extractor hood
5 = External gas valve
6 = External error message
Table 8.3 Diagnostics codes of the second diagnostic level

8 Troubleshooting

d.50 Offset for minimum speed in rpm/10, adjustment range: 0 to 300
d.51 Offset for maximum speed in rpm/10, adjustment range: -99 to 0
d.58 From the third quarter of 2006: Setting range: 0 to 3
Activation of solar reheating 0 = solar reheating disabled (factory setting)
3 = activation of min. hot water target value = 60 °C for solar
reheating
d.60 Number of safety temperature limiter cut offs Quantity
d.61 Number of lock outs Number of unsuccessful ignitions in the last attempt
d.64 Average ignition time in seconds
d.65 Maximum ignition time in seconds
d.68 Unsuccessful ignitions in the first attempt Quantity
d.69 Unsuccessful ignitions in the second attempt Quantity
d.70 Set diverter valve position 0 = Normal mode (factory setting)
1 = Centre position
2 = permanent heating position
d.71 Maximum setting of heater control knob Adjustment range in °C: 40 to 85 (Factory setting: 75)
d.72 Pump overrun time after warm start (combination boil- Adjustment range in sec: 0, 10, 20 to 600
ers only) or charging an electronically controlled hot Factory setting for combination boilers: 80
water storage through C1-C2 (system boilers only) Factory setting for system boilers: 300
d.73 Offset for warm start target value (combination boilers Adjustment range: -15 K to +5 K (Factory setting: 0 K)
only)
d.75 Maximum charging time for a storage without own con- Adjustment range in min: 20, 21, 22 to 90 (Factory setting: 45)
troller (system boilers only)
d.77 Storage partial load (storage charging capacity limit, Adjustment range in kW: appliance-specific
system boilers only) Factory setting: max. output
d.78 Storage charging temperature limit (target flow tem- Adjustment range in °C 55 to 90 (Factory setting: 80)
perature in storage mode, system boilers only)
d.80 Heating operating hours in h1)
d.81 Water heating operating hours (combination boilers in h1)

only)
d.82 Cycles in heating mode Quantity/1001) (3 corresponds 300)
d.83 Cycles in hot water operation Quantity/1001) (3 corresponds 300)
d.84 Maintenance indicator: Number of hours until the next Adjustment range: 0 to 3000 h and “-” for disabled
maintenance Factory setting: “-” (300 corresponds to 3000 h)
d.93 DSN appliance variant setting Adjustment range: 0 to 99
d.96 Factory setting 1 = Resetting adjustable parameters to factory setting
1) Five-digit numbers are saved with the diagnostics codes 80 to 83. If d.80, for example, is selected, only the first two digits of the
number are displayed (e. g. 10). The display switches to the last three digits (e. g. 947) by pressing “i”. In this example the number of
operating hours of the heating is 10947 h. The display returns to the selected diagnostics item by pressing “i” again.
Table 8.3 Diagnostics codes of the second diagnostic level

(continued)
8.1.3 Fault codes

Fault codes take priority over all other display functions To cancel fault error memory display mode, proceed as
in the event of a system fault occurring. follows:
If multiple faults occur, the corresponding fault codes • Press the ”i” button below the display or
are displayed alternately for about two seconds each. • Do not touch any key for about four minutes. The
display will now revert back to showing the current
8.1.4 Fault memory flow temperature.
The fault memory stores details of the ten most recent
faults.
• Press the ”i” and ”–” buttons simultaneously.
• Use the ”+” button to scroll back through the list of
memorised errors.

Troubleshooting 8
Code Meaning Cause

NTC broken, NTC cable broken, Defective connection at NTC,
F. 0 Flow–NTC open circuit
Defective connection at electronics
Return–NTC open circuit NTC broken, NTC cable broken, Defective connection at NTC,
F. 1
Defective connection at electronics
F.10 Flow NTC short circuit NTC defective, short circuit in cable harness, cable/casing shortcut
F.11 Return NTC short circuit NTC defective, short circuit in cable harness, cable/casing shortcut
F.13 Tank NTC short circuit NTC defective, short circuit in cable harness, cable/casing shortcut
Flow-NTC not correctly thermal-connected or defective; appliance
F.20 Safety temperature limiter by NTC activated
does not shut down
Too little water in the appliance, water pressure sensor defective,
F.22 Dry fire cable to pump or water sensor defective, pump blocked or
defective, pump output too low
Water shortage, temperature difference between flow Pump blocked or defective, pump output too low, flow and return
F.23
and return NTC too large NTC interchanged
Pump blocked, insufficient pump output, air in appliance, water
F.24 Water shortage, temperature rise too quick
pressure too low
Interruption in the compact thermal module cable har-
F.25 Compact thermal module cable harness defective
ness
F.27 Incorrect sensing of flame Flame detector defective
Faults in the gas supply such as:
- Gas meter or gas pressure detector defective
- Air in gas
- Gas flow pressure too low
Appliance does not start: Attempts to ignite during start
F.28 - Fire protection tap has disengaged
failed
Faults in the gas valve, wrong gas setting, igniter (ignition
transformer, ignition cable, ignition plug) defective, ionisation
current stopped (cable, electrode), faulty earthing in appliance,
electronics defective
Flame goes off during operation and subsequent ignition
F.29 Gas supply temporarily stopped, faulty earthing of appliance
attempts failed
Fan blocked, plug not inserted correctly on fan, hall sensor
F.32 Fan speed variation
defective, fault in cable harness, electronics defective
Short circuit on eBUS, overload on eBUS or two power sources on
F.49 eBUS undervoltage
eBUS with different polarity
Short circuit/earth (ground) leak in cable harness to gas valves, gas
F.61 Gas–valve control defective valve assembly defective (earth/ground leak from coils), electronic
control system defective
F.62 Gas valve shutoff delay Gas valve leaking, electronics defective
F.63 EEPROM error Electronics defective
F.64 Electronics/NTC fault Short-circuit in flow or return NTC or electronics defective
F.65 Electronics temperature too high Electronics too hot due to external effect, electronics defective
Flame detector input signal is outside the limits
F.67 Electronics defective
(0 or 5 V)
Spare part failure display and maiboard interchanged at same time
F.70 No valid DSN in display and/or mainboard
and device specific number not adjusted
F.71 Flow NTC reports constant value (stuck at) Flow NTC is defective
F.72 Flow and/or return NTC fault Flow and/or return NTC is defective (tolerances too big)
Cable to water pressure sensor is broken or has a short-circuit at
F.73 Water pressure sensor signal out of range (too low)
0 V or water pressure sensor defective
Cable to water pressure sensor has a short-circuit at 5 V / 24 V or
F.74 Water pressure sensor signal out of range (too high)
internal fault in water pressure sensor
Water pressure sensor or/and pump defective
Air in the heating system, quick bleeder defective
F.75 No pressure rise was detected on turning on the pump
Too little water in appliance; check adjustable by-pass; connect
external expension vessel to return
Overheating protection on primary heat exchanger trig- Cable or cable connection of fuse in the primary heat exchanger
F.76
gered defective, or primary heat exchanger defective
condensate pump or feedback of accessorie blocks heat-
F.77 condensate pump defective or flume flap feedback triggered
ing
F.78 wrong configuration with accessory link box VR65 connected to combination boiler
con no communication to mainboard connection error display mainboard
Table 8.4 Error codes

8 Troubleshooting
9 Parts replacement
8.2 Test programs 9 Parts replacement

Special functions can be triggered on the appliances by
activating various test programs. The tasks listed below in this section may be carried out
These programs are given in detail in the Table 8.5. only by a ompetent person approved at the time by the
• The test programs P.0 to P.6 will be started when Health and Safety Executive und in accordance with the
“Power ON” is turned on and the “+” key is pressed Gas Safety (Installation and Use) Regulations 1998.
for 5 s. The display shows “P.0”. • Only use genuine spare parts for repairs.
• Press the “+” key to start counting the test number • Make sure the parts are correctly fitted and that their
upwards. original position and alignment are retained.
• Press the “i” to operate the appliance now and to
start the test program. 9.1 Safety instructions
• Press “i” and “+” simultaneously to exit the test
programs. You can also exit the test programs by not Danger!
pressing any key for 15 minutes. Each time the components are replaced, comply
with the safety instructions below for your own
Display Meaning safety and to avoid damage to the appliance!
P.0 Bleeding test program. The heating circuit and hot • Put the appliance out of operation.
water circuit (combination boiler only) is bled via the
automatic air vent (the cap on the automatic air vent
must be loosened). Caution!
P.1 Test program where the appliance is operated in full Before starting any maintenance work:
load after successful ignition Isolate the mains electricity supply by
P.2 Test program where the appliance is operated with disconnecting the plug at the socket outlet (if
minimum gas volume (ignition gas volume) after suc- there is only an isolating switch remove the
cessful ignition
P.3 not available fuse from the switch).
P.4 not available
• Close the service valve in the gas supply as well as the
P.5 Test program for the safety temperature limit check;
appliance heats up by by-passing a regulating shut- service valves in the heating flow and return pipe.
down through the flow regulator until the shutoff tem- • Close the service valve in the cold water supply line
perature of 97 °C is achieved. (combination boilers only).
P.6 Filling test program. The diverter valve moves to the • Empty the appliance if you want to replace water-
centre position bearing components of the appliance.
Table 8.5 Test programs • Make sure that no water drops on live components
(e.g. switch box etc.).
• Use only new seals and O-rings.
8.3 Resetting parameter to factory settings • After completing the work, check for gas leaks and
Besides the option to reset individual parameters perform a function check (see section 7.6).
manually to the factory settings specified in Tables 8.2 • Always check earth continuity, polarity and resistance
and 8.3, you can also reset all parameters to earth with a multimeter after any service work and
simultaneously. after exchanging any electrical component.
• In the second diagnostic level, under the diagnostic
number “d.96” change the value to 1 (see section 8.1.2).
The parameters of all adjustable diagnostic numbers
now correspond to the factory settings.

Parts replacement 9
9.2 Replacing burner
Danger!
Before replacing the component, comply with
the safety instructions in Section 9.1.
• Dismantle the burner module as described in Section 7.2.1.
1
4 3
Fig. 9.1 Replacing burner
• 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. Fig. 9.2 Dismantling fan with gas fitting
• Install the burner module as described in Section 7.2.4.
• After completing the work, check for gas leaks and • Pull out the plug (4) from the gas valve.
perform a function check (see section 7.6). • Pull out the plug (3) from the fan.
• Remove the three screws (2) on the burner module (1).
9.3 Replacing fan or gas valve • Remove the complete “gas valve/fan” unit.
Danger!
5
the safety instructions in section 9.1.
• Turn off the boiler.

• Isolate the electrical supply to the boiler.
• Remove the air intake pipe (Fig. 7.1, Pos. 2).
• Loosen the gas supply pipe on the gas fitting (Fig. 7.2,
Pos. 3).
Fig. 9.3 Gas fitting/fan screwed joint
• Remove both fixing screws (5) on the gas valve and

remove the fan from the gas valve.
• Replace the defective component.
Caution!
Mount the gas valve and the fan in the same
position as before.
• Screw on the fan with the gas valve. Use new seals.
• Install the complete “gas valve/fan” unit in reverse
sequence.
• After completing the work, check for gas leaks and
perform a function check (see section 7.6).

9 Parts replacement
9.4 Replacing expansion vessel 9.5 Replacing primary heat exchanger
Danger! Danger!
Before replacing the component, comply with Before replacing the component, comply with
the safety instructions in Section 9.1. the safety instructions in Section 9.1.
• Disconnect the appliance from the mains as described • Disconnect the appliance from the mains as described in
in Section 9.1, and close the service valve in the gas Section 9.1, and close the service valve in the gas supply pipe.
supply pipe. • Close the flow and return service valves and drain the
• Close the flow and return service valves and drain the appliance.
water from the boiler. • Remove the burner module as described under 7.2.1.
• Remove the expansion vessel as described under 9.4.
• Pull out the condensate pipe to the siphon from the
primary heat exchanger.
1
2
2
Fig. 9.5 Replacing primary heat exchanger
• Pull out the clamps (1) and (2) and free the return pipe
as well as the flow pipe on the primary heat exchanger.
• Remove the four screws (3) on the primary heat
4 exchanger holder.
Fig. 9.4 Replacing expansion vessel
• Undo the nut (4) on the water pipe on the lower side
of the expansion vessel.
• Remove both screws (1) retaining plate (2) and
remove the retaining plate.
• Pull out the expansion vessel (3) forwards.
• Guide the new expansion vessel back into the appliance.
• Re-connect the new expansion vessel using a new seal.
• Refix the retaining plate.
• Check the pressure of the expansion vessel (minimum
pressure 0.75 bar).
If necessary, adjust the pressure to the static height
of the heating system.
• Fill and vent the boiler.
• After completing the work, check for water leaks and
perform a function check (see section 7.6).

Parts replacement 9
9.6 Replacing electronics and display
Danger!
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
1 parameter adjustment functions automatically. On turning on
2
the appliance, the new component takes over the previously
set parameters from the components that are not replaced.
3
Replacing display and electronics
When replacing both components, after being turned on,
the appliance goes to fault and displays the error
message “F70”.
Fig. 9.6 Primary heat exchanger holder • In the second diagnostic level, under the diagnostic
number “d.93” enter the number of appliance variant
• Disconnect the plug-in connection (2) of the thermal according to Table 9.1 (see section 8.1.2).
fuse in the primary heat exchanger.
• Remove the three screws (3) on the primary heat The electronics is now set to the appliance type and the
exchanger holder. parameters of all adjustable diagnostics numbers
• Turn the holder to the side around the rivet (1), pull correspond to the factory settings.
the primary heat exchanger downwards to the right
and remove it from the appliance. Appliance Device specific number
• Mount the new primary heat exchanger in reverse ecoTEC plus 612 0
order and replace the seals. ecoTEC plus 615 1
ecoTEC plus 618 2
Caution! ecoTEC plus 624 3
Risk of damaging the primary heat exchanger! ecoTEC plus 630 4
Neither loosen nor retighten the four screws ecoTEC plus 637 5
(Fig. 9.5, Pos. 4). ecoTEC plus 824 6
ecoTEC plus 831 7
Caution! ecoTEC plus 837 8
Insert the seal rings for the flow and return pipe ecoTEC pro 24 7
on the primary heat exchanger with a suitable ecoTEC pro 28 0
lubricant. Insert the flow and return connection Table 9.1 Device specific numbers
in the primary heat exchanger as far as they will
go and make sure the clamps are fitted correctly
on the flow and return pipe (see Fig. 9.5).
• Fill and vent the boiler as required.

• After completing the work, check for gas and water
leaks and perform a function check (see section 7.6).

10 Recycling and disposal
11 Vaillant service
10 Recycling and disposal

Both the Vaillant ecoTEC and the associated transport
packaging consist primarily of recyclable raw materials.
The Vaillant ecoTEC and all accessories and packaging
must not be disposed of in the normal household
rubbish. Make sure that the old unit and any existing
accessories and the transport packaging is handed over
to a proper disposal organisation.
11 Vaillant service
To ensure regular servicing, it is strongly recommended
that arrangements are made for a Maintenance
Agreement. Contact Vaillant Service Solutions
(0870 6060 777) for further details.

Appendix
Appendix
EG declaration of conformity
Installation,
Commissioning and
Service Record
Please affix the label from the
rear cover of the control box
over this area.
0020008345-06
SERVICE INTERVAL RECORD
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below .
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service
as described in the boiler manufacturer’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.
SERVICE 1 Date SERVICE 2 Date

Energy Efficiency Checklist completed? Yes No Energy Efficiency Checklist completed? Yes No
Engineer Name Engineer Name
Company Name Company Name
Telephone Number Telephone Number
Engineer ID Number Engineer ID Number
Comments Comments
Signature Signature


Comments Comments
Signature Signature


Comments Comments
Signature Signature


Comments Comments
Signature Signature


Comments Comments
Signature Signature
839592_12 GBIE 062010 — Subject to alterations

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For the installer

Instructions for installation and servicing

ecoTEC plus 824

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.7 Removing the front case . . . . . . . . . . . . . . . . . . . 21

2 Instructions for installation and servicing ecoTEC 839592_12

6 Functional checks (commissioning part II). . 39

7 Inspection and maintenance . . . . . . . . . . . . . 41

10 Recycling and disposal . . . . . . . . . . . . . . . . . . 58

Instructions for installation and servicing ecoTEC 839592_12 3

1 Introduction 1.2 Validity of the manual

ecoTEC system boiler

4 Instructions for installation and servicing ecoTEC 839592_12

The ecoTEC system boiler consists of models with Caution!

1.5 Intended use

Instructions for installation and servicing ecoTEC 839592_12 5

ecoTEC plus ecoTEC pro

6 Instructions for installation and servicing ecoTEC 839592_12

Instructions for installation and servicing ecoTEC 839592_12 7

ecoTEC plus 637,

Fig. 2.1 Dimensions in mm

8 Instructions for installation and servicing ecoTEC 839592_12

2.4 Type plate

Instructions for installation and servicing ecoTEC 839592_12 9

3 General requirements BS. 5440: Installation and maintenance of flues and

10 Instructions for installation and servicing ecoTEC 839592_12

Item Quantity Description Item Quantity Description

1 1 Hanging bracket 1 1 Hanging bracket

Instructions for installation and servicing ecoTEC 839592_12 11

If the boiler is installed in an unusual location, special

12 Instructions for installation and servicing ecoTEC 839592_12

3.6 Flue pipe

3.6.1 Standard 100 mm flue system 650

A standard 100 mm flue system (Art. No. 303 933) is

must be provided and fitted (made by Tower Flue

Fig. 3.5 Art. No. 0020060570

Instructions for installation and servicing ecoTEC 839592_12 13

In order to ensure that the condensate plume does

Fig. 3.8 Flue termination

The flue assembly shall be so placed or shielded as to

3.9 Electrical supply

14 Instructions for installation and servicing ecoTEC 839592_12

Mixing additives with the heating water can result in

Instructions for installation and servicing ecoTEC 839592_12 15

16 Instructions for installation and servicing ecoTEC 839592_12

Vessel Volume [L]

450 49.0 70.2 400

Fig. 3.10.1 Pump specifications ecoTEC plus

Instructions for installation and servicing ecoTEC 839592_12 17

18 Instructions for installation and servicing ecoTEC 839592_12

Instructions for installation and servicing ecoTEC 839592_12 19

• Mark the position of the hanging bracket fixing holes.

4.3 Flue exit

Other flue options

4.4 Fitting the boiler hanging bracket

Fig. 4.3 Appliance with hanging bracket

• Fix the hanging bracket to the wall using the plugs

If the boiler is to be fitted in a timber framed

building ensure that the bracket is secured to a