Installation and Maintenance Instructions: Ecotec Plus

Installation and maintenance instructions
For the competent person
Installation and maintenance instructions
ecoTEC plus
VU GB 656/4-5 A
GB, IE
Publisher/Manufacturer
Vaillant GmbH
Berghauser Str. 40 D-42859 Remscheid
Tel. +49 21 91 18‑0 Fax +49 21 91 18‑2810
[email protected] www.vaillant.de
Contents
Contents 7 Adapting the unit to the heating

installation.......................................................... 23
1 Safety .................................................................... 4 7.1 Calling up diagnostics codes ............................... 23
1.1 Action-related warnings ......................................... 4 7.2 Calling up the installer level (second
diagnostics level) ................................................. 23
1.2 Intended use .......................................................... 4
7.3 Setting the heating partial load ............................ 23
1.3 General safety information .................................... 4
7.4 Setting the pump overrun and pump operating
1.4 Regulations (directives, laws, standards) .............. 6
mode.................................................................... 23
2 Notes on the documentation .............................. 7
7.5 Setting the maximum flow temperature ............... 24
2.1 Observing other applicable documents ................. 7
7.6 Setting the burner anti-cycling time ..................... 24
2.2 Storing documents................................................. 7
7.7 Setting the maintenance interval ......................... 24
2.3 Applicability of the instructions .............................. 7
7.8 Pump diagram ..................................................... 24
2.4 Benchmark............................................................. 7
7.9 Adjusting the product to large flue gas pipe
3 Product description............................................. 7 lengths ................................................................. 25
3.1 Functional elements............................................... 7 7.10 Handing the product over to the operator............ 25
3.2 Information on the identification plate.................... 7 8 Inspection and maintenance ............................ 25
3.3 Serial number ........................................................ 8 8.1 Observing inspection and maintenance
3.4 CE label ................................................................. 8 intervals ............................................................... 25
4 Installation............................................................ 8 8.2 Procuring spare parts .......................................... 26
4.1 Unpacking the product........................................... 8 8.3 Removing the compact thermal module .............. 26
4.2 Checking the scope of delivery.............................. 8 8.4 Cleaning the heat exchanger............................... 26
4.3 Transporting the product ....................................... 8 8.5 Descaling the heat exchanger ............................. 27
4.4 Product dimensions and connection 8.6 Checking the burner ............................................ 27
dimensions............................................................. 9 8.7 Cleaning the condensate duct ............................. 27
4.5 Minimum clearances and installation 8.8 Cleaning the air separation system ..................... 28
clearances ............................................................. 9
8.9 Installing the compact thermal module ................ 28
4.6 Clearance from combustible components ............. 9
8.10 Draining the product ............................................ 28
4.7 Using the installation template............................... 9
8.11 Checking the pre-charge pressure of the
4.8 Wall-mounting the product................................... 10 external expansion vessel ................................... 29
4.9 Removing or installing the front casing................ 10 8.12 Completing inspection and maintenance work .... 29
5 Installation.......................................................... 10 8.13 Checking the product for leak-tightness .............. 29
5.1 Selecting a low loss header ................................. 11 9 Troubleshooting ................................................ 29
5.2 Gas installation .................................................... 12 9.1 Contacting your service partner........................... 29
5.3 Hydraulics installation .......................................... 13 9.2 Calling up status codes........................................ 29
5.4 Installing the air/flue pipe ..................................... 14 9.3 Reading off the fault codes .................................. 29
5.5 Installing and connecting the flue pipe ................ 14 9.4 Querying the fault memory .................................. 29
5.6 Electrical installation ............................................ 14 9.5 Performing diagnostics ........................................ 29
6 Start-up ............................................................... 16 9.6 Using check programmes .................................... 29
6.1 Carrying out the initial start-up............................. 16 9.7 Resetting parameters to factory settings ............. 29
6.2 Switching on the product ..................................... 16 9.8 Preparing the repair work .................................... 29
6.3 Using check programmes .................................... 16 9.9 Replacing defective components......................... 30
6.4 Checking and treating the heating water/filling 9.10 Completing repair work........................................ 30
and supplementary water .................................... 17
10 Decommissioning the product ......................... 30
6.5 Reading off the filling pressure ............................ 18
11 Recycling and disposal..................................... 30
6.6 Reading off the filling pressure ............................ 18
12 Customer service............................................... 30
6.7 Preventing low water pressure ............................ 18
Appendix ............................................................................ 31
6.8 Filling and purging the heating installation .......... 18
A Overview of diagnostics codes ........................ 31
6.9 Flushing the heating installation for the first
B Inspection and maintenance work –
time ("cold") ......................................................... 19
Overview............................................................. 33
6.10 Filling the condensate siphon .............................. 19
C Status codes – Overview .................................. 34
6.11 Filling the condensate trap .................................. 19
D Overview of fault codes .................................... 35
6.12 Gas ratio setting................................................... 19 E Connection diagram .......................................... 37
6.13 Checking leak-tightness ...................................... 22 F Commissioning Checklist................................. 39
6.14 Thoroughly flushing the heating installation
("hot")................................................................... 22
2 Installation and maintenance instructions ecoTEC plus 0020214491_01

Contents
G Opening of the flue pipe.................................... 43

G.1 Positioning of the opening of a fan-supported
flue gas guiding.................................................... 43
H Horizontal terminal positioning........................ 44
I Technical data.................................................... 44
Index ................................................................................... 46
0020214491_01 ecoTEC plus Installation and maintenance instructions 3

1 Safety
1 Safety this document shall be considered improper

use. Any direct commercial or industrial use
1.1 Action-related warnings is also deemed to be improper.
Classification of action-related warnings Caution.
The action-related warnings are classified in Improper use of any kind is prohibited.
accordance with the severity of the possible
danger using the following warning signs and 1.3 General safety information
signal words:
1.3.1 Risk caused by inadequate
Warning symbols and signal words qualifications
Danger!
The following work must only be carried out
Imminent danger to life or risk of by competent persons who are sufficiently
severe personal injury qualified to do so:
Danger! – Assembly
Risk of death from electric shock – Disassembly
Warning. – Installation
Risk of minor personal injury – Start-up
Caution. – Maintenance
Risk of material or environmental – Repair
damage – Decommissioning
▶ Observe all instructions that are included
1.2 Intended use
with the product.
There is a risk of injury or death to the user or ▶ Proceed in accordance with the current
others, or of damage to the product and other state of technology.
property in the event of improper use or use ▶ Observe all applicable directives, stand-
for which it is not intended. ards, laws and other regulations.
The product is intended as a heat generator
for closed heating installations and for hot 1.3.2 Risk of death from escaping gas
water generation. What to do if you smell gas in the building:
Depending on the gas-fired boiler type, the ▶ Avoid rooms that smell of gas.
products referred to in these instructions ▶ If possible, open doors and windows fully
must only be installed and operated in con- and ensure adequate ventilation.
junction with the air/flue pipe accessories lis- ▶ Do not use naked flames (e.g. lighters,
ted in the other applicable documents. matches).
Intended use includes the following: ▶ Do not smoke.
– observance of accompanying operating, ▶ Do not use any electrical switches, mains
installation and servicing instructions for plugs, doorbells, telephones or other com-
the product and any other system compon- munication systems in the building.
ents ▶ If it is safe to do so, close the emergency
– installing and fitting the product in accord- control valve or the main isolator.
ance with the product and system approval ▶ If possible, close the gas isolator cock on
– compliance with all inspection and main- the product.
tenance conditions listed in the instruc- ▶ Warn other occupants in the building by
tions. yelling or banging on doors or walls.
▶ Leave the building immediately and ensure
Intended use also covers installation in ac-
that others do not enter the building.
cordance with the IP class.
▶ Notify the gas supply company or the Na-
Any other use that is not specified in these tional Grid +44 (0) 800 111999 by tele-
instructions, or use beyond that specified in

Safety 1
phone once you are outside of the build- 1.3.8 Risk of death due to lack of safety
ing. devices
1.3.3 Risk of death due to blocked or The schematic drawings included in this doc-
leaking flue gas routes ument do not show all safety devices re-
quired for correct installation.
Installation errors, damage, tampering, unau-
▶ Install the necessary safety devices in the
thorised installation sites or similar can cause
system.
flue gas to escape and result in a risk of pois-
oning. ▶ Observe the applicable national and inter-
national laws, standards and guidelines.
What to do if you smell flue gas in the prop-
erty: 1.3.9 Risk of death from electric shock
▶ Open all accessible doors and windows There is a risk of death from electric shock if
fully to provide ventilation. you touch live components.
▶ Switch off the product. Before commencing work on the product:
▶ Check the flue gas routes in the product
and the flue gas diversions. ▶ Disconnect the product from the power
supply by switching off all power supplies
1.3.4 Risk of poisoning and burns caused (electrical partition with a contact opening
by escaping hot flue gases of at least 3 mm, e.g. fuse or line protec-
tion switch).
▶ Only operate the product if the air/flue pipe
▶ Secure against being switched back on
has been completely installed.
again.
▶ With the exception of short periods for
▶ Wait for at least 3 minutes until the capa-
testing purposes, only operate the product
citors have discharged.
when the front casing is installed and
closed. ▶ Check that there is no voltage.
1.3.5 Risk of poisoning caused by 1.3.10 Risk of being burned or scalded by

insufficient supply of combustion hot components
air ▶ Only carry out work on these components
once they have cooled down.
Conditions: Open-flued operation
▶ Ensure that the air supply to the product's 1.3.11 Risk of death from escaping flue
installation room is permanently unobstruc- gas
ted and sufficient in accordance with the If you operate the product with an empty con-
relevant ventilation requirements. densate siphon, flue gas may escape into the
room air.
1.3.6 Risk of death due to cabinet-type
▶ In order to operate the product, ensure that
casing
the condensate siphon is always full.
Cabinet-type casing can give rise to danger-
ous situations when used on a product which 1.3.12 Risk of death from escaping flue
is operated with an open flue. gas
▶ Ensure that the product is supplied with If you operate the product with an empty con-
sufficient combustion air. densate siphon, flue gas may escape into the
room air.
1.3.7 Risk of death due to explosive and
▶ In order to operate the product, ensure that
flammable materials
the condensate siphon is always full.
▶ Do not use or store explosive or flammable
materials (e.g. petrol, paper, paint) in the 1.3.13 Risk of scalding from hot water
installation room of the product. There is a risk of scalding at the hot water
draw-off points if the hot water temperatures

1 Safety
are greater than 60 °C. Young children and 1.3.19 Risk of damage to the flexible gas
elderly persons are particularly at risk, even pipe
at lower temperatures. The corrugated gas pipe may become dam-
▶ Select a moderate set target temperature. aged if weight is placed on it.
1.3.14 Risk of injury due to the heavy ▶ Do not suspend the compact thermal
weight of the product module on the flexible gas pipe, for
example during maintenance work.
▶ Make sure that the product is transported
by at least two people. 1.4 Regulations (directives, laws,
standards)
1.3.15 Risk of material damage caused by
using an unsuitable tool ▶ Observe the national regulations, stand-
ards, guidelines and laws.
▶ Use the correct tool to tighten or loosen
screw connections.

frost
▶ Do not install the product in rooms prone
to frost.
1.3.17 Risk of corrosion damage due to

unsuitable combustion and room
air
Sprays, solvents, chlorinated cleaning
agents, paint, adhesives, ammonia com-
pounds, dust or similar substances may lead
to corrosion on the product and in the flue
gas guiding.
▶ Ensure that the supply of combustion air is
always free of fluorine, chlorine, sulphur,
dust, etc.
▶ Ensure that no chemical substances are
stored at the installation site.
▶ If you are installing the product in
hairdressing salons, painter's or joiner's
workshops, cleaning businesses or similar
locations, choose a separate installation
room in which the room air is technically
free of chemical substances.

leak detection sprays and liquids
Leak detection sprays and liquids block the
filter of the mass flow sensor on the Venturi,
and thus destroy the mass flow sensor.
▶ During repair work, do not apply any leak
detection sprays or liquids to the covering
cap on the filter of the Venturi.

Notes on the documentation 2
2 Notes on the documentation 3 Product description

2.1 Observing other applicable documents 3.1 Functional elements
▶ You must observe all the operating and installation in-
structions included with the system components. 1
2.2 Storing documents

2
▶ Pass these instructions and all other applicable docu-
ments on to the system operator.
18
2.3 Applicability of the instructions
3
These instructions apply only to:
Product article number
17 4
VU GB 656/4-5 A 0010017820
5
2.4 Benchmark 6
Vaillant is a licensed member of the Benchmark Scheme. 16
Benchmark places responsibilities on both manufacturers 15 7

and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the 14 8
manufacturer’s instructions by a competent person approved
at the time by the Health and Safety Executive and that it
meets the requirements of the appropriate Building Regu-
13 9
lations. The Benchmark Checklist can be used to demon-
strate compliance with Building Regulations and should be 12
provided to the customer for future reference. 10
11
Installers are required to carry out installation, commission-
ing and servicing work in accordance with the Benchmark
1 Connection for the flue 9 Connection for expan-
Code of Practice which is available from the Heating and pipe sion vessel
Hotwater Industry Council who manage and promote the 2 Integrated condensation 10 Electronics box
Scheme. heat exchanger
11 Condensate trap
Benchmark is managed and promoted by the Heating and 3 Air intake pipe
12 Filling and drainage tap
Hotwater Industry Council. 4 Compact thermal flow
module
13 Connection for expan-
5 Ignition electrode sion relief valve
6 Water pressure sensor 14 Gas valve
7 Pump 15 Air separator
8 Filling connection (com- 16 Volume flow sensor
bined filling and empty-
17 Automatic air vent
ing valve)
18 Flow switch with control
lines
For more information visit www.centralheating.co.uk
3.2 Information on the identification plate
The identification plate is mounted on the underside of the
product in the factory.
Information on the Meaning

identification plate
Serial number for identification; 7th to 16th digits =
product article number
VU… Vaillant gas-fired wall-hung boiler for
heating
ecoTEC plus Product description
2H, G20 - 20 mbar Gas group and gas connection pressure
(2 kPa) as set at the factory
Cat. Unit category
Types Gas-fired boiler types

4 Installation
Information on the Meaning Num-

Description
identification plate ber
PMS Permissible total overpressure in heating 1 Bag with small parts
mode
PMW Permissible total overpressure during hot 4.3 Transporting the product
water generation
Tmax. Max. flow temperature 4.3.1 General
ED 92/42 Current efficiency directive fulfilled with ▶ Hold the load as close as possible to your body. Do not
4* rating twist your body – instead, reposition your feet.
230 V 50 Hz Electric connection ▶ If the unit is being lifted by two persons, ensure your
W Max. electrical power consumption movements are coordinated during lifting.
IP Level of protection
▶ Avoid bending your upper body – do not lean forwards or
to the side.
Heating mode
▶ Wear appropriate cut-resistant and non-slip gloves to
P Nominal heat output range protect yourself against sharp edges and maintain a safe
and secure grip.
Q Heat input range
▶ If required, get somebody to assist you in this.
Note 4.3.2 Unloading the box from the delivery van

Make absolutely sure that the product is compat-
ible with the gas group at the installation site.
▶ It is recommended that two people lift the unit together.
▶ Lift the box using the straps provided.
▶ Use safe lifting techniques – keep your back straight and
3.3 Serial number bend your legs at the knee.
The serial number can be found on the identification plate. ▶ Hold the load as close as possible to your body.
▶ If the unit is being lifted by two persons, ensure your
3.4 CE label movements are coordinated during lifting.
▶ If required, get somebody to assist you in this.
4.3.3 Transporting the box from the delivery

point to the installation site – ground floor
The CE label shows that the products comply with the basic ▶ It is recommended that two people lift the unit together.
requirements of the applicable directives as stated on the
identification plate.
▶ Use safe lifting techniques – keep your back straight and
bend your legs at the knee.
The declaration of conformity can be viewed at the manufac-
turer's site.
4 Installation
4.1 Unpacking the product
1. Remove the product from its box.
2. Remove the protective film from all parts of the product.
4.2 Checking the scope of delivery

▶ Check that the scope of delivery is complete and intact.
4.2.1 Scope of delivery

Num-
Description
ber
1 Hanging bracket
1 Heat generator
1 Condensate drain hose
1 Expansion relief valve
1 Compression joint, gas G 1
1 Seal
1 Condensate trap's cartridge installation kit
1 Enclosed documentation

Installation 4
4.4 Product dimensions and connection 1 Flue gas connection, 7 Expansion relief valve
dimensions 80/125 diameter connection
2 Hanging bracket 8 Condensate discharge
480 connection
3 Gas pipe, 25 mm dia-
meter, gas connection 9 Flow drain opening
Ø 80/125
R1“ 10 Filling connection option
4 Expansion vessel con- (combined filling and
nection emptying valve)
1 5 Heating return connec- 11 Condensate trap's
A
119 tion cartridge

6 Heating flow connection
94
2
Consult the installation template that is supplied to find the
dimension A.
4.5 Minimum clearances and installation

clearances
800
A
3
32
61
B
Ø 25, R1 5
7 Rp 1 Rp 1
6 G 1 1/2 G 1 1/2
R 3/4 172 172 R1 A 500 mm B 400 mm
224 224
▶ When using the accessories, observe the minimum clear-
ances/installation clearances.
472
211 4.6 Clearance from combustible components
▶ It is not necessary to maintain a clearance between the
product and components made of combustible materials
that go beyond the minimum clearances.
4.7 Using the installation template

1. Position the installation template vertically over the in-
stallation site.
2. Secure the template to the wall.
3. Mark on the wall all the points required for the installa-
tion.
4. Remove the installation template from the wall.
5. Drill all the holes required.
6. Make any perforations necessary.
140
9
10 75
121
11

5 Installation
4.8 Wall-mounting the product 4.9 Removing or installing the front casing
4.9.1 Removing the front casing
1. Check whether the wall has sufficient load-bearing ca-

1. Undo the bolt (1).
pacity to bear the operational weight of the product.
2. Push in both retaining clips (2) so that the front casing
2. Check if the supplied fixing material may be used for
is released.
the wall.
3. Pull the front casing forwards at the bottom edge.
Conditions: The load-bearing capacity of the wall is sufficient; the fixing 4. Lift the front casing upwards from the bracket.
material is permitted for the wall
▶ Wall-mount the product as described. 4.9.2 Installing the front casing
Conditions: The load-bearing capacity of the wall is not sufficient 1. Place the front casing on the upper brackets.
2. Push the front casing onto the product until both retain-
▶ Ensure that wall-mounting apparatus on-site has a suf- ing clips (2) snap into place at the front casing.
ficient load-bearing capacity. Use individual stands or 3. Secure the front casing by tightening the bolt (1).
primary walling, for example.
▶ Do not wall-mount the product if you cannot provide
wall-mounting apparatus with a sufficient load-bearing
capacity. 5 Installation
Conditions: The fixing material may not be used for the wall Danger!
▶ Wall-mount the product as described using the permitted Risk of explosion or scalding caused by
fixing material provided on-site. incorrect installation.
Stresses in the connection cable can cause
leaks.
▶ Make sure there is no stress in the con-
nection cables when they are installed.
Caution.
Risk of material damage caused by
changes to the connected pipes.
▶ Only bend connection pipes if they have
not yet been connected to the product.

Installation 5
Caution. 5.1.1 Heating circuit connection with low loss

header
Risk of material damage caused by
residues in the pipelines.
Welding remnants, sealing residues, dirt or
other residues in the pipelines may damage
the product.
▶ Flush the heating installation thoroughly
before installing the product. 4
Seals made of rubber-like materials may be subject to plastic 1

deformation, which can lead to pressure losses. We recom-
3
mend using seals made of a paste-like fibre material.
You must only start up the product if a sufficiently dimen- 2
sioned low loss header has been installed between the heat
generation circuit and the heating circuit or cylinder charging
circuit.
1 Product with internal 3 External heating pump
pump
5.1 Selecting a low loss header 4 Consumer (e.g. heating
2 Low loss header circuit)
The low loss header disconnects the heat generator from
the heating system. This means that the system is no longer The product can directly operate a heating circuit via the low
dependent on the heat generator's remaining feed head. loss header.
In conjunction with the heating pump, the low loss header
ensures that a sufficiently high minimum quantity of water is
▶ Downstream of the low loss header, select a heating
pump that is appropriate for the system.
always circulating through the heat generator.
▶ For multi-circuit systems, pay additional attention to the
Heating system output Heating system spread control system accessories.
10 K 15 K 20 K The settings for the internal pump are made at the factory.
Individual unit WH 160 WH 95 WH 95 ▶ Connect the external heating pump to the grey ProE plug
Dual cascade WH 280 WH 160 WH 95 X13.
Three-unit cascade WH 280 WH 280 WH 160
▶ Set the diagnostics code D.26 to 2.
For old systems in particular, we recommend installing a 5.1.2 Cylinder priority switching via low loss
heating dirt filter in the return to the low loss header (not to header
the product). This protects the product against dirt from the
system. Ensure that there is sufficient dimensioning in order
to prevent it from blocking quickly and to prevent high pres-
sure losses. 4
You do not need any electrical accessories when using a
low loss header. You can connect simple systems directly
inside the electronics box; see the connection diagram
(→ Page 37).
1 3
1 Product with internal 3 External cylinder char-

pump ging pump
2 Low loss header 4 Consumer (e.g. cylinder
charging circuit)
The product's electronics are designed in such a way that

you can connect one cylinder charging circuit and one heat-
ing circuit directly without the need for accessories. The cyl-
inder charging circuit connection downstream of the low loss
header means that you can select an individual cylinder size
and a cylinder charging pump.

5 Installation
▶ Note that non-return valves or mixer circuits may be re- 5.2 Gas installation
quired in order to eliminate cross-flow to other circuits or
the effects of high temperatures from the cylinder char- 5.2.1 Checking the gas meter
ging circuit. ▶ Make sure that the existing gas meter is capable of
▶ Connect the cylinder charging pump to the ProE plug X6. passing the rate of gas supply required.
To start up the cylinder charging pump, it is not necessary to
set a diagnostics code. The slot on the PCB is reserved for 5.2.2 Performing the gas installation
the cylinder charging pump.
Caution.
5.1.3 Cylinder priority switching and heating Risk of material damage due to the gas
circuit via low loss header leak-tightness test.
At a test pressure of >11 kPa (110 mbar), gas
leak-tightness tests may cause damage to
the gas valve.
▶ If, during gas leak-tightness tests, you
also place the gas lines and the gas valve
6
in the product under pressure, use a max.
4 test pressure of 11 kPa (110 mbar).
▶ If you cannot limit the test pressure to
1 11 kPa (110 mbar), close any gas isolator
3 5
cocks that are installed upstream from the
product before you carry out the gas leak-
tightness test.
2
▶ If, during gas leak-tightness tests, you
have closed the gas isolator cock that is
1 Product with internal 4 Consumer (e.g. heating installed upstream of the product, relieve
pump circuit) the gas line pressure before you open this
2 Low loss header 5 External cylinder char- gas isolator cock.
ging pump
3 External heating pump
6 Cylinder
Note
The product's electronics are designed in such a way that Do not reduce the gas pipe dimension down-
you can connect a standard system (one heating circuit and stream of the gas meter. Maintain the dimension
one cylinder charging circuit) without the need for special ac- right up to the product. Select the correct gas isol-
cessories. If several circuits are required, special accessor- ator cock. When using an atmospheric sensing
ies and/or controllers are required. The product's remain- device, select the next-highest pipe cross-section.
ing feed head for the low loss header is sufficient. You can
individually design the cylinder charging circuit connection
downstream of the low loss header (cylinder size, cylinder
charging pump size, etc.).
▶ Note that non-return valves or mixer circuits may be re-
quired in order to eliminate cross-flow to other circuits or
the effects of high temperatures from the cylinder char-
ging circuit.
To start up the cylinder charging pump, it is not necessary to
set a diagnostics code. The slot on the PCB is reserved for
the cylinder charging pump.
1
The settings for the internal pump are made at the factory.
▶ Connect the cylinder charging pump to the ProE plug X6.
▶ Connect the external heating pump to the grey ProE plug ▶ Install the gas line without tension in accordance with the
X13. recognised rules of technology.
▶ Set the diagnostics code D.26 to 2. ▶ Make sure that the existing gas meter is capable of
passing the rate of gas supply required.
▶ Remove the residues from the gas pipe by blowing
through the gas pipe beforehand.
▶ Screw the gas pipe (1) to the (preinstalled) gas isolator
cock so that it is gas-tight. To do this, use the enclosed
compression joint G 1.
▶ Purge the gas pipe before start-up.

Installation 5
5.2.3 Checking the gas line for leak-tightness 5.3.2 Installing the expansion relief valve
▶ Check the entire gas line properly for leak-tightness.
5.3 Hydraulics installation
Caution.
Risk of material damage caused by corro-
sion
Due to non-diffusion-tight plastic pipes in the
heating installation, air gets into the heating
water. Air in the heating water causes corro-
sion in the heat generator circuit and in the
product.
▶ If you use non-diffusion-tight plastic pipes
in the heating installation, ensure that no
air gets into the heat generator circuit.
1
Caution. 1. Install the enclosed expansion relief valve.

Risk of material damage due to heat trans- 2. Lay as short a drain line as possible for the expansion
fer during soldering. relief valve, at a downward gradient.
Heat that is transferred during soldering may 3. Terminate the drain line in such a way that escaping
cause damage to the seals in the service water or steam cannot cause injury to persons or dam-
age to electronic components.
valves.
4. Make sure that the line end is visible.
▶ Do not solder the connection pieces if
the connection pieces are screwed to the 5.3.3 Connecting the condensate drain pipework
service valves.
5.3.4 Connecting the condensate drain pipework
▶ If you are using plastic pipes in the heating installation, Danger!
you must install a suitable limit thermostat on-site at the
heating flow. The limit thermostat is required to protect
Risk of death from escaping flue gases!
the heating installation against temperature-related dam- The condensate drain pipework of the con-
age if a fault occurs. densate trap must not be connected tightly to
▶ Install an expansion vessel on-site in the heating return, waste-water piping because, otherwise, the
as close to the product as possible. internal condensate trap may be drained fully
and flue gas may escape.
5.3.1 Connecting the heating flow and heating
return ▶ Do not connect the condensate drain
pipework tightly to the waste-water pip-
ing.
1 2
1. Install service valves properly at the flow connection (1)

and the return connection (2).
1
2. Establish the heating connections in accordance with
the relevant standards.
2
Condensate forms in the product during combustion. The

condensate drain pipework (1) routes the condensate to the
waste water connection via a tundish (2).

5 Installation
▶ Install the enclosed condensate drain pipework (hose) problem. The product must not be connected to a cascade
(1). flue gas installation that is being used by other units.
▶ Observe the applicable international, national and local
Note regulations for flue gas systems, in particular for installa-
If the length of the enclosed hose is not suf- tions in living rooms. Inform the operator how to correctly
ficient, use only pipes that are made from operate the product.
acid-resistant material (e.g. plastic) for the
condensate drain pipework and also for the 5.5 Installing and connecting the flue pipe
waste-water piping.
1. You can find out which flue pipes may be used by con-
sulting the enclosed flue pipe installation manual.
▶ Suspend the condensate drain pipework above the prein- 2. Observe the information on positioning the opening
stalled tundish (2). for the flue pipe. This information can be found in the
appendix.
5.4 Installing the air/flue pipe
1. You can find out which flue pipes may be used by con- Caution.
sulting the enclosed flue pipe installation manual. Risk of poisoning due to escaping flue
gas.
Danger! Mineral-oil-based greases can damage the
Risk of personal injury and material dam- seals.
age due to unapproved air/flue pipes.
▶ Instead of grease, use only water or com-
Vaillant boilers are certified only with Vaillant mercially available soft soap to aid install-
original air/flue pipes. The use of other ac- ation.
cessories may cause personal injury and ma-
terial damage, as well as operating faults. For
3. Install the flue pipe using the installation manual.
installation type B23P, third-party accessor-
ies are also permitted (see the technical data
5.6 Electrical installation
in the appendix).
▶ Only use Vaillant original air/flue pipes. Danger!
▶ If third-party accessories are permitted Risk of death from electric shock as a res-
for B23P, ensure that the flue pipe con- ult of an improper electrical connection!
nections are properly routed, sealed and An improper electrical connection may neg-
secured against slipping out. atively affect the operational safety of the
product and result in material damage or per-
2. Install the flue pipe using the installation manual. sonal injury.
▶ Only carry out the electrical installation if
5.4.1 Information on installing the B23 you are a trained competent person and
A flue gas pipe in accordance with unit type B23 (open-flued are qualified for this work.
gas-fired wall-hung boilers) requires careful planning and im- ▶ Observe all applicable laws, standards
plementation. During planning, observe the technical data for and directives in the process.
the product and refer to the recognised rules of technology.
▶ Earth the product.
5.4.2 Information and specifications for installing
the B23P Danger!
The flue gas system must at least correspond to the clas- Risk of death from electric shock!
sification T 120 P1 W 1 in accordance with EN 1443. The
Touching live connections may cause seri-
maximum pipe length must be calculated based on the per-
missible pressure difference in the technical data. ous personal injury. Since mains connection
terminals L and N also remain live even if the
The maximum pipe length (straight pipe only) corresponds to boiler main switch is turned off:
the maximum permitted flue gas pipe length without any el-
bows. If elbows are used, the maximum pipe length must be ▶ Switch off the power supply.
reduced in accordance with the dynamic flow characteristics ▶ Secure the power supply against being
of the elbows. Elbows must not be connected directly after switched on again.
one another as this method dramatically increases pressure
losses.
In particular, if the flue pipe is installed in cold rooms or out-
side of the building, the freezing point on the surface of the
inside of the pipe may be reached. A proven design in ac-
cordance with EN 13384-1 for a maximum boiler load at a
flue gas temperature of 40 °C must be used to prevent this

Installation 5
5.6.1 Opening or closing the electronics box 5.6.3 Carrying out the wiring
5.6.1.1 Opening the electronics box Caution.
1. Remove the front casing. (→ Page 10) Risk of material damage caused by incor-
rect installation.
Mains voltage at the incorrect plug terminals
on the ProE system may destroy the elec-
tronics.
▶ Do not connect any mains voltage to the
eBUS terminals (+/-).
▶ Only connect the power supply cable to
the terminals marked for the purpose.
2
1. Route the supply lines of the components to be connec-
3
ted through the cable duct provided on the underside of
1 the product on the left.
2. Use strain reliefs.
3. Shorten the supply lines as necessary.
4. Only strip the outer sheathing of flexible lines to a max-
imum of 30 mm to prevent short circuits if a strand acci-
dentally comes loose.
5. Ensure the inner conductor insulation is not damaged
when stripping the outer sheathing.
6. Only strip inner conductors just enough to establish
good, sound connections.
2. Tilt the electronics box (3) forwards. 7. To avoid short circuits resulting from loose individual
3. Detach the left and right clips (1) from the brackets. wires, fit conductor end sleeves on the stripped ends of
4. Fold up the cover (2). the conductors.
8. Screw the respective ProE plug to the supply line.
5.6.1.2 Closing the electronics box 9. Check whether all conductors are sitting mechanically
1. Close the cover (2) by pushing it downwards onto the securely in the terminals of the ProE plug. Remedy this
electronics box (3). if necessary.
2. Ensure that all of the clips (1) audibly click into the 10. Plug the ProE plug into the associated PCB slot.
brackets.
3. Tilt the electronics box upwards. 5.6.4 Installing the controller
▶ Install the controller if necessary.
5.6.2 Establishing the power supply
1. Observe the relevant regulations and the enclosed con- 5.6.5 Connecting controllers to the electronic
nection diagram. system
2. Provide one common electricity supply for the boiler 1. Carry out the wiring. (→ Page 15)
and for the corresponding controller: 2. If you do not connect a room/timer thermostat, bridge
– Power supply: Single-phase, 230 V, 50 Hz terminals 3 and 4, if no bridge exists.
– Fuse protection: ≤ 3 A 3. If you connect a room/timer thermostat to terminals 3
and 4, remove the bridge.
3. Connect the product using a fixed connection and a 4. If you connect a weather compensator or room thermo-
partition with a contact opening of at least 3 mm (e.g. stat (continuous control – connection terminals 7, 8, 9),
fuses or power switches), see Connection diagram leave the bridge inserted between terminal 3 and 4.
(→ Page 37).
5. If you connect a limit thermostat (contact thermostat)
4. Use a flexible line for the mains connection line, which for underfloor heating systems, remove the bridge on
is routed through the cable duct into the product. the blue ProE plug (contact thermostat) and connect the
5. Carry out the wiring. (→ Page 15) limit thermostat here.
6. Screw the ProE plug supplied to a suitable three-core 6. Close the electronics box. (→ Page 15)
mains connection cable which complies with the relev- 7. To access pump operating mode 1 (continuously run-
ant standards. ning pump) for multi-circuit controllers, set D.18 Pump
7. Close the electronics box. (→ Page 15) operating mode (→ Page 23) from 3 (intermittent pump)
8. Make sure that access to the power supply is always to 1.
available and is not covered or blocked.

6 Start-up
5.6.6 Connecting a low loss header sensor 5.6.9 Actuating the circulation pump according
to requirements
1. Connect the low loss header sensor to the edge con-
nector X41 at terminal RF or to the controller. When do- Note
ing so, observe the instructions for the controller.
The product's electronics provide the opportunity
2. Plug the edge connector into the PCB slot X41. to control a domestic hot water cylinder's circula-
3. Activate the low loss header function at the controller. tion pump as necessary (similar to an automatic
light unit for stairs). It is controlled using an ex-
5.6.7 Connecting a cylinder charging pump ternal button (to be fitted on-site) that can be in-
stalled anywhere in the dwelling, e.g. in the bath-
▶ Connect an external cylinder charging pump (to be fitted
room or kitchen. When the button is pressed, the
on-site) to the pink ProE plug X6.
circulation pump starts up. The pump is switched
on again after five minutes. Several buttons can
5.6.8 Connecting additional components be pressed in parallel. Irrespective of the external
You can actuate an additional component with the aid of the control of the circulation pump, the "Control by
auxiliary relay that is installed, and you can actuate two other programmable time periods" function continues to
components with the multi-functional module. be possible when a controller is used.
The following components can be actuated:
Conditions: Domestic hot water cylinder connected
1. Circulation pump
2. External pump ▶ Carry out the wiring. (→ Page 15)
3. Cylinder charge pump ▶ Connect the supply line for an external button using ter-
4. Extractor hood minals 1 (0) and 6 (functional drawing) on the X41
5. External solenoid valve edge connector, which is supplied with the controller.
6. External fault signal ▶ Plug the edge connector into the PCB slot X41.
7. Not active
8. eBUS remote control (not active)
9. Legionella protection pump (not active) 6 Start-up
10. Not active.
6.1 Carrying out the initial start-up
5.6.8.1 Using the auxiliary relay Initial start-up must be carried out by a customer service
1. Connect an additional component directly to the integ- technician or an authorised competent person using the
rated auxiliary relay using the grey plug on the PCB. commissioning checklist. The commissioning checklist in the
2. Carry out the wiring. (→ Page 15) appendix (→ Page 39) of the installation instructions must be
filled in and stored carefully along with the unit's documenta-
3. To start up the connected component, select the tion.
component via D.26, see Calling up diagnostics codes
(→ Page 23).
▶ Carry out the start-up procedure using the commissioning
checklist in the appendix.
5.6.8.2 Using the VR 40 ("2 in 7" multi-functional
▶ Fill in and sign the commissioning checklist.
module)
6.2 Switching on the product
1. Install the components in accordance with the respect-
ive instructions.
▶ Set the product's main switch to 1.
2. Select D.27 (→ Page 23) to actuate relay 1 on the multi- ◁ The basic display appears on the display.
functional module.
3. Select D.28 (→ Page 23) to actuate relay 2 on the multi- 6.3 Using check programmes
functional module.
By activating various check programmes, you can trigger
special functions on the product.
Display Meaning
P.0 Purging check programme:
The internal pump is cyclically actuated.
The heating circuit and the hot water circuit are
purged via the automatic air vent (the cap of the
automatic air vent must be released).
1x : Start heating circuit purging (display view:
HP)
2x : Start cylinder charging circuit purging
(display view: SP)
3x : Exit purging programme
Note
The purging programme runs for 6.5 minutes per
circuit and then terminates.

Start-up 6
Display Meaning Treating the filling and supplementary water

P.1 Maximum load check programme:
▶ Observe all applicable national regulations and technical
standards when treating the filling and supplementary
After successful ignition, the product is operated at
maximum heat input. water.
P.2 Minimum load check programme: Provided the national regulations and technical standards
After successful ignition, the product is operated at do not stipulate more stringent requirements, the following
minimum heat input. applies:
P.5 SCO (safety cut-out) check programme: You must treat the heating water in the following cases:
The burner is switched on and the control is
switched off so that the product heats up until it – If the entire filling and supplementary water quantity dur-
reaches the safety cut-out's switch-off temperature of ing the operating life of the system exceeds three times
97 °C while avoiding a regular shutdown. the nominal volume of the heating installation, or
P.6 Check programme, diverter valve mid-position: (not – If the guideline values listed in the following table are not
active) met, or
– If the pH value of the heating water is less than 8.2 or
You can start check programmes P.0 to P.6 by either: more than 10.0.
– Switching on the main switch and, at the same time, 1)
Total Water hardness at specific system volume
pressing and holding for five seconds or
heating
– Pressing and holding and at the same time, re- output ≤ 20 l/kW
> 20 l/kW
> 50 l/kW
leasing and pressing and holding for five seconds ≤ 50 l/kW
ppm mol/ ppm mol/ ppm mol/
The displays shows P. 0. kW
CaCO₃ m³ CaCO₃ m³ CaCO₃ m³
▶ Press to move up the check programmes in numerical < 50 < 300 <3 200 2 2 0.02
order.
> 50 200 2 150 1.5 2 0.02
▶ Press to start the check programme. to ≤ 200
▶ Press and at the same time to exit the check pro- > 200 150 1.5 2 0.02 2 0.02
grammes. You can also exit the check programmes by to ≤ 600
not pressing any button for 15 minutes. > 600 2 0.02 2 0.02 2 0.02
1) Nominal capacity in litres/heating output; in the case of multi-
6.4 Checking and treating the heating boiler systems, the smallest single heating output is to be used.
water/filling and supplementary water
Caution.
Caution.
Risk of material damage if the heating
Risk of material damage due to poor-qual-
water is treated with unsuitable additives.
ity heating water
Unsuitable additives may cause changes in
▶ Ensure that the heating water is of suffi-
the components, noises in heating mode and
cient quality.
possibly subsequent damage.
▶ Before filling or topping up the system, check the quality

▶ Do not use any unsuitable frost and cor-
of the heating water.
rosion protection agents, biocides or seal-
ants.
Checking the quality of the heating water
▶ Remove a little water from the heating circuit.
No incompatibility with our products has been detected to
▶ Check the appearance of the heating water. date with proper use of the following additives.
▶ If you ascertain that it contains sedimentary materials,
you must desludge the system. ▶ When using additives, follow the manufacturer's instruc-
tions without exception.
▶ Use a magnetic rod to check whether it contains mag-
netite (iron oxide). We accept no liability for the compatibility of any additive or
▶ If you ascertain that it contains magnetite, clean the sys- its effectiveness in the rest of the heating system.
tem and apply suitable corrosion-protection measures, or
Additives for cleaning measures (subsequent
fit a magnet filter.
flushing required)
▶ Check the pH value of the removed water at 25 °C.
– Adey MC3+
▶ If the value is below 8.2 or above 10.0, clean the system
and treat the heating water. – Adey MC5
▶ Ensure that oxygen cannot get into the heating water. – Fernox F3
– Sentinel X 300
Checking the filling and supplementary water – Sentinel X 400
▶ Before filling the system, measure the hardness of the
filling and supplementary water. Additives intended to remain permanently in the
system
– Adey MC1+
– Fernox F1

6 Start-up
– Fernox F2 6.7 Preventing low water pressure
– Sentinel X 100
To prevent damage to the heating installation that is caused
– Sentinel X 200 by low filling pressure, the product is fitted with a water
Additives for frost protection intended to remain pressure sensor. If the filling pressure falls below 0.06 MPa
permanently in the system (0.6 bar), the product indicates low pressure by displaying a
flashing pressure value. If the filling pressure falls below 0.03
– Adey MC ZERO
MPa (0.3 bar), the product switches off. The display shows
– Fernox Antifreeze Alphi 11 F.22.
– Sentinel X 500
▶ Top up the heating water to start the product up again.
▶ If you have used the above-mentioned additives, inform
The pressure value flashes on the display until a pressure of
the operator about the measures that are required.
0.11 MPa (1.1 bar) or higher has been reached.
▶ Inform the operator about the measures required for frost
protection. ▶ If you notice frequent losses in pressure, determine and
eliminate the cause.
6.5 Reading off the filling pressure
6.8 Filling and purging the heating installation
2
1
1. Flush the heating installation thoroughly before filling it.

2. Undo the cap of the automatic air vent (1) by one to two
rotations and leave it open, as the product purges itself
The product has an analogue pressure gauge (1) and a di- via the automatic air vent even in continuous mode.
gital pressure display. 3. Observe the information on the topic of treating
▶ To read off the digital value, press (2). (→ Page 17) heating water.
4. Connect the filling and drainage tap in the heating in-
If the heating installation is full, the indicator on the pressure stallation to a heating water supply in accordance with
gauge must point to the upper half of the grey area when the the relevant standards.
heating installation is cold in order to ensure that it operates
5. Open the heating water supply.
smoothly. This corresponds to a filling pressure of between
0.1 MPa and 0.2 MPa (1.0 bar and 2.0 bar). 6. Open all thermostatic radiator valves.
7. If necessary, check that both service valves on the
If the heating installation extends over several storeys,
product are open.
higher filling pressures may be required to avoid air entering
8. Slowly open the filling and drainage tap so that the wa-
the heating installation.
ter flows into the heating installation.
6.6 Reading off the filling pressure 9. Purge the lowest radiator until water flows out of the
purging valve without bubbles.
The product comes with a digital pressure indicator. 10. Purge all other radiators until the heating installation is
▶ To read off the digital value for the filling pressure, press completely filled with water.
the button briefly. 11. Close all purging valves.
12. Monitor the rising filling pressure in the heating installa-
◁ The display will show the filling pressure for approx-
tion.
imately 5 seconds.
13. Fill with water until the required filling pressure is
If the heating installation is full, the filling pressure must be reached.
between 0.1 MPa and 0.2 MPa (1.0 bar and 2.0 bar) to en- 14. Close the filling and drainage tap and the heating water
sure it operates properly. supply.
If the heating installation extends over several storeys, 15. Check all connections and the entire system for leaks.
higher filling pressures may be required to avoid air entering 16. To purge the heating installation, select the check pro-
the heating installation. gramme P.0.
◁ The product does not start up, the internal pump
operates intermittently and purges either the heating

Start-up 6
circuit or the hot water circuit. The display shows 6.11 Filling the condensate trap
the filling pressure of the heating installation.
Danger!
17. To be able to carry out the purging process properly,
the heating installation filling pressure must not fall be- Risk of poisoning due to escaping flue
low the minimum filling pressure. gas.
– Minimum heating installation filling pressure: An empty or insufficiently filled condensate
0.08 MPa (0.80 bar) trap may allow flue gas to escape into the
room air.
Note
The check programme P.0 runs for
▶ Fill the condensate trap with water before
6.5 minutes per circuit. starting up the product.
At the end of the filling procedure, the
filling pressure of the heating installation
should be at least 0.02 MPa (0.2 bar) above
the counter-pressure of the expansion
vessel ("Exp") (PInstallation ≥ PExp + 0.02 MPa
(0.2 bar)).
18. If there is still too much air in the heating installation at

the end of the check programme P.0, repeat the check
programme. 1
19. Check all connections for leaks.
6.9 Flushing the heating installation for the first

time ("cold")
Note
The complete heating system must be flushed
at least twice: Once with cold water and once
1. Install the condensate trap's cartridge (1) in accordance
with hot water in accordance with the following
with the enclosed installation manual.
instructions.
2. Fill the condensate trap in accordance with the en-
closed description.
1. Check whether all thermostatic radiator valves and both
service valves on the product are open. 6.12 Gas ratio setting
2. Connect a hose to the drain valve that is located at the
lowest position in the heating system. 6.12.1 Checking the factory setting
3. Open the radiator valves and the drain valves so that Caution.
the water can drain quickly. Start at the next point in the
system and open the purging valves on the radiators so An incorrect gas group setting may cause
that the contaminated water can completely drain. operating faults or a reduction in the
4. Close the drain cocks. working life of the product.
5. Refill the heating system with water. If the product design does not match the local
6. Check that the expansion relief valve of the heating gas group, malfunctions will occur or you will
system is functioning correctly by turning the handle have to replace product components prema-
on the valve. turely.
7. Check the pressure in the heating system and top up
with water if necessary. ▶ Before you start up the product, compare
8. Close the filling valve and the cold water valve. the gas group information on the identific-
ation plate with the gas group available at
6.10 Filling the condensate siphon the installation site.
Danger! The product's combustion has been factory tested and is

Risk of poisoning due to escaping flue preset for operation with the gas group indicated on the iden-
gas. tification plate. In some supply areas, these settings may
need to be adjusted at the installation site.
An empty or insufficiently filled condensate
siphon may allow flue gas to escape into the Conditions: The product design is not compatible with the local gas
room air. group
▶ Fill the condensate siphon with water be- ▶ Do not start up the product.
fore starting up the product.

6 Start-up
Conditions: The product design is compatible with the local gas group 6.12.4 Checking the gas flow pressure
▶ Proceed as described below. 1. Ensure that the gas inlet working pressure can be
obtained with all other gas appliances in the property
6.12.2 Checking the leak-tightness of the flue gas working.
installation and flue gas recirculation 2. Close the gas isolator cock.
1. Check the flue gas installation is intact in accordance

with the latest gas safe technical bulletin and informa-
tion supplied in the installation instructions. 1
2. For extended flue gas installations check for flue gas
recirculation using the air analysis point.
3. Use a flue gas analyser.
4. If you discover CO or CO2 in the supply air, search for
the leak in the flue gas installation or for signs of flue
gas recirculation.
5. Eliminate the damage properly.
6. Check again whether the supply air contains any CO or
CO2.
7. If you cannot eliminate the damage, do not start up the
product.
2
6.12.3 Checking the gas flow rate
3. Undo the sealing screw (1) that is marked with in on the
The boiler is fitted with a multifunctional automatic gas valve
gas valve.
which ensures that the precise air/gas ratio is provided under
all operating conditions. 4. Connect a digital pressure gauge or U-tube manometer
(2).
The gas flow rate has been set during production and does 5. Open the gas isolator cock.
not require adjustment. With the front casing fitted check the
6. Start up the product with the check programme P.1.
gas flow rate of the boiler as follows:
7. In addition, ensure that maximum heat can be dissip-
▶ Start up the product with the check programme P.01. ated into the heating system by turning up the room
▶ In addition, ensure that maximum heat can be dissipated thermostat.
into the heating system by turning up the room thermo-
stat. 8. With the boiler operating at full load check that the gas
inlet working pressure at the reference test point (1)
▶ Wait at least 5 minutes until the boiler has reached its
complies with the requirements.
operating temperature.
– Permissible gas flow pressure for operation with
▶ Ensure that all other gas appliances in the property are
G20 natural gas: 1.6 … 2.3 kPa (16.0 … 23.0 mbar)
turned off.
9. Should the pressure recorded at the reference test point
▶ Measure the gas flow rate at the gas meter.
in the boiler be lower than indicated check if there is
▶ Compare the measured values with the corresponding any blockage in the pipework or if the pipework is un-
values in the table. dersized.
Qnw from the data H gas in m³/h
plate Conditions: Gas flow pressure not in the permissible range
Nom. +5 % −10 %
46,0 4,87 5.13 4,38 Caution.
65,0 6,88 7,24 6,19 Risk of material damage and operating
faults caused by incorrect gas flow pres-
Conditions: Gas flow rate not in the permissible range sure.
▶ Check all of the piping and ensure that the gas flow rates If the gas flow pressure lies outside the per-
are correct. missible range, this can cause operating
▶ Only put the product into operation once the gas flow faults in and damage to the product.
rates have been corrected. ▶ Do not make any adjustments to the
product.
Conditions: Gas flow rate in the permissible range
▶ Check the gas installation.
▶ End the check programme P.01. ▶ Do not start up the product.
▶ Allow the boiler to cool down by allowing pump overrun to
operate for a minimum of 2 minutes.
▶ If you cannot correct the failure, notify the gas supply
▶ Record the boiler maximum gas flow rate onto the company and proceed as follows:
Benchmark gas boiler commissioning checklist.
▶ End the check programme P.01.
▶ Allow the boiler to cool down by allowing pump overrun
to operate for a minimum of two minutes.
▶ Close the gas isolator cock.

Start-up 6
▶ Remove the pressure gauge and retighten the sealing Conditions: The CO₂ content must be adjusted
screw (1) for the measuring nipple.
▶ Open the gas isolator cock. ▶ Unscrew the screw (2) and tilt the air intake pipe (3) for-
wards by 90°. Do not remove the air intake pipe.
▶ Check the measuring nipple for gas tightness.
▶ Set the CO₂ content (value with front casing removed)
by turning the screw (4).
▶ Install the front casing. (→ Page 10)
▶ Disconnect the product from the power mains.
Note
▶ You must not start up the boiler.
Turn to the left: Higher CO₂ content
Conditions: Gas flow pressure in the permissible range Turn to the right: Lower CO₂ content
▶ End the check programme P.01.

▶ Allow the boiler to cool down allowing pump overrun to ▶ Only carry out the adjustment in increments of 1/8 turn
operate for a minimum of two minutes. and wait approximately 1 minute after each adjustment
▶ Close the gas isolator cock. until the value stabilises.
▶ Remove the pressure gauge and retighten the sealing ▶ After performing the adjustments, tilt the air intake pipe
screw (1) for the measuring nipple. back up.
▶ Open the gas isolator cock. ▶ Check the CO₂ content again.
▶ Check the measuring nipple for gas tightness. ▶ If necessary, repeat the setting process.
▶ Install the front casing. (→ Page 10) ▶ Press the button. Full load mode is also exited if no
buttons are pressed for 15 minutes.
▶ Reset boiler controls for normal operation.
▶ Record the appliance gas inlet working pressure (kPa
▶ Use the screw (2) to secure the air intake pipe again.
resp. mbar) in the Benchmark gas boiler commissioning ▶ If an adjustment is not possible in the specified adjust-
checklist. ment range, you must not start up the product.
▶ If this is the case, inform Vaillant Customer Service.
6.12.5 Checking the CO₂ content and, if ▶ Install the front casing. (→ Page 10)
necessary, adjusting it (air index setting)
6.12.6 Checking the CO₂ content and, if
1. Start up the product with the check programme P.1.
necessary, adjusting it (air index setting)
2. Wait at least five minutes until the product reaches its
operating temperature. 1. Start up the product with the check programme P.1.
2. Wait at least five minutes until the product reaches its
1 operating temperature.
4
2
3
2
3. Measure the CO₂ content at the flue gas analysis point

(1).
4. Compare the measured value with the corresponding 3. Measure the CO₂ content at the flue gas analysis point
value in the table. (1).
Settings Unit G20 natural 4. Compare the measured value with the corresponding
gas value in the table.
CO₂ after 5 minutes in full load Settings Unit G20 natural
Vol.–% 9.2 ± 1.0 gas
mode with front casing closed
CO₂ after 5 minutes in full load CO₂ after 5 minutes in full load
Vol.–% 9.0 ± 1.0 Vol.–% 9.2 ± 1.0
mode with front casing removed mode with front casing closed
Set for Wobbe index W₀ kWh/m³ 14.1 CO₂ after 5 minutes in full load
Vol.–% 9.0 ± 1.0
mode with front casing removed
O₂ after 5 minutes in full load
Vol.–% 4.53 ± 1.8 Set for Wobbe index W₀ kWh/m³ 14.1
mode with front casing closed

6 Start-up
Settings Unit G20 natural ◁ If the cylinder is charged correctly, the display
gas shows S.24.
O₂ after 5 minutes in full load 2. If you have connected a controller which can be used to
Vol.–% 4.53 ± 1.8
mode with front casing closed set the hot water temperature, set the hot water temper-
ature on the boiler to the maximum possible temperat-
Conditions: The CO₂ content must be adjusted ure.
▶ Unscrew the screw (2) and tilt the air intake pipe (3) for- Conditions: Water hardness: > 3.57 mol/m³, Boiler with cylinder
wards by 90°. Do not remove the air intake pipe. – Water temperature: ≤ 50 ℃
▶ Set the CO₂ content (value with front casing removed) 3. Adjust the target temperature for the connected do-
by turning the screw (4). mestic hot water cylinder to the controller.
◁ The boiler adopts the set target temperature which
Note is set on the controller (automatic calibration in
Turn to the left: Higher CO₂ content newer controllers).
Turn to the right: Lower CO₂ content
6.14 Thoroughly flushing the heating installation
▶ Only carry out the adjustment in increments of 1/8 turn ("hot")
and wait approximately 1 minute after each adjustment 1. Operate the appliance until the boiler and the heating
until the value stabilises. system are up to temperature.
▶ After performing the adjustments, tilt the air intake pipe 2. Check the heating system for leaks.
back up. 3. Connect a hose to the drain valve located at the lowest
▶ Check the CO₂ content again. position of the heating system.
▶ If necessary, repeat the setting process. 4. Shut off the boiler, open the drain valve and all purge
▶ Press the button. Full load mode is also exited if no valves on the radiators and allow the water to flow out
buttons are pressed for 15 minutes. of the heating system and the boiler quickly and fully.
▶ Use the screw (2) to secure the air intake pipe again. 5. Close the drain valve.
▶ If an adjustment is not possible in the specified adjust- 6. Fill the heating system again with water as de-
ment range, you must not start up the product. scribed in "Filling and purging the heating installation"
▶ If this is the case, inform Vaillant Customer Service. (→ Page 18).
▶ Install the front casing. (→ Page 10) 7. Re-fill the system until the system design pressure of
0,1 MPa (1,0 bar) is attained.
6.13 Checking leak-tightness
Note
▶ Check the gas pipe, the heating circuit and the hot water
circuit for leak-tightness. The actual reading on the digital pressure
gauge should ideally be 0,05 MPa (0,5 bar)
▶ Check that the flue gas pipe has been installed correctly.
plus an additional pressure corresponding
to the highest point of the system above the
6.13.1 Checking the heating mode base of the boiler – 10 m head equals an ad-
1. Make sure that there is a heat requirement. ditional 1 bar reading on the pressure gauge.
2. Press to activate the status display. The minimum pressure should not be less
than 0,1 MPa (1 bar) in any installation. If
◁ If the product is working correctly, the display shows the system is to be treated with an inhibitor it
S.4. should be applied at this stage in accordance
with the manufacturer’s instructions. Further
6.13.2 Checking the hot water generation information can be obtained from Sentinel,
Betz Dearborn Ltd., Tel: 0151 420 9595, or
Conditions: Cylinder connected Fernox, Alpha– Fry technologies. Tel: 0870
8700362.
Danger!
Risk of death from Legionella.
8. Install the front casing. (→ Page 10)
Legionella multiply at temperatures below
60 °C.
▶ Ensure that the operator is familiar with
all of the Anti-legionella measures in or-
der to comply with the applicable regula-
tions regarding legionella prevention.
▶ Make sure that the cylinder thermostat is requesting

heat.
1. Press to activate the status display.

Adapting the unit to the heating installation 7
7 Adapting the unit to the heating

installation
7.1 Calling up diagnostics codes
+
You can use the parameters that are marked as adjustable
in the overview of diagnostics codes to adapt the product to
the heating installation and the needs of the customer.
Overview of diagnostics codes (→ Page 31)
▶ Exit Diagnostics mode by pressing and at the

same time or by not pressing any button for four minutes.
◁ The current heating flow temperature appears in the
+ display.
Note
If you activate the installer level (second dia-
gnostics level), all of the diagnostics codes are
visible and accessible.
▶ Press and below the display at the same time.
◁ The display shows D.0 (heating partial load). 7.2 Calling up the installer level (second
diagnostics level)
▶ In the first diagnostics level, scroll to D.97.
▶ Change the displayed value to 17 (password).
▶ Save the setting.
7.3 Setting the heating partial load

The product's heating partial load is set to 46 kW at the fact-
ory. You can specify a value that corresponds to the product
output in kW under diagnostics code D. 0.
▶ Press . 7.4 Setting the pump overrun and pump

◁ The display shows the associated diagnostics inform-
operating mode
ation. You can set the pump overrun under D.1 (default setting: 5
▶ min.).
If required, use or to change the value (the display
flashes). You can set the overrun behaviour of the pump to a different
mode under D.18.
Overrun: After ending the heating demand, the pump over-
runs the time that is set under D.1.
Continuous: The pump is switched on if the rotary knob for
setting the heating flow temperature is not at the left-hand
stop and the heat requirement is enabled by an external con-
troller.
Intermittent: This pump operating mode is useful for remov-
ing residual heat after charging when the heat demand is ex-
tremely low and large temperature differences exist between
the cylinder charging and heating mode target values. This
▶ Save the new value by pressing and holding for ap- prevents the living rooms from overheating. If there is a heat
prox. five seconds until the display no longer flashes. demand, the pump is switched on every 25 minutes for 5
minutes once the overrun time has elapsed.

7 Adapting the unit to the heating installation
7.5 Setting the maximum flow temperature 7.7 Setting the maintenance interval
You can set the maximum flow temperature for the heating If you set the maintenance interval, the maintenance mes-
mode under D.71 (default setting: 75 °C). sage SEr appears in the display after a configurable number
of burner operating hours. The display on the eBUS control-
7.6 Setting the burner anti-cycling time ler shows the information Maintenance.
To prevent frequent switching on and off of the burner and ▶ Use D.84 to set the operating hours until the next main-
thus prevent energy losses, an electronic restart lockout tenance work is due. Guideline values can be found in
is activated for a specific period each time the burner is the following table.
switched off. You can adjust the burner anti-cycling time to
Burner operating hours until the
the conditions of the heating installation. The burner anti- Heat de-
Number
next inspection/maintenance work
cycling time is only active for the heating mode. Hot water of per-
mand is due (dependent upon the sys-
handling mode during a burner anti-cycling time does not sons
tem type)
affect the time function element. You can set the maximum
1‑2 1050 h
burner anti-cycling time under D.2 (default setting: 20 min.). 5.0 kW
The effective burner anti-cycling times with respect to the 2‑3 1150 h
target flow temperature and the maximum set burner anti- 1‑2 1500 h
cycling time can be found in the following table: 10.0 kW
2‑3 1600 h
TFlow Set maximum burner anti-cycling time [min] 2‑3 1800 h
(target) 15.0 kW
1 5 10 15 20 25 30 3‑4 1900 h
[°C]
3‑4 2600 h
30 2.0 4.0 8.5 12.5 16.5 20.5 25.0 20.0 kW
4‑5 2700 h
35 2.0 4.0 7.5 11.0 15.0 18.5 22.0
3‑4 2800 h
40 2.0 3.5 6.5 10.0 13.0 16.5 19.5 25.0 kW
4‑6 2900 h
45 2.0 3.0 6.0 8.5 11.5 14.0 17.0
3‑4 3000 h
50 2.0 3.0 5.0 7.5 9.5 12.0 14.0 > 27.0 kW
4‑6 3000 h
55 2.0 2.5 4.5 6.0 8.0 10.0 11.5
60 2.0 2.0 3.5 5.0 6.0 7.5 9.0 The values stated correspond to an average operating time
65 2.0 1.5 2.5 3.5 4.5 5.5 6.5 of one year.
70 2.0 1.5 2.0 2.5 2.5 3.0 3.5 If you do not set a numerical value but do set the symbol "–",
75 2.0 1.0 1.0 1.0 1.0 1.0 1.0
the Maintenance display function is not active.
TFlow Set maximum burner anti-cycling time [min] Note

(target) On completion of the set operating hours, you
[°C] 35 40 45 50 55 60
must set the maintenance interval again.
30 29.0 33.0 37.0 41.0 45.0 49.5
35 25.5 29.5 33.0 36.5 40.5 44.0 7.8 Pump diagram
40 22.5 26.0 29.0 32.0 35.5 38.5
45 19.5 22.5 25.0 27.5 30.5 33.0 A
50 16.5 18.5 21.0 23.5 25.5 28.0 1200

1100
55 13.5 15.0 17.0 19.0 20.5 22.5
1000
60 10.5 11.5 13.0 14.5 15.5 17.0
900
65 7.0 8.0 9.0 10.0 11.0 11.5 800
70 4.0 4.5 5.0 5.5 6.0 6.5 700
600 53% 100%
75 1.0 1.0 1.0 1.0 1.0 1.0
500
400
Note 300
The remaining burner anti-cycling time following a 200
regular shutdown in heating mode can be called 100
up under D.67. B
0
0 500 1000 1500 2000 2500 3000 3500
250 750 1250 1750 2250 2750 3250
A Pump remaining feed B System volume flow in

head in hPa (mbar) l/h
Min. vortex and rated volume flow (ΔT 20 K) are marked.

Inspection and maintenance 8
7.9 Adjusting the product to large flue gas pipe Warning.
lengths
Risk of injury and death due to improper
At flue gas pipe lengths greater than 10 m (system 80/125), inspection and maintenance!
you can increase the product's fan speed.
Improper performance of inspections and
▶ Increase the value by 20 under D.51. maintenance work may result in leaks or
◁ The maximum speed of the fan is increased by even an explosion.
200 rpm. ▶ Inspection and maintenance work on the
product must only be carried out by pro-
7.10 Handing the product over to the operator
fessionally qualified persons.
1. When you have finished the installation, attach the
sticker supplied (835593) to the front of the product in
the operator's language. Any customer service work must be carried out by a profes-
sionally qualified person in accordance with the safety, in-
2. Explain to the operator how the safety devices work and
stallation and operating provisions for gas-fired units. Pro-
where they are located.
fessional qualification must be confirmed by an adequately
3. Inform the operator how to handle the product. Answer recognised organisation or public office.
any questions the operator may have. In particular,
draw attention to the safety information which the op-
erator must follow. Note
4. Inform the operator of the necessity to have the product The person who carries out a combustion meas-
maintained according to the specified intervals. urement must be trained in the use of a flue gas
measuring instrument and in interpreting the res-
5. Pass all of the instructions and documentation for the
ults. The flue gas measuring instrument that is
product to the operator for safe-keeping.
used must be calibrated in accordance with the
6. Inform the operator about measures taken to ensure the specifications of the measuring instrument manu-
supply of combustion air and flue gas guiding, and in- facturer. The correct fuel type must be set on the
struct the operator that he must not make any changes. flue gas measuring instrument.
Maintenance
8 Inspection and maintenance
Maintenance is required in order to eliminate any deviations
▶ Carry out all inspection and maintenance work in the of the actual condition from the target condition. This is nor-
order shown in the table "Overview of inspection and mally done by cleaning, setting and, if necessary, replacing
maintenance work". individual components that are subject to wear.
As the competent person, you determine the maintenance
8.1 Observing inspection and maintenance intervals (at least once every two years) and their scope
intervals based on the how you define the condition of the product
during the inspection. Carry out all inspection and mainten-
Warning. ance work in the sequence shown in Appendix C.
Risk of injury and a risk of material dam- Proper, regular inspection and maintenance, and the
age caused by negligent inspection and exclusive use of original spare parts are absolutely essential
maintenance work. to ensure fault-free operation and a long working life for the
product.
Negligence in inspection and maintenance
work, as well as failure to comply with the Inspection
specified inspection and maintenance in- The inspection is intended to determine the actual condition
tervals, may impair the operational safety of of the product and compare it with the target condition. This
the product and lead to injuries and material is done by measuring, checking and observing.
damage. Maintenance
▶ Instruct the operator that the prescribed Maintenance is required in order to eliminate any deviations
inspection and maintenance intervals of the actual condition from the target condition. This usually
must be complied with as a minimum re- involves cleaning, adjusting and, if required, replacing indi-
vidual components that are prone to wear (e.g. the burner
quirement.
flange seal (article number 180904), the burner insulation on
▶ Carry out a regular inspection once a the burner flange (article number 180913) and the burner in-
year. sulation on the back wall of the heat exchanger (article num-
▶ Carry out regular maintenance work in line ber 0020093190)).
with the findings from the inspection. The
maintenance interval must not be longer
than two years.

8.2 Procuring spare parts
1
The original components of the product were also certified
by the manufacturer as part of the declaration of conformity. 2
If you use other, non-certified or unauthorised parts during
maintenance or repair work, this may void the conformity of
the product and it will therefore no longer comply with the
applicable standards.
3
We strongly recommend that you use original spare parts
4
from the manufacturer as this guarantees fault-free and safe
operation of the product. To receive information about the
available original spare parts, contact the contact address
provided on the reverse of these instructions.
5
▶ If you require spare parts for maintenance or repair
work, use only the spare parts that are permitted for the
product. 6
8.3 Removing the compact thermal module

7
Danger!
Risk of death and risk of material damage
caused by hot flue gas.
The seal, burner insulation and self-locking
nuts on the burner flange must not be dam- 10 9 8
aged. Otherwise, hot flue gases may escape
and cause personal injury and material dam- 5. Unscrew the retaining screw (3).
age. 6. Tilt the air intake pipe (2) forwards.
▶ Replace the seal each time you open the 7. Remove the air intake pipe from the intake manifold.
burner flange. 8. Remove the ignition line and ground connection plugs
from the ignition electrode (5).
▶ Replace the self-locking nuts on the
9. Disconnect the gas line (9) from the underside of the
burner flange each time you open the
gas valve.
burner flange.
10. Pull out the cable (7) from the fan motor, the PWM
▶ If the burner insulation on the heat ex- signal cable from the underside of the fan (8) and the
changer's burner flange shows signs of cable to the gas valve (10).
damage, replace the burner insulation. 11. Unscrew the six nuts (4).
▶ Replace the burner insulation on the back 12. Remove the entire compact thermal module (6) from
wall after each time the burner flange is the heat exchanger (1).
opened. 13. Check the burner and the heat exchanger for damage
and dirt.
14. If necessary, clean or replace the components accord-
Note ing to the following sections.
The compact thermal module consists of four 15. Replace the burner insulation on the back wall of the
main components: heat exchanger.
– Speed-regulated fan, 16. Check the burner insulation on the burner flange. If
you notice any signs of damage, replace the burner
– Gas-air mixture fitting,
insulation.
– Gas supply (mixture pipe) to the premix burner,
– Premix burner. 8.4 Cleaning the heat exchanger
1. Protect the folded down electronics box against sprayed
1. Use the main switch to switch off the product. water.
2. Close the gas isolator cock.
3. Remove the front casing. (→ Page 10)
4. Tilt the electronics box forward.

Inspection and maintenance 8
8.6 Checking the burner
1
1 2
1
2
1. Check the surface of the burner for damage. If you see

any damage, replace the burner.
2. Use vinegar (max. 5% acid) to clean the heating coils
(2) on the heat exchanger (1). 2. Replace the silicone seal (1) and the silicate cord (2).
3. Check the burner insulation (3) on the burner flange
3. After a reaction time of 20 minutes, use a sharp jet of and, if required, replace the burner insulation.
water or a plastic brush to rinse the loosened dirt. Do
not point the water jet directly at the burner insulation 8.7 Cleaning the condensate duct
on the back of the heat exchanger.
◁ The water flows out of the heat exchanger through
the condensate trap.
8.5 Descaling the heat exchanger

1. Drain the product. (→ Page 28)
2. Remove the automatic air vent from the air separator.
1
3. Fill the product with descaler (ET 990098) via the open
connection on the automatic air vent.
4. Fill the product with clean water up to the nominal pres- 2
sure.
5. Set the pump to "Continuous".
6. Use the chimney sweep button to heat up the product.
7. Leave the descaler to work in maximum output opera-
tion for approx. 30 minutes.
8. Then thoroughly rinse out the product with clean water.
9. Set the pump back to its starting condition.
10. Open the service valves and, if required, fill the heating
installation. 1. Observe the installation manual for the condensate
trap's cartridge.
2. Remove the condensate trap's cartridge from below the
product.
3. Pull out the clamp from below the heat exchanger.
4. Remove the elbow connector.
5. Remove the condensate trap (2) and the corrugated
pipe (1). In doing so, note the position of the latching
lugs.
6. Clean the condensate trap, the corrugated pipe and the
condensate trap's cartridge.
7. Fill the condensate trap's cartridge with water.
8. Install the components with new seals and six new, self-
locking nuts.

– Tightening torque: 6 Nm 8.9 Installing the compact thermal module
8.8 Cleaning the air separation system 1

8.8.1 Cleaning or replacing the filter in the air 2
separator
3
1 4
2
5
3 6
7
1. Unscrew the brass cover (1) on the steel casing (3).
2. Pull the filter (2) up and out.
3. Use hot water to clean the filter, or replace the filter.
4. Insert the filter into the air separator.
5. Screw in the brass cover tightly.
10 9 8
8.8.2 Cleaning the air separator
1. Connect the compact thermal module (6) to the heat
exchanger (1).
1
2. Tighten the six nuts (4), including the retainer for the
air intake pipe, in a cross-wise pattern until the burner
2 flange fits closely and uniformly onto the mating sur-
faces.
3 3. Check that the blue sealing ring in the air intake pipe is
positioned correctly in the seal seat.
4
4. Place the air intake pipe (2) on the intake manifold, and
tighten the screw (3).
5. Connect the ignition line and the ground connection to
the ignition electrode (5).
6. Insert the cable (7) from the fan motor, the PWM signal
cable on the underside of the fan (8) and the cable to
1. Unscrew the nut (4). the gas valve (10).
2. Unscrew the cap nut (1). 7. Connect the gas line (9) using a new seal. In the pro-
3. Remove the cable harness. cess, secure the gas pipe against twisting.
4. Slide the casing (3) forwards and pull the entire air sep- 8. Open the gas isolator cock.
arator forwards and out. 9. Make sure that there are no leaks.
5. If required, remove the pipe (2).
6. Remove the filter. 8.10 Draining the product
7. Use hot water to clean the air separator and the filter. 1. Close the service valves of the product.
8. Replace all of the O-rings. 2. Open the drain valves on the service valves.
9. Reinstall the air separator. 3. Ensure that the automatic air vent cap on the air separ-
ator is open so that the product can be drained fully.

Troubleshooting 9
8.11 Checking the pre-charge pressure of the 9.3 Reading off the fault codes
external expansion vessel
If a fault develops in the product, the display shows a fault
1. Depressurise the heating installation. code F.xx.
2. Measure the pre-charge pressure of the expansion ves- Fault codes have priority over all other displays.
sel at the vessel valve.
If multiple faults occur at the same time, the display shows
3. Fill the expansion vessel with air at a pre-charge pres-
the corresponding fault codes for two seconds each in se-
sure of less than 0.075 (0.75 bar) according to the static
quence.
head of the heating installation.
4. If water escapes from the valve of the expansion ves- ▶ Rectify the fault.
sel, you must replace the expansion vessel. ▶ To restart the product, press (→ Operating instruc-
tions).
8.12 Completing inspection and maintenance ▶ If you are unable to rectify the fault and the fault recurs
work despite several reset attempts, contact Customer Ser-
vice.
▶ Check the CO₂ content and, if necessary, adjust it (air
index setting). (→ Page 21)
9.4 Querying the fault memory
▶ Check the CO₂ content and, if necessary, adjust it (air
index setting). (→ Page 21) The product has a fault memory. You can use this to query
▶ If required, reset the maintenance interval (→ Page 24). the last ten faults that occurred in chronological order.
▶ Press and at the same time to display the last ten
8.13 Checking the product for leak-tightness faults that occurred.
▶ Check that the product is leak-tight. (→ Page 22) Overview of fault codes (→ Page 35)
▶ Use to scroll back in the fault memory.
▶ To exit the fault memory display, press or do not
press any button for approximately four minutes.
9 Troubleshooting
◁ Depending on the settings, the current flow temperat-
You can find an overview of the fault codes in the appendix. ure or current water pressure of the heating installa-
Overview of fault codes (→ Page 35) tion reappears in the display.
9.1 Contacting your service partner 9.5 Performing diagnostics
If you contact your service partner, if possible, please men- ▶ You can use the diagnostics codes (→ Page 23) during
tion fault diagnostics to change individual parameters or to
display further information.
– the fault code that is displayed (F.xx),
– the product status (S.xx) that is displayed. 9.6 Using check programmes
9.2 Calling up status codes

▶ You can also use the check programmes (→ Page 16)for
troubleshooting.
You can find an overview of the status codes in the
appendix. 9.7 Resetting parameters to factory settings
Status codes – Overview (→ Page 34) ▶ To simultaneously reset all parameters to the default
▶ To call up the display of the status codes, press . settings, set D.96 to 1.
◁ The display shows the status code, e.g. S.4 for 9.8 Preparing the repair work
"Burner mode: Heating".
1. Decommission the product.
▶ To exit the status codes display, press or do not press
2. Disconnect the product from the power mains.
any button for approximately four minutes.
3. Remove the front casing. (→ Page 10)
◁ Depending on the settings, the current flow temperat- 4. Close the gas isolator cock.
ure or current water pressure of the heating installa- 5. Close the service valves in the heating flow and in the
tion reappears in the display. heating return.
6. Close the service valve in the cold water pipe.
7. Drain the product if you want to replace water-bearing
components of the product.
8. Make sure that water does not drip on live components
(e.g. the electronics box).
9. Use only new seals.

10 Decommissioning the product
9.9 Replacing defective components 9.10 Completing repair work
9.9.1 Replacing the burner ▶ Check that the product works correctly.
1. Remove the compact thermal module. (→ Page 26)
10 Decommissioning the product

▶ Switch off the product.
1 ▶ Disconnect the product from the power mains.
▶ Drain the product. (→ Page 28)
11 Recycling and disposal

Disposing of the packaging
▶ Dispose of the packaging correctly.
2. Remove the four screws (1) from the burner.

▶ Observe all relevant regulations.
3. Remove the burner.

4. Fit the new burner with a new seal.
5. Make sure that the cutouts in the seal and the burner
12 Customer service
are situated above the burner flange sight glass.
To ensure regular servicing, it is strongly recommended
6. Install the compact thermal module. (→ Page 28) that arrangements are made for a Maintenance Agreement.
Please contact Vaillant Service Solutions for further details:
9.9.2 Replacing the PCB and/or the display
Telephone: 0330 100 3461
Note
If you are replacing only one component, the set
parameters are transferred automatically. When
the product is switched on, the new component
adopts the previously set parameters from the
unreplaced component.
1. Disconnect the product from the power mains and make

sure that it cannot be switched back on again.
Conditions: Replacing the display or PCB
▶ Replace the PCB or display according to the assembly

and installation instructions supplied.
Conditions: Replacing the PCB and display at the same time
▶ Replace the PCB and display according to the assembly

and installation instructions supplied.
◁ If you replace both components at the same time, the
product switches to fault mode and displays the fault
message F.70 after it is switched on.
▶ In the second diagnostics level under the diagnostics
code d.93, enter the number of the product type.
▶ Confirm your setting.
◁ The electronics are now set to the product type and
the parameters of all diagnostics codes are set to
default settings.
▶ Make the system-specific settings.

Appendix
Appendix
A Overview of diagnostics codes
Note
Since the code table is used for various products, some codes may not be visible for the product in question.
Default set- Own setting

Code Parameter Values or explanations
ting
D.0 Heating partial load, adjustable val- Adjustable heating partial load Approx. 70%
ues in kW of the max-
imum output
D.1 Internal heating pump overrun time 2 … 60 min 5 min
D.2 Max. burner anti-cycling time heating 2 … 60 min 20 min
at 20 °C flow temperature
D.4 Measured value for the cylinder tem- If a domestic hot water cylinder with sensor is connected Not
perature in °C adjustable
D.5 Flow temperature target value (or Current target value, max. of the value set in D.71, re- Not
return target value) in °C stricted by an eBUS controller, if connected adjustable
D.7 Target cylinder temperature (15 °C = frost protection, 40 °C up to D.20 (max. 70 °C)) Not
adjustable
D.8 Room thermostat at terminals 3-4 0 = Room thermostat open (no heat requirement) Not
1 = Room thermostat closed (heat requirement) adjustable
D.9 Target feed temperature in °C from Minimum from the external BUS target value and target Not
the external continuous controller at value for terminal 7 adjustable
terminal 7-8-9/BUS
D.10 Status of the internal heating pump 0 = Off Not
1 = On adjustable
D.11 Status of additional external heating 0 = Off Not
pump 1-100 = On adjustable
D.12 Status of cylinder charge pump 0 = Off Not
1-100 = On adjustable
D.13 Status of circulation pump 0 = Off Not
1-100 = On adjustable
D.14 Setting for speed-controlled internal 0 = Auto 0
heating pump 1 = 53
2 = 60
3 = 70
4 = 85
5 = 100
in %
D.15 Current speed of the internal heating Not
pump in % adjustable
D.17 Control type 0 = Flow control 0
1 = Return flow temperature control
D.18 Pump operating mode (overrun) 0 = Overrun 3
1 = Continuous
2 = Winter
3 = Intermittent
D.20 Max. setting for cylinder target value Adjustment range: 40-70 °C 65 ℃
D.22 External cylinder charging, terminal 1 = on, 0 = off
C1-C2
D.23 Summer/winter mode (heating off/on) 0 = Heating off (Summer mode) Not
1 = Heating on adjustable
D.24 Not relevant Not relevant
1. Five-digit numbers are saved for diagnostics codes 80 to 83. If you select D.80, for example, only the first two digits of the number
will be displayed (e.g. 10). Pressing switches the display to the last three digits (e.g. 947). In this example, the number of oper-
ating hours for the heating is 10947 hrs. Pressing the again causes the display to switch back to the diagnostics code that was
called up.

Appendix

ting
D.25 Hot water generation enabled by 1 = Yes, 0 = No
eBUS controller
D.26 Internal accessory relay at X6 (pink 1 = Circulation pump 2
plug) 2 = Second external pump
3 = Cylinder charging pump
4 = Flue non-return flap/extractor hood
5 = External gas valve
6 = External fault message
D.27 Switching accessory relay 1 for 1 = Circulation pump 2
accessory "2-in-7" multi-functional 2 = Second external pump
module
D.28 Switching accessory relay 2 for 1 = Circulation pump 3
accessory "2-in-7" multi-functional 2 = Second external pump
module
D.30 Control signal for gas valve 0 = Off; 1 = On Not
adjustable
D.33 Fan speed target value in rpm/10 Not
adjustable
D.34 Fan speed actual value in rpm/10 Not
adjustable
D.40 Flow temperature Actual value in °C Not
adjustable
D.41 Return temperature Actual value in °C Not
adjustable
D.44 Digitalised ionisation voltage Display field 0 to 102 Not
>80 no flame adjustable
< 40 good flame
D.47 Outside temperature (with weather Actual value in °C, if the outside temperature sensor is Not
compensator) connected to X41 adjustable
D.50 Offset for minimum speed in rpm/10, adjustment range: 0 to 300 30
D.51 Offset for maximum speed in rpm/10, adjustment range: -99 to 0 -45
D.60 Number of temperature limiter shut- Number of shutdowns Not
downs adjustable
D.61 Number of ignition device cutoffs Number of unsuccessful ignitions in the last attempt Not
adjustable
D.64 Average ignition time In seconds Not
adjustable
D.65 Maximum ignition time In seconds Not
adjustable
D.67 Remaining burner anti-cycling time In minutes Not
adjustable
D.68 Unsuccessful ignitions at 1st attempt Number of unsuccessful ignitions Not
adjustable
D.69 Unsuccessful ignitions at 2nd at- Number of unsuccessful ignitions Not
tempt adjustable
D.71 Maximum target value heating flow 40 … 85 ℃ 75 ℃
temperature
called up.

Appendix

ting
D.72 Pump overrun after cylinder charging Adjustable from 0 to 600 seconds 80 s
D.75 Max. charging time for domestic hot 20 - 90 min 45 minutes
water cylinder without independent
control system
D.76 Unit variant: Device-specific number .. 656/4‑5 = 47
(DSN)
D.77 Limit on cylinder charging output in Adjustable cylinder charging output in kW Maximum
kW output
D.78 Cylinder charging temperature limit 55 °C-85 °C 80 ℃
(target flow temperature in cylinder
charging mode) in °C
D.80 Operating hours, heating in hrs ¹ Not
adjustable
D.81 Operating hours, hot water genera- in hrs ¹ Not
tion adjustable
D.82 Number of burner start-ups in heat- Number of burner start-ups /100 (3 equals 300) ¹ Not
ing mode adjustable
D.83 Number of burner start-ups in hot Number of burner start-ups /100 (3 equals 300) ¹ Not
water mode adjustable
D.84 Maintenance indicator: Number of Adjustment range: 0 to 3000 hrs and "-" for deactivated „-”
hours until the next maintenance 300 equals 3000 hrs
D.90 Status of digital controller 0 = Not recognised (eBUS address ≤ 10) Not
1 = Recognised adjustable
D.91 Status of DCF with external temper- 0 = No reception Not
ature sensor connected 1 = Reception adjustable
2 = Synchronised
3 = Valid
D.93 Product type setting (device specific Setting range: 0 to 99
number) .. 656/4‑5 = 47
D.96 Default setting Reset all adjustable parameters to factory setting 0
0 = No
1 = Yes
D.97 Activating the installer level Service code 17
D.98 Telephone: Competent person Programmable telephone number
called up.
B Inspection and maintenance work – Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If na-
tional regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of
the intervals listed in the table.
Mainten-
ance
Inspection
No. Work (At least
(annual)
every
two years)
Check the flue pipe for leak-tightness and to ensure that it is fastened correctly. Make sure that
1 it is not blocked or damaged and has been installed in accordance with the relevant Installation X X
Manual.
Check the general condition of the product. Remove dirt from the product and from the vacuum
2 X X
chamber.
Visually inspect the general condition of the compact thermal module. In doing so, pay particular
3 attention to signs of corrosion, rust and other defects. If you notice any damage, carry out main- X X
tenance work.
Check the gas flow pressure at maximum heat input. If the gas flow pressure is not within the
4 X X
correct range, carry out maintenance work.

Appendix
Mainten-
ance
Inspection
No. Work (At least
(annual)
every
two years)
Check the CO₂ content (the air ratio) of the product and, if necessary, adjust it. Keep a record of
5 X X
this.
Disconnect the product from the power mains. Check that the electrical plug connections and
6 X X
other connections are seated correctly and correct these if necessary.
7 Close the gas isolator cock and the service valves. X
Drain the product on the water side (observe the pressure gauge). Check the pre-charge pres-
8 sure of the expansion vessel, and top up the vessel if necessary (approx. 0.03 MPa/0.3 bar un- X
der the system filling pressure).
9 Remove the compact thermal module. X
10 Install the burner insulation on the back wall of the heat exchanger. X
11 Clean the heat exchanger. X
Replace the burner insulation (article number 0020093190) on the back wall of the heat ex-
12 X
changer. Replace the burner insulation each time maintenance work is carried out.
Check the burner insulation on the burner flange. If you notice any damage, replace the burner
13 insulation (article number 180913). Replace the burner flange seal (article number 180904) each X
time it is opened and, accordingly, each time maintenance work is carried out.
14 Check the burner for damage and replace it if necessary. X
15 Check the condensate trap in the product, and clean and fill this, if required. X X
16 Clean the condensate duct in the product. X
17 Install the compact thermal module. Caution: Replace the seals (article number 130904). X
18 Clean the air separation system. X
19 Open the gas isolator cock, reconnect the product to the power mains and switch the product on. X X
Open the service valves, fill up the product/heating installation to 0.1-0.2 MPa/1.0-2.0 bar (de-
20 X
pending on the static height of the heating installation) and start the purging programme P.0.
Perform a test operation of the product and heating installation, including hot water generation,
21 X X
and purge the system once more if necessary.
22 Check the product's gas ratio setting and, if required, reset it. Log the setting. X
23 Visually inspect the ignition and burner behaviour. X X
24 Check the CO₂ content (the air ratio) of the product again. X
Ensure that no gas, flue gas, hot water or condensate is leaking from the product. Restore leak-
25 X X
tightness if necessary.
26 Record the inspection/maintenance work carried out. X X
C Status codes – Overview
Status code Meaning

Heating mode
S.0 Heating: No heat demand
S.1 Heating mode: Fan start-up
S.2 Heating mode: Pump pre-run
S.3 Heating mode: Ignition
S.4 Heating mode: Burner on
S.5 Heating mode: Pump/fan overrun
S.6 Heating mode: Fan overrun
S.7 Heating mode: Pump overrun
S.8 Heating mode: Remaining anti-cycling time
Cylinder charging mode
S.20 DHW demand
S.21 DHW mode: Fan start-up
S.22 DHW mode: Pump pre-run
S.23 DHW mode: Ignition

Appendix
Status code Meaning

S.24 DHW mode: Burner on
S.25 DHW mode: Pump/fan overrun
S.26 DHW mode: Fan overrun
S.27 DHW mode: Pump overrun
S.28 Hot water burner anti-cycling time
Special cases
S.30 Room thermostat (RT) is blocking heating mode
Summer mode active or no heat requirement
S.31
from eBUS controller
S.32 Waiting period because of fan speed deviation
S.34 Frost protection mode active
S.36 Reference setting for the continuous controller 7-
8-9 or eBUS controller is < 20 °C and blocks the
heating mode
S.39 Contact thermostat tripped
S.41 Water pressure > 0.28 MPa (2.8 bar)
S.42 Flue non-return flap return signal blocks burner
operation (only in connection with accessories)
or condensate pump faulty, heat requirement is
blocked.
S.53 Product is within the waiting period of the mod-
ulation block/operation block function as a res-
ult of low water pressure (flow/return spread too
large)
S.54 Product is within the waiting period of the oper-
ation blocking function as a result of low water
pressure (temperature gradient)
S.59 Waiting period: Minimum volume of circulation
water not achieved
S.85 Service message: "Check circulation water
quantity".
S.96 Return sensor test running, heating demands are
blocked.
S.97 Water pressure sensor test running, heating de-
mands are blocked.
S.98 Flow/return sensor test running, heating de-
mands are blocked.
D Overview of fault codes
Code Meaning Cause

F. 0 Flow temperature sensor interruption NTC plug not plugged in or has come loose, multiple plug on the PCB
not plugged in correctly, interruption in cable harness, NTC defective
F. 1 Return temperature sensor interruption NTC plug not plugged in or has come loose, multiple plug on the PCB
not plugged in correctly, interruption in cable harness, NTC defective
F.10 Flow NTC short circuit NTC defective, short circuit in cable harness, cable/casing
F.11 Return NTC short circuit NTC defective, short circuit in cable harness, cable/casing
F.13 Cylinder temperature sensor short circuit NTC defective, short circuit in cable harness, cable/casing
F.20 Safety switch-off: Temperature limiter Incorrect earth connection between cable harness and product, flow or
return NTC defective (loose connection), black discharge via ignition
cable, ignition plug or ignition electrode
F.22 Safety switch-off: Low water pressure No or insufficient water in the product, water pressure sensor defective,
cable to pump or water pressure sensor loose/not connected/defective
F.23 Safety switch-off: Temperature difference too Pump blocked, insufficient pump output, air in product, flow and return
great NTC connected the wrong way round
F.24 Safety switch-off: Temperature rise too fast Pump blocked, insufficient pump output, air in product, system pressure
too low, non-return valve blocked/incorrectly installed

Appendix
Code Meaning Cause

F.27 Safety switch-off: Flame simulation Moisture on the electronics, electronics (flame monitor) defective, gas
solenoid valve leaking
F.28 Failure during start-up: Ignition unsuccessful Gas meter defective or gas pressure monitor has triggered, air in gas,
gas flow pressure too low, thermal isolator device (TAE) has triggered,
condensate duct blocked, incorrect gas restrictor, incorrect spare part
gas valve, fault on the gas valve, multiple plug on PCB incorrectly
plugged in, break in cable harness, ignition system (ignition transformer,
ignition cable, ignition plug, ignition electrode) defective, ionisation
current interrupted (cable, electrode), incorrect earthing of product,
electronics defective
F.29 Failure during operation: Re-ignition unsuccess- Gas supply temporarily stopped, flue gas recirculation, condensate duct
ful blocked, defective earthing of product, ignition transformer has spark
failure
F.32 Fan fault Plug on fan not correctly plugged in, multiple plug on PCB not correctly
plugged in, break in cable harness, fan blocked, Hall sensor defective,
electronics defective
F.49 Fault: eBUS Short circuit on eBUS, eBUS overload or two power supplies with differ-
ent polarities on the eBUS
F.61 Gas valve actuation fault The gas valve cannot be actuated
– Cable harness supply line to the gas valve is defective (short to

earth, short circuit)
– Gas valve defective
– PCB defective
F.62 Gas valve switch-off delay Delayed shutdown of gas valve detected
– Secondary light (ignition and monitoring electrode indicates delayed

extinguishing of the flame signal)
– Gas valve defective
– PCB defective
F.63 Fault: EEPROM Electronics defective
F.64 Fault: Electronics/NTC Flow or return NTC short circuited, electronics defective
F.65 Fault: Electronics temp. Electronics overheating due to external influences, electronics defective
F.67 Fault: Electronics/flame Implausible flame signal, electronics defective
F.70 Invalid device specific number (DSN) If spare parts fitted: Display and PCB replaced at same time and DSN
not reset, incorrect or missing output range coding resistance
F.71 Flow NTC fault Flow temperature sensor signalling constant value:
– Flow temperature sensor incorrectly positioned at supply pipe

– Flow temperature sensor defective
F.72 Flow/return NTC fault Flow/return NTC temperature difference too great → flow and/or return
temperature sensor defective
F.73 Water pressure sensor signal in the wrong range Interruption/short circuit of water pressure sensor, interruption/short
(too low) circuit to GND in supply line to water pressure sensor or water pressure
sensor defective
F.74 Water pressure sensor signal outside correct Line to water pressure sensor has a short circuit to 5 V/24 V or internal
range (too high) fault in the water pressure sensor
F.75 Fault: No pressure change detection when start- Water pressure sensor and/or pump defective, air in the heating installa-
ing pump tion, insufficient water in the product; check adjustable bypass, connect
external expansion vessel to the return
F.77 Fault: Flue non-return flap/condensate pump No response from flue non-return flap or condensate pump defective
con No communication with the PCB Communication fault between display and PCB in the electronics box

Appendix
E Connection diagram
brown X11
14 Cylinder thermostat (accessory)
black "C1/C2"
black
10
4 orange Cylinder sensor
violet
2
5
9 black
1
red P
11 green
2 Water pressure sensor
12 4
red
X2 +
green
13 signal Flow sensor
black
1 -
blue 1 Earth
17
black 2 Hall signal
Mains
3
3 Fan
Extra-low voltage plug
grey 4 PWM signal

4
16 red 5 + 24 V
5 red natural
7 black Flow sensor
blue
8
black black Return sensor
12
13 black
black
X20 14
black
6
black Flow Switch
10
blue
18
red Gas valve
9
15
Coding resistance
1210 
2
Ignition unit
Ignition electrode
green/yellow
X14 Appliance earth

Appendix
Fan
230 V~
X13
N Auxiliary relay (can be adjusted under D.26)
grey
N
blue
L
L
X11 Internal pump
green
N
X18 L
Cylinder
230 V~
5
white turquoise violet
charging pump
Supply voltage
4 Option: Ext. controller/room thermostat 3-4

3 (Contact)
N Mains input
L
N
L
9 Option: Ext. controller/room thermostat 7-8-9

Extra-low voltage
pink
8
X6 (continuous, analogue)
7
X1 +
blue red
- Option: Bus connection (controller/digital room therm.)

2
Option: Contact thermostat
24 V
1
1 0 Earth
Edge connector
0 Earth
DCF DCF connection Plug for controller accessory
RF Low loss header sensor VRC 4xx or ZP control system
X41 AF External sensor
6 FB Circulation pump remote control PWM signal: Internal pump
X22
Fan

Appendix
F Commissioning Checklist
Benchmark Commissioning and

Servicing Section
It is a requirement that the boiler is installed and commissioned to the
completed in full.
www.centralheating.co.uk
© Heating and Hotwater Industry Council (HHIC)

Appendix
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
CONTROLS
Optimum start control
Fitted
Fitted
Fitted
Fitted
ALL SYSTEMS
Yes
Yes
CENTRAL HEATING MODE

OR
mbar OR mbar
COMBINATION BOILERS ONLY

Yes
Yes
DOMESTIC HOT WATER MODE

OR
mbar OR mbar
Yes Temperature
CONDENSING BOILERS ONLY

Yes
ALL INSTALLATIONS
AND ² Ratio
AND ² Ratio
Yes
Yes
Yes
Yes

Appendix
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
SERVICE 01 SERVICE 02
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%
AND ²% AND ²%

Appendix
PRIOR TO CO AND COMBUSTION RATIO CHECK

NOTE
The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas
THE AIR GAS RATIO VALVE IS FACTORY
supply pressure/rate checked as required prior to commissioning.
SET AND MUST NOT BE ADJUSTED
As part of the installation process, especially where a flue has been fitted by persons other than the
DURING COMMISSIONING UNLESS THIS
boiler installer, visually check the integrity of the whole flue system to confirm that all components are
ACTION IS RECOMMENDED FOLLOWING
correctly assembled, fixed and supported. Check that manufacturer’s max. flue lengths have not been
CONTACT WITH THE MANUFACTURER.
exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
If any such adjustment is recommended and
The flue gas analyser should be of the correct type, as specified by BS 7967
further checking of the boiler is required the
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the
installer/service engineer must be competent
manufacturer. The installer must have the relevant competence for use of the analyser.
to carry out this work and to use the flue gas
Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.
analyser accordingly.
If the boiler requires conversion to operate with
a different gas family (e.g. conversion from
natural gas to LPG) separate guidance will be
provided by the boiler manufacturer SET BOILER TO MAXIMUM RATE
In accordance with boiler instructions, set boiler to operate at max. rate
(full load condition). Allow sufficient time for combustion to stabilise.
NOTE - Do not insert analyser probe during this period to avoid
possible “flooding” of sensor.
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER

Insert analyser probe into air inlet test point and allow readings to stabilise.
NOTE - where no air inlet test point is provided then a flue integrity check
with the analyser is not possible. The installer should verify that flue
integrity has been visually checked in accordance with the “Prior to
CO and combustion ratio check” box above before proceeding to the
“Check CO and combustion ratio at maximum rate” stage below.
VERIFY FLUE INTEGRITY

Analyser readings indicate that combustion products
Is
and inlet air must be mixing. Further investigation of
the flue is therefore required.
NO O2 20.6%
and
Check that flue components are assembled, fixed
CO2 < 0.2%
and supported as per boiler/flue manufacturer’s
instructions.
Check that flue and flue terminal are not obstructed.
YES
Is
O2 20.6% YES
and
CO2 < 0.2%
NO
TURN OFF APPLIANCE AND CALL CHECK CO AND COMBUSTION RATIO AT MAX. RATE
MANUFACTURER’S TECHNICAL HELPLINE With boiler still set at maximum rate, insert analyser probe into flue gas
FOR ADVICE. sampling point. Allow readings to stabilise before recording.
THE APPLIANCE MUST NOT BE NOTE - If no flue gas sampling point is present and the correct procedure is
COMMISSIONED UNTIL PROBLEMS ARE not specified in the manual, consult boiler manufacturer for guidance.
IDENTIFIED AND RESOLVED.
Is
CO less than
Check all seals around the appliance burner, NO 350ppm and
internal flue seals, door and case seals. CO/CO2 ratio
Rectify where necessary. less than 0.004
Is YES
CO less than
335ppm YES
and
CO/CO2 ratio less
than 0.004
SET BOILER TO MINIMUM RATE
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
NO NOTE - If manufacturer’s instructions do not specify how to set boiler to minimum
rate contact Technical Helpline for advice.
CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE

With boiler still set at minimum rate, insert analyser probe into flue gas sampling
point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is not
specified in the manual, consult boiler manufacturer for guidance.
TURN OFF APPLIANCE AND CALL

MANUFACTURER’S TECHNICAL HELPLINE Is
FOR ADVICE. CO less than
THE APPLIANCE MUST NOT BE NO 350ppm and
COMMISSIONED UNTIL PROBLEMS ARE CO/CO2 ratio
IDENTIFIED AND RESOLVED. IF less than 0.004
COMMISSIONING CANNOT BE FULLY
COMPLETED, THE APPLIANCE MUST BE
DISCONNECTED FROM THE GAS SUPPLY IN
ACCORDANCE WITH THE GSIUR. YES
NOTE: Check and record CO and combustion ratio
at both max. and min. rate before contacting the BOILER IS OPERATING SATISFACTORILY
manufacturer. no further actions required.
Ensure test points are capped, boiler case is correctly replaced and
all other commissioning procedures are completed.
Complete Benchmark Checklist, recording CO and combustion ratio
readings as required.

Appendix
G Opening of the flue pipe
S
Q
Q
T
Q
I
D, E
Q
F
O N
J B C
M
L
N
A H
G
I H
M
K
G.1 Positioning of the opening of a fan-supported flue gas guiding

Minimum dimen-
Installation site
sions
A Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm
B Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm
C Horizontally to an opening, air bricks, opening windows, etc., that can be opened. 300 mm
Below temperature-sensitive building components, e.g. plastic gutters, down pipes or wastewater
D 75 mm
pipes
E Below eaves 200 mm
F Below balconies or car port roofs 200 mm
G From vertical wastewater pipes or down pipes 150 mm
H From external or internal corners 200 mm
I Above floors, roofs or balconies 300 mm
J From a surface facing a terminal 600 mm
K From a terminal facing a terminal 1200 mm
L From an opening in the car port (e.g. door, window) which leads into the dwelling 1200 mm
M Vertical from a terminal on the same wall 1500 mm
N Horizontal from a terminal on the same wall 300 mm
O From the wall on which the terminal has been installed 0 mm
P From a vertical structure on the roof N/A
Q Above the roof area 300 mm
R Horizontal from adjacent windows on pitched or flat roofs 600 mm
S Above adjacent windows on pitched or flat roofs 600 mm
T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix
H Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows:
a) at least 2 m from an opening in the building directly opposite, and
b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely to
cause a nuisance to a neighbour or discharge over a walkway or patio.
For IE see current issue of IS 813.
For boilers covered within this manual.
1) Dimensions D, E, F and G:
These clearances may be reduced to 25 mm without affecting the performance of the boiler. In order to ensure that the con-
densate plume does not affect adjacent surfaces the terminal should be extended as shown below.
Balcony/eaves
Gutter
Adequately secured The flue pipe must

air/flue gas pipe protrude beyond any overhang
2) Dimension H:
This clearance may be reduced to 25 mm without affecting the performance of the boiler. However, in order to ensure that
the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred.
For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed away
from the building fabric.
I Technical data
Technical data – Power/load
The lowest nominal heat output may be higher than the value in the technical data, depending on the design of the system
and the current operating status.
VU GB 656/4-5 A
Nominal heat output range P at 40/30 °C 14.9 … 69.2 kW
Maximum heat input, heating side 65.0 kW
Minimum heat input heating side 14.0 kW
Technical data – Heating

VU GB 656/4-5 A
Maximum flow temperature 90 ℃
Max. flow temperature adjustment range (default setting: 35 … 85 ℃
75 °C)
Permissible total overpressure 0.3 MPa
(3.0 bar)
Circulation water volume (with reference to ΔT= 20 K) 2,750 l/h
Approx. condensate rate (pH value approx. 3.7) in heat- 6.5 l/h
ing mode at 40/30 °C

Appendix
Technical data – cylinder charging mode

VU GB 656/4-5 A
Maximum heat input in cylinder charging mode 65.0 kW
Cylinder charging output Such as heating
Technical data – General

VU GB 656/4-5 A
Gas connection, boiler side 1″
Flow/return heating connections, inside thread, boiler 1″
side
Flow/return heating connections, outside thread, boiler 1,5″
side
Gas connection pressure, G20 natural gas 2.0 kPa
(20.0 mbar)
Gas flow at 15 °C and 1013 mbar (based on hot water 6.9 m³/h
generation if applicable), G20
Min. flue gas mass rate 6.5 g/s
Max. flue gas mass rate 30.3 g/s
Min. flue gas temperature 40 ℃
Max. flue gas temperature 70 ℃
Permissible pressure difference in the flue gas pipe for 190 Pa
installation type B23P as a single occupancy max.
Permissible pressure difference in the flue gas pipe for 50 Pa
installation type B23P as multiple occupancy max.
30% efficiency 108 %
NOx class 5
Boiler dimension, width 480 mm
Boiler dimension, height 800 mm
Boiler dimension, depth 472 mm
Approx. net weight 75 kg
Technical data – Electrics

VU GB 656/4-5 A
Rated voltage 230 V/50 Hz
Built-in fuse (slow-blow) 2A
Max. electrical power consumption 249 W
Electrical power consumption, 30% 159 W
Level of protection IP X4 D
Test symbol/registration no. CE-0085BS0402

Index
Index Frost ...................................................................................... 6

G
A Gas connection ................................................................... 12
Air index setting................................................................... 21 Gas ratio setting .................................................................. 19
Air separator........................................................................ 28 H
Air separator, filter ............................................................... 28 Handing the product over to the operator............................ 25
Air/flue pipe ......................................................................... 14 Handling ................................................................................ 8
Air/flue pipe, installed ............................................................ 5 Heat exchanger ................................................................... 26
Article number ....................................................................... 8 Heating flow......................................................................... 13
Automatic air vent................................................................ 18 Heating partial load ............................................................. 23
B Heating return...................................................................... 13
Burner anti-cycling time....................................................... 24 Hot water temperature, risk of scalding................................. 5
C I
Calling up diagnostics codes............................................... 23 Identification plate ................................................................. 7
Carrying out inspection work ............................................... 25 If you smell gas ..................................................................... 4
Carrying out maintenance work........................................... 25 Inspection and maintenance intervals ................................. 25
CE label ................................................................................. 8 Installation clearances........................................................... 9
Check programmes ............................................................. 16 Installation site................................................................... 5–6
Checking the burner ............................................................ 27 Installer level ....................................................................... 23
Checking the CO₂ content ................................................... 21 Installing the compact thermal module................................ 28
Checking the pre-charge pressure of the expansion Installing the front casing..................................................... 10
vessel .................................................................................. 29 Intended use.......................................................................... 4
Circulation pump ................................................................. 16 L
Cleaning the condensate duct and the condensate trap..... 27 Leak detection spray ............................................................. 6
Compact thermal module ................................................ 6, 26 M
Competent person................................................................. 4 Maintenance interval ........................................................... 24
Completing inspection work ................................................ 29 Minimum clearances ............................................................. 9
Completing maintenance work ............................................ 29 P
Completing repair work ....................................................... 30 Performing diagnostics........................................................ 29
Completing, repair work ...................................................... 30 Power supply....................................................................... 15
Condensate drain pipework................................................. 13 Preparing the repair work .................................................... 29
Condensate duct ................................................................. 27 Product dimensions............................................................... 9
Connecting the controller .................................................... 15 Pump operating mode ......................................................... 23
Connection dimensions ......................................................... 9 Pump overrun...................................................................... 23
Corrosion............................................................................... 6 Purging the heating installation ........................................... 18
Corrugated gas pipe.............................................................. 6 Purging, heating installation ................................................ 18
D Q
Decommissioning ................................................................ 30 Qualification........................................................................... 4
Decommissioning the product ............................................. 30 R
Descaling the heat exchanger............................................. 27 Reading off the filling pressure............................................ 18
Descaling, heat exchanger.................................................. 27 Regulations ........................................................................... 6
Diagnostics level ................................................................. 23 Removing the condensate trap ........................................... 27
Disposal, packaging ............................................................ 30 Replacing the burner ........................................................... 30
Disposing of the packaging ................................................. 30 Replacing the display .......................................................... 30
Documents ............................................................................ 7 Replacing the PCB .............................................................. 30
Draining the product ............................................................ 28 Replacing, display ............................................................... 30
E Replacing, PCB ................................................................... 30
Electricity ............................................................................... 5 Resetting parameters .......................................................... 29
Expansion relief valve ......................................................... 13 Resetting, all parameters .................................................... 29
F S
Fault codes.................................................................... 29, 35 Safety device......................................................................... 5
Fault memory ...................................................................... 29 Schematic drawing ................................................................ 5
Filling pressure .................................................................... 18 Second diagnostics level..................................................... 23
Filling the condensate siphon.............................................. 19 Serial number ........................................................................ 8
Filling the condensate trap .................................................. 19 Service partner .................................................................... 29
Filling the heating installation .............................................. 18 Setting the CO₂ content....................................................... 21
Filling, heating installation ................................................... 18 Spare parts.......................................................................... 26
Filter, air separator .............................................................. 28 Supply of combustion air ....................................................... 5
Flow temperature, maximum............................................... 24 Switching on the product ..................................................... 16
Flue gas route ....................................................................... 5 T
From the delivery point to the installation site ....................... 8 Tool ....................................................................................... 6
Front casing, closed .............................................................. 5 Transport ............................................................................... 6

Index
Treating the heating water................................................... 17

U
Unloading the box ................................................................. 8
V
Voltage .................................................................................. 5
W
Wall-mounting the product .................................................. 10

0020214491_01
0020214491_01 04.01.2017
Supplier
Vaillant Ltd.
Nottingham Road Belper Derbyshire DE56 1JT
Telephone 0330 100 3461
[email protected] www.vaillant.co.uk
© These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with
the manufacturer's written consent.
We reserve the right to make technical changes.

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Installation and maintenance instructions

For the competent person

Installation and maintenance instructions

Contents 7 Adapting the unit to the heating

2 Installation and maintenance instructions ecoTEC plus 0020214491_01

G Opening of the flue pipe.................................... 43

0020214491_01 ecoTEC plus Installation and maintenance instructions 3

1 Safety this document shall be considered improper

4 Installation and maintenance instructions ecoTEC plus 0020214491_01

1.3.5 Risk of poisoning caused by 1.3.10 Risk of being burned or scalded by

0020214491_01 ecoTEC plus Installation and maintenance instructions 5

1.3.16 Risk of material damage caused by

1.3.17 Risk of corrosion damage due to

1.3.18 Risk of material damage caused by

6 Installation and maintenance instructions ecoTEC plus 0020214491_01

2 Notes on the documentation 3 Product description

2.2 Storing documents

Benchmark places responsibilities on both manufacturers 15 7

Information on the Meaning

0020214491_01 ecoTEC plus Installation and maintenance instructions 7

Information on the Meaning Num-

Note 4.3.2 Unloading the box from the delivery van

4.3.3 Transporting the box from the delivery

4.2 Checking the scope of delivery

4.2.1 Scope of delivery

8 Installation and maintenance instructions ecoTEC plus 0020214491_01

119 tion cartridge

4.5 Minimum clearances and installation

4.7 Using the installation template

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1. Check whether the wall has sufficient load-bearing ca-

▶ Wall-mount the product as described. 4.9.2 Installing the front casing

10 Installation and maintenance instructions ecoTEC plus 0020214491_01

Caution. 5.1.1 Heating circuit connection with low loss

Seals made of rubber-like materials may be subject to plastic 1

1 Product with internal 3 External cylinder char-

The product's electronics are designed in such a way that

0020214491_01 ecoTEC plus Installation and maintenance instructions 11

12 Installation and maintenance instructions ecoTEC plus 0020214491_01

5.3 Hydraulics installation

Caution. 1. Install the enclosed expansion relief valve.

1. Install service valves properly at the flow connection (1)

Condensate forms in the product during combustion. The

0020214491_01 ecoTEC plus Installation and maintenance instructions 13

14 Installation and maintenance instructions ecoTEC plus 0020214491_01

0020214491_01 ecoTEC plus Installation and maintenance instructions 15

16 Installation and maintenance instructions ecoTEC plus 0020214491_01

Display Meaning Treating the filling and supplementary water

▶ Before filling or topping up the system, check the quality

0020214491_01 ecoTEC plus Installation and maintenance instructions 17

1. Flush the heating installation thoroughly before filling it.

18 Installation and maintenance instructions ecoTEC plus 0020214491_01

18. If there is still too much air in the heating installation at

6.9 Flushing the heating installation for the first

Danger! The product's combustion has been factory tested and is

0020214491_01 ecoTEC plus Installation and maintenance instructions 19

1. Check the flue gas installation is intact in accordance

20 Installation and maintenance instructions ecoTEC plus 0020214491_01

▶ End the check programme P.01.