Installation and maintenance instructions. For the competent person. Installation and maintenance instructions. ecotec plus VU VUW GB, IE

Transcription

1 Installaton and mantenance nstructons For the competent person Installaton and mantenance nstructons ecotec plus VU VUW GB, IE

2 Table of Contents BEFORE PROCEEDING - ENSURE BOILER IS CORRECT FOR GAS GROUP SUPPLIED! Table of Contents Notes on the documentaton.... Storng documents.... Symbols used.... Applcablty of the nstructons.... Identfcaton plate....5 CE label....6 Benchmark....7 Type overvew...5 Safety...6. Safety and warnng nformaton Classfcaton of warnngs Structure of warnngs...6. Intended use...6. Basc safety nstructons...6. Important nformaton regardng propane-fred bolers General requrements Related documents Installaton ste Gas supply Ar supply Compartment ventlaton Electrcal supply Water supply Combnaton bolers Water crculaton system Pressure relef valve Ventng... 0 Descrpton of the applance... Installaton.... Accessores..... Controller..... Installaton and operaton.... Scope of delvery..... Unpackng the boler..... Checkng the scope of delvery..... Dsposng of the packagng.... Transportng the applance.... Requrements for the nstallaton ste Requred mnmum clearances/nstallaton clearances Usng nstallaton templates Dmenson drawng and connecton measurements Wall-mountng the boler Removng/fttng the front casng Removng/fttng the sde panel Gas nstallaton Preparng for nstallaton Connectng the gas ppe Hydraulc nstallaton Preparng for nstallaton Connectng the hot and cold water (VUW boler).. 6. Connectng the domestc hot water cylnder Connectng the heatng flow and heatng return VUW boler VU boler Low loss header Connectng the condensate dscharge ppework Connectng the dscharge ppe to the expanson relef valve on the boler... 7 Flue gas nstallaton Ar/flue gas duct Flue termnaton Electrcal nstallaton Preparng for nstallaton Openng/closng the electroncs box Establshng the mans connecton Connectng the controller Fttng the controller Connectng controllers to the electronc system Connectng addtonal components Connectng the auxlary relay (grey connector on PCB) Connect VR 0 " from 7" mult-functonal module Actuatng the crculaton pump demandcontrolled Connecton dagrams... 9 Operaton Callng up the nstaller level Overvew of the menu structure Commssonng Swtchng on the boler Installaton assstant Language Fllng mode Purgng Target feed temperature Hot water temperature Comfort mode Heatng partal load Auxlary relay and mult-functonal module Competent person telephone number Termnatng the nstallaton assstant Restartng the nstallaton assstant Applance confguraton and dagnoss menu Usng test programs Preparng the heatng water Read off the fllng pressure... Installaton and mantenance nstructons ecotec plus _06

3 Table of Contents 0.7 Fllng and purgng the heatng nstallaton Fllng the heatng nstallaton Purgng the heatng system Flushng the system for the frst tme ("cold") Avodng low water pressure Top up VUW bolers usng a fllng devce Fll and purge the hot water system Fllng the condensate sphon Checkng the gas settng Factory settng Checkng for tghtness of the flue gas nstallaton and flue gas recrculaton Checkng the gas flow rate Checkng the gas nlet workng pressure Carryng out a full functon test Checkng the heatng mode Checkng hot water generaton (VUW bolers only) Checkng hot water generaton (VU bolers only) Fnal flush of the heatng system ("hot")... 8 Adaptng the boler to the heatng nstallaton Dagnoss codes Overvew Settng the heatng partal load Settng pump overrun tme and pump operatng mode Settng the maxmum flow temperature Settng the return flow temperature control Burner ant-cyclng tme Settng the mantenance nterval Settng the pump output Settng the by-pass valve Handng over the boler to the operator Inspecton and mantenance Inspecton and mantenance ntervals General nspecton and mantenance nstructons Safety nstructons Checkng the CO/CO rato and the CO concentraton Adjustng the CO concentraton (or the ar rato) Performng the gas famly check Inspecton and mantenance work steps Fllng the boler and the heatng nstallaton Dranng the boler Dranng the entre heatng nstallaton...6. Usng the functon menu Carryng out electroncs self-tests...6. Carryng out mantenance work Removng the compact thermal module Cleanng the heat exchanger Checkng the burner Cleanng the condensate sphon Clean the flter n the cold water nlet (VUW bolers only) Installng the compact thermal module Checkng the charge pressure of the expanson vessel Checkng the gas flow pressure Checkng CO content Troubleshootng Contact Vallant Servce Solutons ( ) Performng dagnostcs Call up Lve Montor (status codes) Status codes Overvew Servce messages Callng up dagnoss levels Readng off the fault codes Queryng the fault memory Reset fault memory Overvew of fault codes Usng the functon menu Runnng test programs Resettng parameters to factory settngs...70 Replacng components...7. Preparng for and completng replacement work Preparng for replacement work Completng replacement work...7. Replacng the burner...7. Replacng the fan...7. Replacng the gas valve Replacng the ventur ncludng the mass flow sensor Replacng the expanson vessel Replacng the heat exchanger Replacng the PCB and/or the dsplay Replacng ether the dsplay or the PCB Replacng the PCB and the dsplay at the same tme Decommssonng Temporarly shuttng down the boler Takng the boler permanently out of servce Dsposng of the boler Guarantee and customer servce Factory guarantee Vallant Servce Techncal data Glossary... 8 Benchmark Commssonng and Servcng Secton... 8 Index Installaton and mantenance nstructons ecotec plus _06

4 Notes on the documentaton Notes on the documentaton The followng nstructons are ntended to gude you throughout the entre documentaton. Further documents apply n combnaton wth these nstallaton and mantenance nstructons. We accept no lablty for any damage caused by nonobservance of these nstructons. Other applcable documents > Follow all nstallaton nstructons for the varous parts and components of the system wthout excepton when nstallng the ecotec plus. These nstallaton nstructons are enclosed wth the varous system components as well as addtonal components. > Also observe all the operatng nstructons ncluded wth the system components.. Storng documents > Pass these nstallaton nstructons and all other applcable documents and, f necessary, any requred ads to the system operator. The operator wll store the nstructons and ads so that they are avalable when requred.. Symbols used The symbols used n the text are explaned below: Symbol that denotes useful tps and nformaton > Symbol for a requred acton. Applcablty of the nstructons These nstallaton nstructons are only vald for bolers wth the followng artcle numbers: Boler Type desgnaton Artcle number Gas Councl Number ecotec plus 6 (VU GB 6/5-5) ecotec plus 65 (VU GB 56/5-5) ecotec plus 68 (VU GB 86/5-5) ecotec plus 68 (VU GB 86/5-5) (LPG) ecotec plus 6 (VU GB 6/5-5) ecotec plus 60 (VU GB 06/5-5) ecotec plus 60 (VU GB 06/5-5) (LPG) ecotec plus 67 (VU GB 76/5-5) ecotec plus 8 (VUW GB 6/5-5) ecotec plus 8 (VUW GB 6/5-5) ecotec plus 8 (VUW GB 6/5-5) (LPG) ecotec plus 87 (VUW GB 76/5-5) Applance types, artcle numbers and Gas Councl Number The artcle number of the boler can be found on the dentfcaton plate.. Identfcaton plate The dentfcaton plate of the Vallant ecotec plus s attached to the undersde of the boler n the factory. The artcle number of the gas fred wall hung boler can be found n the seral number. The seventh to sxteenth numbers consttute the artcle number. The seral number can also be found on the lft out badge located behnd the front flap at the bottom of the boler. The seral number can also be shown on the dsplay of the boler ( Operatng nstructons)..5 CE label The CE label shows that the bolers comply wth the basc requrements of the applcable drectves as stated on the dentfcaton plate. The declaraton of conformty can be vewed at the manufacturer s ste..6 Benchmark Vallant Ltd. supports the Benchmark Intatve. You wll fnd the Benchmark Logbook on the last pages of ths nstructon manual. It s very mportant that ths document be flled out properly when nstallng, commssonng, Installaton and mantenance nstructons ecotec plus _06

5 Notes on the documentaton and fully explaned at hand over to the operator of the nstallaton. Installers should pont out also the servce record secton for completon followng servce calls to ths applance. Vallant Ltd. s a lcensed member of the Benchmark Scheme whch ams to mprove the standards of nstallaton and commssonng of domestc heatng and hot water systems n the UK and to encourage regular servcng to optmze safety, effcency and performance. Benchmark s managed and promoted by the Heatng and Hot water Industry Councl. > For more nformaton vst www. centralheatng.co.uk Vallant supply a specal self adhesve stcker on top of the boler for use n enterng the seral number detals straght onto the commssonng checklst found n the last pages of ths document..7 Type overvew Applance type ecotec plus 6 (VU GB 6/5-5) 65 (VU GB 56/5-5) 68 (VU GB 86/5-5) 6 (VU GB 6/5-5) 60 (VU GB 06/5-5) 67 (VU GB 76/5-5) 8 (VUW GB 6/5-5) 8 (VUW GB 6/5-5) 87 (VUW GB 76/5-5). Type overvew Desgnated country (desgnaton n accordance wth ISO 66) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) GB (Great Brtan) IE (Ireland) Approval category I H I H II HP II HP II HP II HP II HP II HP II HP Installaton and mantenance nstructons ecotec plus _06 5

6 a Safety a Safety. Safety and warnng nformaton > When nstallng the ecotec plus, take account of the general safety nstructons and the warnng notes that appear before all of the actons... Classfcaton of warnngs The warnng notes are classfed n accordance wth the severty of the possble danger usng the followng warnng sgns and sgnal words: Warnng sgn Sgnal word a Danger! e Danger! a Warnng. b Cauton.. Classfcaton of warnngs Explanaton Immedate danger to lfe or rsk of severe personal njury Rsk of death from electrc shock Rsk of mnor personal njury Rsk of materal or envronmental damage. Intended use There s a rsk of njury or death to the user or others, or of damage to the product and other property n the event of mproper use or use for whch t s not ntended. Ths boler s not desgned to be used by persons (ncludng chldren) wth lmted mental and sensory capabltes or by persons who do not have enough experence and/or knowledge, unless they are supervsed by a person who s responsble for ther safety or they have been nstructed by hm/ her about how to use the boler. Chldren must be supervsed to ensure that they do not play wth the boler. The boler s ntended as a heater for closed hot water/central heatng nstallatons and for hot water generaton. The use of the ecotec plus n vehcles, such as moble homes and caravans, s not classed as ntended use. Unts that are not classed as vehcles are those that are nstalled n a fxed and permanent locaton and that do not have any wheels (fxed nstallaton). Any other use, or use beyond that specfed, shall be consdered as mproper use. Any drect commercal or ndustral use s also deemed to be mproper. The manufacturer or suppler s not lable for any damage resultng from such use. The user alone bears the rsk. Intended use ncludes the followng: observance of accompanyng operatng, nstallaton and mantenance nstructons for Vallant products as well as for other parts and components of the system nstallng and fttng the applance n accordance wth the boler and system approval complyng wth all of the nspecton and mantenance condtons lsted n the nstructons. Cauton. Any mproper use s forbdden... Structure of warnngs Warnng sgns are dentfed by an upper and lower separatng lne. and are lad out accordng to the followng basc prncple: a Sgnal word! Type and source of danger! Explanaton of the type and source of danger > Measures for avertng the danger. Basc safety nstructons > Observe the followng safety nstructons at all tmes. European nstallaton drectve Installaton and mantenance of the applance should only be undertaken by a competent person (referred to n these nstructons as competent person or sklled trade company and thereby ndcatng male and female persons) approved at the tme by the Health and Safety executve and n accordance wth the gas safety (nstallaton and use) regulatons 998. The exstng regulatons, rules and gudelnes must be observed when dong so. The competent person s also responsble for nspecton, mantenance and repars to the unt, as well as alteratons to the gas volume settng. Only IE: The nstallaton must comply wth the current Verson of I.S.8 "Domestc Gas Installatons" and the current Buldng Regulatons. The current ETCI Regulatons for nstallng electrcal equpment must also be observed. 6 Installaton and mantenance nstructons ecotec plus _06

7 a Safety a Installaton and settngs In the followng cases, the boler must be operated only wth the front casng ftted and closed and wth a completely mounted ar/flue gas duct: startng up test purposes contnuous operaton, Otherwse, under unfavourable operatng condtons, njury, death or materal damage may occur. Exclusvely for test purposes such as gas workng pressure testng the boler may be operated wth the front casng removed for short duratons ONLY but must have a completely mounted ar/flue gas duct. What to do f you smell gas Installaton errors, damage, manpulaton, an unauthorsed nstallaton ste or smlar can cause gas to escape and result n a rsk of posonng and exploson. If there s a smell of gas n the buldng, proceed as follows: > Avod rooms that smell of gas. > If possble, open doors and wndows fully and ensure ar s crculatng. > Avod the use of naked flames (e.g. lghters, matches). > Do not smoke. > Do not use any electrcal swtches, plugs, doorbells, telephones or other communcaton systems n the buldng. > Close the gas meter solator devce or the man solator devce. > If possble, close the gas stop cock on the unt. > Warn the occupants n the buldng by knockng or callng. > Leave the buldng. > If you can actually hear gas leakng, leave the buldng mmedately and ensure that no thrd partes enter the buldng. > Alert the polce and fre brgade when you are outsde the buldng. > Use a telephone outsde the buldng to nform the gas supply company or Natonal Grd Transco Materal damage due to mproper use and/or unsutable tools The use of unsutable tools or mproper use thereof may cause damage, such as gas or water leaks. > When tghtenng or loosenng threaded connectons, always use sutable open-end spanners, but do not use ppe wrenches, extensons, etc.. Important nformaton regardng propane-fred bolers Purgng the lqud gas tank when nstallng the system: > Before nstallng the boler, make sure that the gas tank has been purged. The lqud gas suppler s responsble for proper ventlaton of the tank. Ignton problems can result f the tank s not purged properly. > In such cases, frst contact the person n charge of fllng the tank. > Also observe the nformaton on converson to lqud gas n ( secton 0.) of ths manual. Usng the correct gas group Usng the wrong gas group may cause a fault shutdown on the boler. Furthermore, gnton and combuston nose may occur n the boler. > Only use propane gas G. Affx tank stcker Affx the enclosed tank stcker (propane qualty) to the tank where t wll be clearly vsble, or on then cylnder cabnet near the fller nozzle f possble. What to do f you smell exhaust fumes Installaton errors, damage, manpulaton, unauthorsed nstallaton stes or the lke can cause flue gas to escape and result n a rsk of posonng. If there s a smell of exhaust fumes n the buldng, proceed as follows: > If possble, open doors and wndows fully and ensure adequate ventlaton. > Swtch the boler off. > Check the flue gas route n the boler and the flue gas ppes. Materal damage caused by corroson To prevent corroson on the boler and also on the ar/flue gas duct, note the followng: > Do not use sprays, solvents, chlornated cleanng agents, pant, adhesves or smlar substances n the vcnty of the boler. Under unfavourable crcumstances, these substances may cause corroson. Installaton and mantenance nstructons ecotec plus _06 7

8 a Safety a.5 General requrements.5. Related documents To ensure the safe nstallaton and contnued satsfactory operaton of your applance, all works shall be carred out by a competent nstaller fully conversant wth the requred current and up to date, acts standards, laws and regulatons relevant for ths range of equpment at the tme of nstallaton. In addton any specal requrements of Local Authortes, gas undertakngs or nsurers must be compled wth. Installers shall carryout a full ste rsk assessment and put nto place all necessary steps and procedures to comply wth Health and safety at work act and ensure safety of themselves and others wth regard to manual handlng and workng at heght requrements. Attenton shall be pad to (but not restrcted to) the followng: Gas Safety (Installaton and Use) regulatons. All Buldng Regulatons 000 for England and Wales,(as amended). (Includes Approved Codes of Practce and Approved Documents for buldng regulatons e.g. L, LA, LB, L8.) The Buldng Standards, Scotland, and any requrements determned by the local authortes wthn. The current Verson of I.S.8 Domestc Gas Installatons and the current Buldng Regulatons for IE. The current ETCI Regulatons for nstallng electrcal equpment for IE. BS 767 Requrements for electrcal nstallatons. IEE Wrng Regulatons The Electrcty at Work Regulatons. The Water supply (water fttngs) regulatons 999. BS 585 Code of practce for flues and flue structures n buldngs. BS EN 88 Desgn of water-based heatng systems. BS EN 806 parts - 5 BS 8558 BS 6880 Code of practce for low temperature heatng systems wth outputs greater than 5 kw. Part Fundamental and desgn consderatons. Part Selecton of equpment. Part Installaton, commssonng and mantenance. BS 698 Installaton of low pressure gas ppework of up to 5 mm n domestc premses. BS 8 Specfcaton for: Expanson vessels usng an nternal daphragm, for sealed hot water and heatng systems. BS 707 Applcaton, selecton and nstallaton of expanson vessels and ancllary equpment for sealed water systems. Part Code of practce for domestc heatng and hot water. Part Code of practce for low and medum temperature hot water systems. BS 759 Code of practce for treatment of water n domestc hot water central heatng systems BS EN 8 Closed expanson vessels wth bult n daphragm BS EN 6 Heatng systems n buldngs. Installaton and commssonng of water based heatng systems. BS 50 Installaton of flues and ventlaton for gas applances of rated nput not exceedng 70 kw* BS 50 Flueng and ventlaton for gas applances of rated nput not exceedng 70 kw* * st nd and rd famly gases. BS EN 6798 Installaton & mantenance of gas fred hot water bolers of rated nput not exceedng 70 kw net Insttute of Gas Engneers Publcatons: IGE/UP/B (Edton ) Tghtness testng and drect purgng of small natural gas nstallatons. IGE/UP/ 7 (Edton ) Gas n tmber and lght steel framed buldngs. I.S. 8 - Domestc Gas Installatons - nd edton (Ireland) BS 58 - Part Domestc butane and propane gas burnng nstallatons.5. Installaton ste The locaton chosen for the boler must permt the provson of a satsfactory flue termnaton. The locaton must also provde adequate space for servcng and ar crculaton around the boler. Before commencement of any works the nstaller should carry out a full rsk assessment n accordance wth Health and Safety executve regulatons. The boler may be nstalled n any room, although partcular attenton s drawn to the requrements of BS 767 (IEE Regulatons), the electrcal provsons of the Buldng Regulatons (Scotland) and n IE the current edton of IS 8 and the current ETCI rules, n respect of the nstallaton of a boler n a room contanng a bath or shower. In case of nstallaton of the boler n an unusual locaton, specal procedures may be necessary and BS 556 and BS 6798 gve detaled gudance on ths aspect. The boler must be mounted on a flat, vertcal wall, whch must be suffcently robust to take the weght of the boler. The boler may be nstalled on a combustble wall, subject to the requrements of the Local Authortes and Buldng Regulatons. A compartment used to enclose the boler must be desgned and constructed specfcally for ths purpose. (An exstng cupboard or compartment may be used provded that t s modfed for the purpose). Detals of essental features of cupboard/compartment desgn ncludng arng cupboard nstallatons are gven n BS 689. In IE the current edton of IS 8. If the boler s to be nstalled n an arng cupboard t s not requred to separate the boler wth a non-combustble partton. However nstallaton and servcng clearances must be mantaned, and the boler kept clear of any clothng. 8 Installaton and mantenance nstructons ecotec plus _06

9 a Safety a b Cauton. Rsk of damage caused by aggressve vapours and dust. Aggressve vapours and dust n the nstallaton room may cause corroson damage to the boler and to the flue gas nstallaton. > Ensure that the boler s room sealed f the ar n the nstallaton room contans aggressve vapours or dust. > Observe the followng when choosng the nstallaton ste and operatng the boler, Do not nstall the boler n rooms prone to frost. Do not nstall the boler n rooms n whch the combuston ar contans chemcal substances, e.g. fluorde, chlorne, sulphur, dust, etc. (e.g. sprays, solvents, cleanng agents, pant, adhesves). > Please ensure that the boler s room sealed or n a separate nstallaton room f the combuston ar supply contans the aforementoned substances, you nstall the boler n hardresser salons, panter's or joner's workshops, cleanng busnesses or smlar. > Do not route the combuston ar through an old ol furnace chmney, as ths can also cause corroson..5. Gas supply An exstng gas meter should be checked to ensure that t s capable of passng the rate of gas supply requred. Installaton ppes should be ftted n accordance wth BS 689, n IE n accordance wth the current ssue of IS 8. Ppework from the meter to the boler must be of an adequate sze. Do not use ppes of a smaller sze than the boler gas connecton. The complete nstallaton must be tested and purged n accordance wth: IGE/UP /B for systems up to 0.05 m capacty for larger systems IGE/UP/A and for LPG nstallatons refer to BS 58 - or IGE/UP Edton for larger volume nstallatons..5. Ar supply Detaled recommendatons for ar supply are gven n BS 50: Part. It s not necessary to have an ar vent n the room or nternal space n whch the boler s nstalled..5.5 Compartment ventlaton The bolers are very hgh effcency applances. As a consequence the heat loss from the applance casng durng operaton s very low. Compartment ventlaton s requred f the flue used s not concentrc and ar s suppled from the room or compartment the boler s nstalled n..5.6 Electrcal supply a Danger! Rsk of death from electrc shock. If the applance s not earthed, t may hold voltage f a defect occurs. > Earth the applance. A 0 V, ~ 50 Hz sngle phase electrcty supply fused to Amp. must be provded n accordance wth the latest edton of BS 767 (IEE Wrng Regulatons) and any other local regulatons that may apply. In IE reference should be made to the current edton of the ETCI rules. The method of connecton to the mans electrcty supply must provde a means of completely solatng the boler and ts ancllary controllers. Isolaton s preferably by the use of a fused three pn plug and unswtched shuttered socket outlet, both complyng wth the requrements of BS 6. Alternatvely, a Amp. fused doublepole swtch wth a mm contact openng on both poles may be used..5.7 Water supply Combnaton bolers Desgners and nstallers must ensure that all ppe work and fttngs connected to the ecotec comples wth the necessary water fttngs regulatons. See related documents above (ref BS 6700 and new BSEN 806 parts - 5 plus BS 8558) For combnaton bolers the ncomng water supply should be checked to ensure that suffcent pressure and flow rate are avalable to sute the ntended use, see the techncal data at the back of ths manual. All mans water heated by the ecotec combnaton boler wll be classed as Category flud and small expanson volumes created durng warm up must be allowed to flow back nto the supply ppe. No back flow preventon s necessary wth ths applance as the very small expanson volume s unlkely to heat the ncomng servce ppe above 5 Deg C. Note that where back flow preventon devces are ftted (ths may nclude water meters) these can prevent the permtted expanson nto the cold supply. Ths along wth the effects of pumpng and / or water hammer can result n a pressure buld-up that may cause damage to the boler (and other household devces such as showers). Vallant cannot accept responsblty for damage caused to the boler or ts surroundngs where an applance has been ftted to supples wth mechancal back flow preventon. In these cases the requrement would be that a competent nstaller correctly nstalls a sutable shock arrestor / mn-expanson vessel adjacent to the boler n the cold water supply ppe..5.8 Water crculaton system Detaled recommendatons concernng the water crcut system can be taken from BS 6798 and BS 59, Part (for Installaton and mantenance nstructons ecotec plus _06 9

10 a Safety a "Small Bore" and "Mcro Bore" central heatng nstallatons). Lnes whch do not form part of the usable heatng surface should be nsulated to prevent heat losses and possble freezng up, especally where the lnes run under rooves and ventlated cellar rooms. The dran connectons must be easly-accessble, so that the entre system ncludng the boler and hot water system can be draned. The dran connectons should be at least / " (BSP nomnal sze) and must be n accordance wth BS 879. The boler s sutable for Mnbore and Mcrobore systems. Water lnes are to be copper ppes n accordance wth BS 87, Part. These must be thoroughly cleaned, especally when connectng a new boler to an exstng system. Rsk of damage f the heatng water s treated wth unsutable frost or corroson protecton agents. Frost and corroson protecton agents can cause changes to seals, nose durng heatng mode and may lead to other consequental damage. > Do not use any unsutable frost or corroson protecton agents. Mxng addtves wth the heatng water can result n materal damage. However no ncompatblty wth Vallant bolers has been detected wth proper use of the followng products over a long perod. > When usng addtves, follow the manufacturer's nstructons wthout excepton. Vallant accepts no lablty for the compatblty of any addtve or ts effectveness n the rest of the heatng nstallaton. Addtves for cleanng measures (subsequent flushng requred) Fernox F Sentnel X 00 Sentnel X 00 Addtves ntended to reman permanently n the system Fernox F Fernox F Sentnel X 00 Sentnel X 00 Addtves for frost protecton ntended to reman permanently n the system Fernox Antfreeze Alph Sentnel X 500 > Inform the operator of the necessary measures f you have used these addtves. > Inform the operator about the requred measures for frost protecton. Permssble water hardness > Observe all vald natonal and techncal regulatons when condtonng fllng and supplementary water. Provded the natonal regulatons and techncal standards do not stpulate more strngent requrements, the followng apples: > You must condton the heatng water n the followng cases: If the entre fllng and supplementary water quantty durng the operatng lfe of the system exceeds three tmes the nomnal volume of the heatng nstallaton or If the lmt values shown n the tables are not observed. Total heatng output kw < 50 > 50 to 00 >00 to 600 > 600 Overall hardness at smallest boler heatng surface ) 0 l/kw > 0 l/kw < 50 l/kw mol/m (mg/l CaCO ) mol/m (mg/l CaCO ) No requrement or < ) (00) < (00) ).5 (00).5 (50) 0.0 (.0) (50) 0.0 (.0) 0.0 (.0) > 50 l/kw mol/m (mg/l CaCO ) 0.0 (.0) 0.0 (.0) 0.0 (.0) 0.0 (.0) ) on systems wth crculaton water heaters and for systems wth electrc heatng elements ) from the specfc system volume (nomnal capacty n ltres/heatng output; for multple boler systems, the lowest ndvdual heatng output should be used). Ths data only apples up to tmes the system volume for fllng and top-up water. If tmes the system volume fgure s exceeded, the water must be treated n exactly the same way as f the lmts quoted n table. were exceeded (softenng, desalnaton, hardness stablsaton or desludgng).. Gudelne values for heatng water: water hardness.5.9 Pressure relef valve The boler s equpped wth a pressure relef valve. Ths safety devce s requred for all sealed central heatng systems, s preset to bar and s ftted wth a 5 mm compresson connecton for the dscharge ppe, whose dameter must not be less than 5 mm. The pressure relef valve must not be used for dranng purposes. For stuatons where the dscharge cannot be easly routed Vallant have a remote pressure relef valve mountng kt avalable whch can be used to provde a sutable way to acheve ths..5.0 Ventng The boler s ftted wth an automatc ar vent. Other measures need to be taken to allow the heatng system to be ether automatcally or manually vented durng fllng and durng commssonng. 0 Installaton and mantenance nstructons ecotec plus _06

11 Descrpton of the applance Descrpton of the applance Desgn Functonal elements of the VU system boler. Functonal elements of the VUW combnaton boler Key Gas valve Water pressure sensor Ventur wth mass flow sensor Heat exchanger 5 Connecton for the ar/flue gas duct 6 Expanson vessel 7 Ar ntake ppe 8 Compact thermal module 9 Ignton electrode 0 Fan Automatc ar vent Pressure gauge Internal pump By-pass valve 5 Expanson relef valve 6 Electroncs box Key Gas valve Water pressure sensor Ventur wth mass flow sensor Heat exchanger 5 Connecton for the ar/flue gas duct 6 Expanson vessel 7 Ar ntake ppe 8 Compact thermal module 9 Ignton electrode 0 Fan Automatc ar vent Pressure gauge Internal pump By-pass valve 5 Expanson relef valve 6 Electroncs box 7 Dverter valve wth bypass 8 Impeller sensor (hot water) 9 Secondary heat exchanger Installaton and mantenance nstructons ecotec plus _06

12 Installaton Installaton BEFORE PROCEEDING - ENSURE BOILER IS CORRECT FOR GAS GROUP SUPPLIED! The work descrbed n ths secton must only be carred out by a competent person.. Accessores.. Controller To control the ecotec, Vallant offers varous controller versons for connectng to the swtchng ral or for pluggng nto the operator control screen. Room Thermostats VRT 0 Room Thermostat (0 V) VRT 50 Room Thermostat ebus Tmers / Programmers tmeswitch 50 mechancal clock tmeswitch 60 7 day programmer Dgtal Room Temperature Controls VRT 50 Programmable Room Control VRT 9f RF Programmable Room Control * VRT 50f RF Programmable Room Control Weather Compensatng Controls The ppes can be routed upwards behnd the boler n front of the wall (surface nstallaton) usng the spacer frame. Whch means the dstance between the wall and the boler ncreases by 65 mm.. Scope of delvery The Vallant ecotec plus s delvered pre-mounted n a packagng unt... Unpackng the boler > Remove the boler from ts box. > Remove the protectve flm from all parts of the boler... Checkng the scope of delvery. > Check that all parts have been delvered and are ntact ( fg.. and table. or fg.. and table.). 8 7 VRC 70 Weather Compensator VRC 70f RF Weather Compensator Communcaton vrnetdialog comdialog Accessores VR 65 Control Centre VR 66 Control Centre VR 6/ Two Zone Wrng Centre VR 8/ Remote Control Unt VR 68/ Solar Module. Controller accessores * Note 9f RF transmtter wred external to boler.. Installaton and operaton Optonal accessores are avalable for use n conjuncton wth the nstallaton and operaton of the ecotec. The current prce lst shows the complete range of hydraulc accessores for the ecotec plus seres Scope of delvery for ecotec plus VU boler Installaton and mantenance nstructons ecotec plus _06

13 Installaton Item Qty Descrpton Wall bracket Boler Lower cover Supply ppes (gas, heatng, expanson relef valve) 5 Servce valves 6 Installaton template 7 Enclosure documentaton 8 Bags wth parts Addtonal for propane bolers: stcker for tank. Scope of delvery for ecotec plus VU boler Scope of delvery for ecotec plus VUW boler Item Qty Descrpton Wall bracket Boler Lower cover 6 Supply ppes (gas, heatng, water, expanson relef valve) 5 Servce valves 6 Installaton template 7 Enclosure documentaton 8 Bags wth parts Addtonal for propane bolers: stcker for tank. Scope of delvery for ecotec plus VUW boler.. Dsposng of the packagng > Dspose of the cardboard packagng used on the eco- TEC plus at a cardboard recyclng ste. > Dspose of the plastc flm and plastc fllng at an approprate plastc recyclng ste. > Observe natonal regulatons.. Transportng the applance Important: Wth regards to the Manual Handlng Operatons, 99 Regulatons, the followng lft operaton exceeds the recommended weght for a one man lft. General recommendatons when handlng > Clear the route before attemptng the lft. > Ensure safe lftng technques are used keep back straght bend usng legs. > Keep load as close to body as possble. Do not twst reposton feet nstead. > If persons performng lft, ensure co-ordnated movements durng lft. > Avod upper body/top heavy bendng - do not lean forward/sdeways. > Recommend wear sutable cut resstant gloves wth good grp to protect aganst sharp edges and ensure good grp. > Always use assstance f requred. Removal of carton from delvery van Recommend person lft or person wth use of sack truck. > If person s performng lft, straddle the load, tlt and place carton nto poston on truck. > Recommend secure applance onto truck wth sutable straps. > Ensure safe lftng technques are used keep back straght bend usng legs. > Keep load as close to body as possble. > If persons performng lft, ensure co-ordnated movements durng lft. > Always use assstance f requred. Carrage of carton from pont of delvery to pont of nstallaton ground floor. Recommend person lft or person wth use of sack truck. > If person s performng lft, straddle the load, tlt and place carton nto poston on truck. > Recommend secure applance onto truck wth sutable straps. > Ensure safe lftng technques are used keep back straght bend usng legs. > Keep load as close to body as possble. > If persons performng lft, ensure co-ordnated movements durng lft. > Clear the route before attemptng the lft. Installaton and mantenance nstructons ecotec plus _06

14 Installaton > If removng boler from truck straddle the load and tlt forwards to facltate secure grp. > Ensure safe lftng technques are used keep back straght bend usng legs. > Do not twst reposton feet nstead. > Take care to avod trp hazards, slppery or wet surfaces and clmbng steps and stars. > Always use assstance f requred. Carrage of carton from pont of delvery to pont of nstallaton frst or hgher floor, cellar. Recommend -person lft or person wth use of sack truck. > If person s performng lft, straddle the load, tlt and place carton nto poston on truck. > Recommend secure applance onto truck wth sutable straps. > Ensure safe lftng technques are used keep back straght bend usng legs. > Keep load as close to body as possble. > If persons performng lft, ensure co-ordnated movements durng lft. > Avod upper body/top heavy bendng - do not lean forward/sdeways. > Clear the route before attemptng the lft. > If removng boler from truck straddle the load and tlt forwards to facltate secure grp. > Ensure safe lftng technques are used keep back straght bend usng legs. > Do not twst reposton feet nstead. > Take care to avod trp hazards, slppery or wet surfaces and clmbng steps and stars. > Always use assstance f requred. Carrage of carton from pont of delvery to pont of nstallaton roofspace. > Recommend -person lft. > Ensure co-ordnated movements durng lft. > Avod upper body/top heavy bendng - do not lean forward/sdeways. > Clear the route before attemptng the lft. > Take care to avod trp hazards, slppery or wet surfaces and clmbng steps and stars. > When transferrng applance nto roofspace, recommend person to be n roofspace to receve the applance and other person to be below to pass up and support applance. > Ensure safe lftng technques are used keep back straght bend usng legs. > Keep load as close to body as possble. > Always use assstance f requred. > It s assumed safe access, floorng and adequate lghtng are provded n the roof space. > It s recommended a rsk assessment of the roof space area be carred out before movng the applance nto the area to take nto account access, stablty of floorng, lghtng and other factors, and approprate measures taken. Unpackng of applance from carton. > Recommend persons unpack applance from carton. > Always keep workng area clear. > Recommend straps and open carton flaps, then remove tems from the top ncludng the polystyrene packng and remove carton by sldng up over the boler. > Ensure safe lftng technques are used keep back straght bend usng legs. > Keep load as close to body as possble. > Always use assstance f requred. > Dspose of packagng n a responsble manner. > Recommend wear sutable cut resstant gloves wth good grp to protect aganst sharp edges and ensure good grp when handlng applance outsde packagng. Postonng of Applance for Fnal Installaton no obstructons. > If applance weght s over 5 kg always use persons to move where practcal. > Ft bracket securely onto wall before lftng applance nto poston. > Obtan frm grp on front and sdes of applance, lft upwards, ensure stable balance acheved and lft upwards to poston n place on bracket. > Ensure safe lftng technques are used keep back straght bend usng legs - when lftng load from floor level. > Do not twst reposton feet nstead. > Keep boler as close as possble to body throughout lft to mnmse stran on back. > Ensure co-ordnated movements to ensure equal spread of weght of load. > Always use assstance f requred. > Recommend wear sutable cut resstant gloves wth good grp to protect aganst sharp edges and ensure good grp when handlng applance. Postonng of Applance for Fnal Installaton above worktop, foreseeable obstructons etc. > If applance weght s over 5 kg always use persons to move where practcal. > Ft bracket securely onto wall before lftng applance nto poston. > Obtan frm grp on front and sdes of applance, lft upwards, onto worktop f practcable. > Ensure stable balance acheved and lft upwards to poston n place on bracket. > If persons postonng onto bracket obtan frm grp at front and sdes/base of boler. > Ensure coordnated movements durng person lfts to ensure equal spread of weght of load. > Ensure safe lftng technques are used keep back straght bend usng legs - when lftng load from floor level. > Do not twst reposton feet nstead. > Keep boler as close as possble to body throughout lft to mnmse stran on back. > Avod upper body/top heavy bendng - do not lean forward/sdeways. Installaton and mantenance nstructons ecotec plus _06

15 Installaton > Always use assstance f requred. > Recommend wear sutable cut resstant gloves wth good grp to protect aganst sharp edges and ensure good grp when handlng applance. Postonng of Applance for Fnal Installaton wthn compartment etc. restrctng nstallaton. > If applance weght s over 5 kg always use persons to move where practcal. > Ft bracket securely onto wall before lftng applance nto poston. > Obtan frm grp on front and sdes of applance, lft upwards, onto worktop f practcable. > Ensure stable balance acheved and lft upwards to drop nto place onto bracket. > If persons postonng onto bracket obtan frm grp at front and sdes/base of boler. > Ensure coordnated movements durng person lfts to ensure equal spread of weght of load. > If person postonng onto bracket recommend obtan frm grp supportng base of boler. > Ensure safe lftng technques are used keep back straght bend usng legs - when lftng load from floor level. > Do not twst reposton feet nstead. > Keep boler as close as possble to body throughout lft to mnmse stran on back. > Always use assstance f requred. > Recommend wear sutable cut resstant gloves wth good grp to protect aganst sharp edges and ensure good grp when handlng applance. Postonng of Applance for Fnal Installaton n roof space restrctng nstallaton. > If applance weght s over 5 kg always use persons to move where practcal. > Obtan frm grp on front and sdes of applance, lft upwards, ensure stable balance acheved and lft upwards to drop nto place onto bracket. > If persons postonng onto bracket obtan frm grp at front and sdes/base of boler. > Ensure co-ordnated movements durng person lfts to ensure equal spread of weght of load. > If person postonng onto bracket recommend obtan frm grp supportng base of boler. > Ensure safe lftng technques are used - keep back straght bend usng legs - when lftng load from floor level. > Do not twst reposton feet nstead. > Keep boler as close as possble to body throughout lft to mnmse stran on back. > Always use assstance f requred. > Recommend wear sutable cut resstant gloves wth good grp to protect aganst sharp edges and ensure good grp when handlng applance. > It s recommended a rsk assessment of the roof space area be carred out before movng the applance nto the area to take nto account access, stablty of floorng, lghtng and other factors, and approprate measures taken.. Requrements for the nstallaton ste.. Requred mnmum clearances/nstallaton clearances > When usng accessores, observe the mnmum clearances/nstallaton clearances ( fg..). C A B. Recommended mnmum clearances/nstallaton clearances Key A 65 mm (ar/flue gas duct Æ 60/00 mm) 6 mm (ar/flue gas duct Æ 80/5 mm) B 80 mm C 5 mm; optmum approx. 50 mm 500 mm n front of the boler to enable easy access for servcng (may be provded by an openng door). Clearance at the sde s not requred, but the sde panels can also be removed f there s adequate sde clearance (at least approx. 50 mm) n order to facltate mantenance or repar work ( secton..8). It s not necessary to ensure suffcent clearance between the boler and combustble materals or components as the temperature of the boler wll always be less than the maxmum permssble temperature of 85 C due to ts nomnal heat output. C Installaton and mantenance nstructons ecotec plus _06 5

16 Installaton.. Usng nstallaton templates An nstallaton template s suppled wth the boler to ad wall mountng. The template shows the followng: The poston of the fxng holes for the hangng bracket. The poston of the connectons. The poston of the wall breakthrough of the ar/flue gas duct. Poston the nstallaton template vertcally over the nstallaton ste. > Attach the template to the wall, usng tacks for example. > Mark the drll holes for the hangng bracket on the wall. > If necessary, mark the poston for the wall breakthrough for the ar/flue gas duct. > Remove the nstallaton template from the wall. > Drll holes Æ 0 mm for the hangng bracket n the wall. > If necessary, cut the wall breakthrough for the ar/flue gas duct. 6 Installaton and mantenance nstructons ecotec plus _06

17 Installaton.5 Dmenson drawng and connecton measurements A B Connecton measurements n mm Key Wall breakthrough for ar/flue gas duct Hangng bracket Heatng flow (Æ x.5) Hot water connecton (Æ 5 x.5), only for VUW bolers 5 Gas connecton (Æ 5 x.5; ecotec 87: Æ x.5) 6 Cold water connecton (Æ 5 x.5), only for VUW bolers 7 Heatng return (Æ x.5) 8 Ar/flue gas duct connecton 9 Condensate sphon 0 Condensate dscharge connecton, Æ 9 mm Heatng expanson relef valve dscharge ppe connecton, Æ 5 mm Dmenson B ecotec plus nstallaton depth [mm] 6 (VU GB 6/5-5) 65 (VU GB 56/5-5) 68 (VU GB 86/5-5) 8 6 (VU GB 6/5-5) 8 (VUW GB 6/5-5) 8 (VUW GB 6/5-5) 60 (VU GB 06/5-5) 7 67 (VU GB 76/5-5) (VUW GB 76/5-5).5 Dmenson B for nstallaton depth on VU and VUW bolers Mnmum dmenson from wall bracket to center lne of ar/flue gas duct wall breakthrough Dmenson A [mm] 60/00 wth elbow 87, PP 75 80/5 wth elbow 87, PP. Dmenson A for ar/flue gas duct wall breakthrough wth VU and VUW bolers Installaton and mantenance nstructons ecotec plus _06 7

18 Installaton.6 Wall-mountng the boler.7 Removng/fttng the front casng a Danger! Rsk of death f the load-bearng capacty of the fxng elements used s nsuffcent! If the fxng elements or wall do not have suffcent load-bearng capacty, the boler can come loose and fall down. Ths may also cause leaks n the gas lne, whch s potentally fatal. > When fttng the boler, ensure that the fxng elements and the wall have a suffcent load-bearng capacty. > Check the qualty of the wall..6 Removng the front casng.5 Wall-mountng the boler > Mount the hangng bracket () on the wall usng the wall plugs and screws () provded wth the unt. > Hang the boler () on the hangng bracket from above usng the hangng bracket. Removng the front casng > Loosen the screw () on the bottom of the boler usng a screwdrver or small spanner. > Push n both retanng clps () on the bottom of the boler so that the front casng s released. > Pull the front casng forwards usng the bottom edge. > Lft the front casng upwards from the bracket. Fttng the front casng > Place the front casng on the upper brackets. > Push the front casng onto the boler so that untl both retanng clps () snap nto place at the front casng. > Fasten the front casng by screwng n the bolt () on the undersde of the boler. 8 Installaton and mantenance nstructons ecotec plus _06

19 Installaton.8 Removng/fttng the sde panel You can also remove a sde panel for nstallaton or mantenance purposes. b Cauton. Rsk of damage caused by mechancal tenson. Removng both sde panels may cause mechancal dstorton n the boler, whch can cause damage to the ppng and potentally result n leaks. > Always only remove one sde panel, never both sde panels at the same tme. > Fold the electroncs box (.) forwards. > Unscrew the two screws (.) from the top and bottom of the sde panel. > Hold onto the sde panel (.) when dong ths. > Swvel the sde panel outwards and remove t from below by pullng t downwards (.). > Install the sde panel n reverse order Removng/fttng the sde panel b Cauton Rsk of damage to the sde panel. Unscrewed sde panels that are merely suspended from the back wall can fall down. > Hold onto the sde panel when you are unscrewng t, and always remove t from the boler. Installaton and mantenance nstructons ecotec plus _06 9

20 5 Gas nstallaton 5 Gas nstallaton 5. Connectng the gas ppe The work descrbed n ths secton must only be carred out by a competent person. 5. Preparng for nstallaton a Danger! Rsk of death from ncorrectly nstalled gas system! An ncorrect gas nstallaton can result n leaks and an exploson. > Durng nstallaton, the legal drectves and the local regulatons for gas supply companes must be observed. a Danger! Rsk of death from ncorrectly nstalled gas system! Tenson n the gas lne can result n leaks or an exploson. > Make sure there are no stresses n the gas lnes when t s nstalled. b Cauton. Rsk of damage caused by ncorrect gas nstallaton. Excess test pressure or operatng pressure can cause damage to the gas valve. > When the entre gas nstallaton s tested for leaks, the maxmum pressure at the gas valve must not exceed 0.75 kpa (75 mbar). 5. Fttng the gas connecton (example: VUW boler) > Make the gas connecton as shown. b Cauton. Rsk of damage caused by contamnated lnes. Foregn bodes such as weldng remnants. sealng resdue or drt n the connecton lnes for gas can cause damage to the boler. > Blow the gas lne clean pror to nstallaton. b Cauton. Rsk of damage caused by usng the wrong gas type. Usng the wrong gas type can cause a fault shutdown on the boler. Furthermore, gnton and combuston nose may occur n the boler. > Only use propane gas for propane-fred bolers n accordance wth BS 50: Part (987). 0 Installaton and mantenance nstructons ecotec plus _06

21 Hydraulc nstallaton 6 6 Hydraulc nstallaton The work descrbed n ths secton must only be carred out by a competent person. 6. Preparng for nstallaton a Danger! Rsk of death caused by an ncorrectly nstalled system! Heatng water that leaks from the dscharge ppe of the expanson relef valve can cause severe burns. > Install the expanson relef valve and ts dscharge ppe work termnaton ensurng that there s no danger to persons n or about the buldng. Ths may be outsde or to a sutable open dran n the nstallaton room. > Make sure that the dran s vsble. b Cauton. Rsk of damage caused by contamnated lnes. Foregn bodes such as weldng remnants, sealng resdue or drt n the water lnes can cause damage to the boler. > Flush the heatng nstallaton thoroughly pror to nstallaton. b Cauton. Rsk of damage from corroson. If non-dffuson-tght plastc ppes are used n the heatng nstallaton, ths may cause ar to enter the heatng water and corroson of the heat generator crcut and the boler. > If usng non-dffuson-tght plastc ppes n the heatng nstallaton, separate the system by nstallng an external heat exchanger between the boler and the heatng nstallaton. a Danger! Rsk of scaldng and/or damage due to ncorrect nstallaton leadng to leakng water. Stresses n the supply lne can cause leaks. > Make sure there are no stresses n the supply lnes when they are nstalled. b Cauton. Rsk of damage caused by heat transfer when solderng. Heat that s transferred durng solderng can cause damage to the seals n the servce valves. > Do not solder the connecton peces f the connecton peces are screwed to the servce valves. Seals made of rubber-lke materals may be subject to plastc deformaton, whch can lead to pressure losses. We recommend usng seals made of a paste-lke fbre materal. The Vallant ecotec boler s equpped wth a 0 l expanson vessel wth a gas-sde fllng pressure of MPa (0.75 bar), whch s sutable for a closed heatng system wth a maxmum water volume of 00 ltres. > Before nstallng the boler, check whether the volume of the nstalled expanson tank s suffcent. > If the volume of the expanson vessel s nsuffcent, then nstall an addtonal expanson vessel connected as close to the boler as possble nto the boler return ppe. When usng an external expanson vessel together wth a VUW boler, t s advsable to nstall a non-return valve n the outlet (boler flow) or take the nternal expanson vessel out of servce. Otherwse, the warm start functon may be more frequently actvated because of backflow, whch causes unnecessary energy loss. Vessel volume (n l) Intal system pressure (n bar).0.5 Expanson relef valve settng 0. (.0) (n MPa (bar)) Wth system volumes greater than 00 l, multply the volume by the adjacent factor. 6. Sze of an addtonal expanson vessel Installaton and mantenance nstructons ecotec plus _06