Vaillant ecoTEC exclusive 832 Installation And Maintenance Instructions Manual
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Summary of Contents for Vaillant ecoTEC exclusive 832
- Page 1 Installation and maintenance instructions For the heating engineer Installation and maintenance instructions ecoTEC exclusive ecoTEC exclusive 832 ecoTEC exclusive 838 GB, IE...
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Page 2: Table Of Contents
8.3.2 Cleaning the heat exchanger ........ 45 timer to the connection rail ........22 Checking the burner ..........45 5.10.5 Optional plug-in timers by Vaillant .......23 8.4.1 Thermo-Kompaktmodul einbauen ....... 45 5.10.6 Wiring diagrams ............24 Maintaining the secondary heat exchanger ..46 Cleaning the condense trap ........47... - Page 3 Replacing fan or gas fittings ......... 56 10.4 Replacing primary heat exchanger ......57 10.5 Replacing electronics and display ......57 Vaillant service ............58 Recycling and disposal ..........59 Technical data ............60 Appendix ..................61 Installation and maintenance instructions ecoTEC exclusive 0020017768_07...
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Page 4: Notes On The Documentation
Notes on the documentation Notes on the documentation Validity of the manual The following information is intended to help you This installation manual applies exclusively to units with throughout the entire documentation. the following part numbers: Further documents apply in combination with this instal- –... -
Page 5: Gas Council Numbers
Notes on the documentation Vaillant Ltd. supports the Benchmark Initia- tive. You will find the Benchmark Logbook on the last page of this instruction manual. It is very important that this document be filled out properly when installing, commissioning and handing-over to the operator of the installation. -
Page 6: Description Of The Appliance
Description of the appliance Description of the appliance Design Fig. 2.1 Functional elements of ecoTEC exclusive Legend: Expansion vessel 8 Aqua-Sensor 2 Air intake pipe 9 Electronics box 3 Burner assembly 10 Pump 4 Ignition electrode 11 Auto air vent 5 Gas Valve 12 Pressure sensor 6 Diverter valve... -
Page 7: Safety
Safety damage to the unit and other property in the event of improper use or use for which it is not intended. The Vaillant ecoTEC exclusive units mentioned in these instructions may only be installed and operated in con- Warnings junction with the accessories listed in the associated air/ flue gas duct installation manual (see section “Other... - Page 8 Safety What to do in an emergency if you smell gas Maintaining operation in the event of a power cut A malfunction may mean that gas is leaking and there Your competent person connected your gas-fired wall- may be a risk of poisoning or explosion. If there is a hung boiler to the power mains during installation.
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Page 9: General Requirements
Safety General requirements BS. 4814: Specification for: Expansion vessels using an internal diaphragm, for sealed hot water heating sys- tems. BS. 5440: Installation and maintenance of flues and 3.4.1 Preliminary remarks ventilation for gas appliances of rated input not exceed- ing 70 kW net (1st, 2nd and 3rd family gases). -
Page 10: Assembly
Assembly Assembly 4.1.1 Transporting the appliance The Vaillant ecoTEC exclusive is delivered Important: pre-assembled in a package unit. With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the rec- ommended weight for a one man lift. - Page 11 Assembly Carriage of carton from point of delivery to point of Unpacking of appliance from carton. > Recommend 2 persons unpack appliance from carton. installation – first or higher floor, cellar. > Recommend 2-person lift or 1 person with use of sack >...
- Page 12 Assembly Positioning of Appliance for Final Installation – above Positioning of Appliance for Final Installation – in worktop, foreseeable obstructions etc. roof space restricting installation. > If appliance weight is over 25 kg always use 2 persons > If appliance weight is over 25 kg always use 2 persons to move where practical.
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Page 13: Dimensioned Drawing And Dimensions For Connection
Assembly Dimensioned drawing and dimensions for connection Ø 20 Ø 20 Ø 20 100 100 Fig. 4.2 Dimensions for connection (mm) Legend: Flue connection 2 Mounting bracket 3 Heating return 4 Cold water connection 5 Gas connection 6 Hot water connection 7 Heating flow Installation and maintenance instructions ecoTEC exclusive 0020017768_07... -
Page 14: Installation Site
Assembly Installation site Caution! Possible material damage due to an unsuit- The site of erection of the boiler should allow proper able installation site! connection of the air/exhaust ducting. In addition, there The appliance may be damaged by frost, should be adequate room for maintenance work and air aggressive vapours or dust. -
Page 15: Mounting The Appliance
Assembly The boiler must be mounted on a flat, vertical wall sur- Removing the front case face which is large enough for the boiler including the required minimum space requirement and the space required for assembly (Fig. 4.3). These are shown on the mounting template supplied with the boiler, and are: –... -
Page 16: Installation
G20 natural gas and can be converted for observed. use with G31 propane gas by the Vaillant Service or a competent person approved at the time by the Health and Safety executive and in accordance with the gas... -
Page 17: Connecting Hot And Cold Water Pipes
Before connecting the heating circuit to the boiler, all outlet connection (5) of the appliance. pipework and radiators must be thoroughly flushed to The Vaillant ecoTEC exclusive is set in the factory to a remove any installation debris. > Connect the central heating flow and return service nominal water quantity of 11.6 l/min. -
Page 18: Pressure Relief Valve
Vaillant boilers are certified only with genuine Vaillant air/flue gas duct. The use of other accessories can cause personal injury and material damage as well as operating faults.. > Only use genuine Vaillant air/flue gas duct. -
Page 19: 5.6.2 Optional 125 Mm Flue Pipe
Installation 5.6.2 Optional 125 mm flue pipe A concentric flue pipe having an outside diameter of 125 mm is available, which can be extended to a length of up to 21 m. You can also get a vertical system. Further information can be obtained from the installation instructions for the flue pipe. -
Page 20: Air Connection
Installation BS 5440–1: We recommend that the terminal of a Condensate discharge fan-assisted flue pipe system be positioned as follows: At least 2 m from an opening in the building directly opposite, and so that the combustion products do not flow out at right angles to a boundry. -
Page 21: Connecting The Unit To The Electricity Supply
Installation Connection into the domestic waste water drain 5.10.2 Connecting controllers, accessories and pipe (e.g. a sink or washing machine) with an exter- external installation components nal termination. The condensate drain pipe should have a minimum The following controllers, accessories and installation diameter of 22 mm, without length restriction, and components can be connected to the ecoTEC exclusive also be fitted with a siphon (3) having a connection... -
Page 22: External Electrical Controllers (Non Ebus)
Installation 5.10.4 Details for the connection of an external timer to the connection rail - + 7 8 9 3 4 5 20 VDC (DO NOT USE 7, 8, 9 IN UK!) ROOM SWITCH 3 A FUSE THERMOSTAT CONTACTS MAINS - + 7 8 9 3 4 5 SUPPLY... -
Page 23: 5.10.5 Optional Plug-In Timers By Vaillant
Installation 5.10.5 Optional plug-in timers by Vaillant Further details for the connection can be found in the relevant instructions of the accessories. The cover on the connection box should be replaced after all the elec- trical connections have been made. The cover is secured with two clips. -
Page 24: 5.10.6 Wiring Diagrams
Installation 5.10.6 Wiring diagrams Connection eBUS accessories Cable harness compact thermal module PWM pump Connection accessories module Diagnosis via eBUS, vrnetDIALOG External sensor External flow or return sensor Cable harness hydraulics Connection for external eBUS controller Caution: Do not connect mains voltage! Room thermostat 24 V: Danger of damage to Connection 7, 8 and 9... - Page 25 Installation Return temperature Flow temperature Ignition electrode sensor (NTC) sensor (NTC) X 20/5 red X 20/7 black X 20/8 blue X 20/7 black Plug connection Gas valve X 20/16 blue (Earth) X 20/4 grey (PWM) X 20/3 black (Hall signal) X 20/18 red (24 VDC) X 20/17 red (24 VDC) X 20/9 blue (Earth)
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Page 26: Start-Up
> 20 l/kW material damage. However no incompatibility with 20 l/kW > 50 l/kW < 50 l/kW Vaillant units has been detected with proper use of the mol/m mol/m mol/m following products over a long period. > Follow the instructions provided by the manufacturer No requirement or ... -
Page 27: Filling And Venting The Unit And The Heating System
Start-up Heating water charac- Unit Low-salt Saline teristics Electrical conductivity S/cm 100 100 - 1500 at 25 °C Appearance free of sedimentary materials pH value at 25 °C 8.2 - 10.0 8.2 - 10.0 0.1 0.02 Oxygen mg/l 1) For aluminium and aluminium alloys, the pH range is restricted from 6.5 to 8.5. -
Page 28: First Flushing Of The System
Start-up Proceed as follows to fill the system: 6.1.4 Filling and bleeding from the hot water side > Open all radiator valves on the system. > Ensure that the boiler CH service valves are open. > Open the cold water stop cock on the appliance on >... -
Page 29: Checking The Gas Setting
Start-up Checking the gas setting 6.2.1 Checking for tightness of the flue gas installation and flue gas recirculation > Check the integrity off the flue gas installation Caution! Malfunctions or reduction in working life of according to TB 200. > Should the flue gas installation be longer than 2 m we the boiler! If the boiler version does not correspond to strongly recommend to check the system for flue gas... -
Page 30: 6.2.2 Checking The Gas Flow Rate
> If the measured gas flow rate lies outside the toler- ance limits specified in Table 6.3, do not operate the boiler and inform the Vaillant Service Solutions (0870 6060 777). If the measured gas flow rate is within the tolerance lim- its shown in Table 6.3, then proceed as follows:... - Page 31 If the gas inlet working pressure at the reference test point (1) is not within the permissible range and you cannot correct the failure, notify the gas supply com- pany or the Vaillant Service Solutions team and proceed as follows: > Take the boiler out of operation by –...
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Page 32: Checking The Equipment Function
> Hand the unit over to the user. Fig. 6.8 Display during heating mode The Vaillant ecoTEC exclusive has status codes which indicate the operating condition of the appliance in the As soon as there is a heat demand, the appliance goes display. -
Page 33: Handing Over The Appliance To The Owner
It is strongly recommended that a maintenance contract be taken out to ensure regular maintenance. Further information can be obtained from Vaillant Service Solutions (0870 6060 777). > Enter the operating pressure of the central heating... -
Page 34: Adapting The Appliance To The Heating System
Adapting the appliance to the heating system Adapting the appliance to the In the diagnostic mode, you can change the various parameters required to match the boiler to the heating heating system system. Table 7.1 shows only those diagnostic points where modi- The ecoTEC exclusive units are fitted with a digital infor- fications are possible. -
Page 35: Overview Of The Settable Installation Parameters
Default Appliance-specific Display Meaning Adjustable parameters setting setting Heating partial load ecoTEC exclusive 832 27 kW 22 kW ecoTEC exclusive 838 30 kW 27 kW Pump overrun time for heating operation 2 - 60 min 5 min (starts after completion of heat demand) Max. -
Page 36: Setting The Pump Overrun Time
Adapting the appliance to the heating system 7.2.2 Setting the pump overrun time The burner is electronically locked for a specific time after each time it is switched off (“re-start interlock”) to The pump overrun time for the heating operation is set avoid frequent switching on and off of the burner in the factory to a value of 5 minutes. -
Page 37: Determination Of The Maintenance Interval/ Maintenance Display
Table 7.3; these values correspond to an approximate operating time for the appliance of one year. Fig. 7.2 Characteristic pump line for ecoTEC exclusive 832 and The operating hours can be set in steps of ten from 0 to 3000 h. -
Page 38: Adjusting The Bypass Valve
Adapting the appliance to the heating system Adjusting the bypass valve The appliances have a bypass valve. The pressure can be adjusted between 170 and 350 hPa (mbar). Approx. 250 hPa (mbar) is preset (mid-position). The pressure changes by approx. 10 hPa (mbar) each time the adjusting screw is rotated. -
Page 39: Inspection And Maintenance
Safety Executive. Work must be in accord- You must carry out an annual inspection of the ance with regulations introduced in 1998 Vaillant ecoTEC. governing the safety of gas installations It is possible to perform a quick, accurate inspection (installation and use). -
Page 40: General Inspection And Maintenance Instructions
Safety instructions instructions To ensure the faultless operation, long term availability Danger! of all functions and long working life of your Vaillant Risk of death from electric shock through boiler and to prevent modifications to the approved contact with live connections! -
Page 41: Concentration
Inspection and maintenance > Carry out a functional check of the boiler 8.1.3 Checking the CO concentration (see Section 6). > Always check earth continuity, polarity and resistance to earth with a multimeter after any service work and Checking/adjustment of the CO concentra- after replacing any electrical component. -
Page 42: Concentration (Or The Air Ratio)
Inspection and maintenance 8.1.4 Adjusting the CO concentration (or the air Settings Natural gas (H) Propane Unit Tolerance Tolerance ratio) after 5 minutes full 9.2 1,0 10.2 0,5 Vol.–% load mode with boiler front casing closed Danger! after 5 minutes full 9.0 ... -
Page 43: Inspection And Maintenance Work Steps
Inspection and maintenance 8.1.5 Inspection and maintenance work steps Column 2 Maintenance Column 1 must be carried Inspection must No. Activity out at regular be carried out intervals – but each year no longer than 5 years Check the air flue gas installation for leaks and for proper fixation and ensure it is not blocked or damaged and is fitted correctly, complying with the relevant installation instructions. -
Page 44: Filling/Draining The Heating Installation
> Pull the two plugs of the ignition and grounding lines starting work. off the ignition electrode (4). > Only ecoTEC exclusive 832: Pull the cable plug off the fan motor and the cable off the gas fitting. Installation and maintenance instructions ecoTEC exclusive 0020017768_07... -
Page 45: 8.3.2 Cleaning The Heat Exchanger
Inspection and maintenance Only ecoTEC exclusive 838: Open the mains coupling Checking the burner to the fan. > Undo the five nuts (2). > Pull the entire compact thermal module (5) off the heat exchanger. > After dismantling the burner and the heat exchanger, check for damage and dust and, if necessary, clean the components as described below. -
Page 46: Maintaining The Secondary Heat Exchanger
> Insert the ignition cable and the earth cable of the ignition electrode (4). > Only ecoTEC exclusive 832: Insert the cables on the fan motor and the cable on the gas fitting. Only eco- TEC exclusive 838: Close the mains coupling to the fan. -
Page 47: Cleaning The Condense Trap
Inspection and maintenance Cleaning the condense trap Checking the expansion vessel Danger! Risk of poisoning due to escaping flue gas! Flue gases may escape through the empty condensate siphon. > After cleaning, fill the condensate siphon with water to prevent flue gas from escap- ing through the siphon. -
Page 48: Checking The Connection Pressure (Gas Inlet Working Pressure)
Inspection and maintenance Checking the connection pressure (gas inlet working pressure) To check the connection pressure proceed as described in Section 6.2.3. 8.8.1 Checking CO content and adjusting if necessary To check the air figure proceed as described in Section 8.1.3. Test operation Always perform the following checks after completing any inspection/maintenance task:... -
Page 49: Troubleshooting
Troubleshooting Troubleshooting Display Meaning Heating mode If you wish to contact the Vaillant Service No heat required Team, refer to the error code displayed (F.xx) Fan start and the appliance status (S.xx) if possible. Water pump flow Ignition Burner mode... -
Page 50: Diagnosis Codes
Troubleshooting 9.1.2 Diagnosis codes In the diagnosis mode, you can change certain para- meters or display more information. The diagnosis information is divided into two diagnosis levels. The 2nd diagnosis level can be reached only after entering a password. Caution! Possible material damage caused by incor- rect handling! Improper settings in the 2nd diagnostic level... - Page 51 Digitalised ionisation voltage Display range 0 to 102, >80 no flame, <40 good flame display External temperature (with weather-controlled d.47 actual value in °C Vaillant controller) d.67 Remaining burner locking time in minutes d.76 Appliance variant (device specific number) 00 to 99 1 = identified, 0 = unidentified (eBUS Address ...
- Page 52 Troubleshooting Display Meaning Display value/adjustable value target value internal pump in % - possible settings: d.14 Pump speed target value 0=Auto, 1=53, 2=60, 3=70, 4=85, 5=100 % (Factory setting: Auto) d.17 Heating flow/return regulation changeover 0 = flow, 1 = return (factory setting: 0) d.18 Pump mode (return flow) 0 = overrun 1 = continuous, 2 = winter (Factory setting: 0)
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Page 53: Error Codes
Troubleshooting 9.1.3 Error codes The error codes displace all other displays when errors occur. If many errors occur simultaneously, the relevant error codes are displayed alternately for approx. 2 seconds each. 9.1.4 Error memory You can exit the error memory display as follows: >... -
Page 54: Test Programs
Troubleshooting Code Meaning Cause F.71 Constant value feed NTC Feed NTC faulty F.72 Flow and/or return sensor fault Flow and/or return sensor is faulty (tolerance too great) Signal water pressure sensor in the wrong range Line to water pressure sensor is interrupted or has F.73 (too low) a short-circuit to 0V or water pressure sensor faulty... -
Page 55: Replacing Components
Replacing components 10 Replacing components 10.2 Replacing burner The work specified below in this section should only be fitted by a competent person with Health and Safety Danger! Executive approval in accordance with the Gas Safety Risk of personal injury and/or material (Installation and Use) Regulations 1998. -
Page 56: Replacing Fan Or Gas Fittings
> Release the gas supply pipe (4) on the gas valve. > Pull out the plug from the gas valve. > Only ecoTEC exclusive 832: Pull out the plug from the fan printed circuit board. Only ecoTEC exclusive 838: Open the coupling of the mains input. -
Page 57: Replacing Primary Heat Exchanger
Fig. 10.4 Fig. 10.4 Replacing primary heat exchanger Appliance Number of the appliance variant > Remove the clamps (4) on the trap (3), release the ecoTEC exclusive 832 fittings on the trap and remove the trap from the pri- mary heat exchanger. ecoTEC exclusive 838 >... -
Page 58: Vaillant Service
Vaillant service Vaillant service To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agree- ment. Please contact Vaillant Service Solutions (0870 6060 777) for further details. Installation and maintenance instructions ecoTEC exclusive 0020017768_07... -
Page 59: Recycling And Disposal
Both your Valliant ecoTEC exclusive and its packaging consist mainly of recyclable raw materials. The Vaillant ecoTEC exclusive and all accessories and the packaging must not be disposed of in the household waste. Make sure that the old appliance and any acces- sories and the transport packaging are disposed of in the proper way. -
Page 60: Technical Data
Technical data 13 Technical data ecoTEC exclusive Unit Nominal heat output range P at 40/30 °C 11,0 - 29,3 12,1 - 32,4 Nominal heat output range P at 50/30 °C 10,8 - 28,7 11,9 - 31,8 Nominal heat output range P at 60/40 °C 10,5 - 27,9 11,5 - 30,9 Nominal heat output range P at 80/60 °C... -
Page 61: Appendix
Appendix Appendix Installation and maintenance instructions ecoTEC exclusive 0020017768_07... - Page 63 Installation, Commissioning and Service Record...
- Page 64 Please affix the label from the top of the boiler over this area. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statuatory rights.
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Page 65: Service Record
Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. - Page 68 Supplier Manufacturer...
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