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  4. ecoTEC plus 612
  5. Instructions For Installation And Servicing

Vaillant ecoTEC plus 612 Instructions For Installation And Servicing

Summary of ecoTEC plus 612

  • Page 1

    For the installer ecotec plus 612 ecotec plus 615 ecotec plus 618 ecotec plus 624 ecotec plus 630 ecotec plus 637 ecotec plus 824 ecotec plus 831 ecotec plus 837 ecotec pro 28 ecotec pro 24 instructions for installation and servicing ecotec wall hung room sealed fan assisted condensing boiler gb.

  • Page 2

    2 contents instructions for installation and servicing ecotec / 839592_09 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 notes on the documentation . . . . . . . . . . . . . . . . 4 1.1.1 applicable documents . . . . . . . . . . . . . . . . . . . . . . 4 1.1.2 retention o...

  • Page 3

    3 instructions for installation and servicing ecotec / 839592_09 contents 7.1.3 overview of the inspection and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 7.1.4 functional check of boiler operation . . . . . . . . . 38 7.2 servicing the bu...

  • Page 4

    4 instructions for installation and servicing ecotec / 839592_09 1 introduction 1 introduction 1.1 notes on the documentation the following information is intended to help you throughout the entire documentation. Further documents apply in combination with this instal- lation and maintenance manual....

  • Page 5

    5 instructions for installation and servicing ecotec / 839592_09 increase the flexibility. If desired, an inhibitor may be used in the system. Guidance on the use of inhibitors is contained in these instructions. All boilers have a built in diagnostic system which indi- cates the operational status ...

  • Page 6

    6 instructions for installation and servicing ecotec / 839592_09 2 boiler specifications 2.1 technical data technical data ecotec plus ecotec pro units 824 831 837 24 28 ch heat output range 80 °c flow/60 °c return 60 °c flow/40 °c return 50 °c flow/30 °c return 40 °c flow/30 °c return 6.7 – 19.0 6....

  • Page 7

    7 instructions for installation and servicing ecotec / 839592_09 technical data ecotec plus units 612 615 618 624 630 637 ch heat output range 80 °c flow/60 °c return 60 °c flow/40 °c return 50 °c flow/30 °c return 40 °c flow/30 °c return 4.9 – 12.0 5.1 – 12.3 5.2 – 12.7 5.3 – 12.9 4.9 – 15.0 5.1 – ...

  • Page 8

    8 instructions for installation and servicing ecotec / 839592_09 2.2 dimensions 24 1 20 64 2 72 0 883 12 5 100 100 440 35 35 130 180 300 ecotec plus 630: 334 ecotec plus 637, ecotec plus 837: 368 17 5 190 65 75 45 8 6 4 3 2 1 5 7 10 9 1 2 3 4 5 11 12 fig. 2.1 dimensions in mm legend: 1 heating retur...

  • Page 9

    9 instructions for installation and servicing ecotec / 839592_09 2.3 installation 1 2 3 4 6 5 7 8 9 14 13 12 10 11 fig. 2.2 function elements of combination boilers legend: 1 expansion vessel 2 air intake pipe 3 burner module 4 ignition electrode 5 fan 6 diverter valve with by-pass 7 pump 8 aqua-sen...

  • Page 10

    10 instructions for installation and servicing ecotec / 839592_09 3 general requirements 3.1 preliminary remarks for room sealed appli- ances this appliance should only be installed in conjunction with either a vaillant flue system or an alternative approved system (details of flue approval categori...

  • Page 11

    11 instructions for installation and servicing ecotec / 839592_09 1 2 3 4 7 8 6 5 fig. 3.1 contents included with delivery of ecotec plus system boilers do not remove the boiler from the polystyrene base at this stage. Item quantity description 1 1 hanging bracket 2 1 boiler 3 1 bottom cover 4 4 con...

  • Page 12

    12 instructions for installation and servicing ecotec / 839592_09 bar i f p 1 2 3 7 6 5 4 fig. 3.3 contents included with delivery of ecotec pro combi- nation boilers do not remove the boiler from the polystyrene base at this stage. Item quantity description 1 1 hanging bracket 2 1 boiler 3 2 connec...

  • Page 13

    13 instructions for installation and servicing ecotec / 839592_09 3.6 flue pipe danger! Vaillant appliances are certified only for use with genuine vaillant flue pipes. Only use genu- ine vaillant flue pipes. Malfunctions can occur if you use other accessories. These may result in damage and injury....

  • Page 14

    14 instructions for installation and servicing ecotec / 839592_09 a bcd a g h, i f j b f m l l k k g g f f e a a fig. 3.8 flue termination note vertical flues must not terminate within 600 mm of an openable window, air vent or any other ventilation opening. The flue assembly shall be so placed or sh...

  • Page 15

    15 instructions for installation and servicing ecotec / 839592_09 3.10 guide to system requirements 3.10.1 water circulation system detailed recommendations for the water circulation sys- tem are given in bs 6798 and bs 5449: part 1 (for small bore and micro bore central heating systems). Pipework n...

  • Page 16

    16 instructions for installation and servicing ecotec / 839592_09 400 300 200 100 0 0 200 400 600 800 1000 1200 1600 lift [ mbar ] volumeflow [l/h] 1800 1400 2. Step 1. Step fig. 3.10.1 pump specifications ecotec plus (except ecotec 637 and 837) 400 300 200 100 0 0 200 400 600 800 1000 1200 1600 lif...

  • Page 17

    17 instructions for installation and servicing ecotec / 839592_09 4 boiler installation sequence 4.1 transporting the appliance caution! With regards to the manual handling operations, 1992 regulations, the following lift operation exceeds the recommended weight for a one man lift. General recommend...

  • Page 18

    18 instructions for installation and servicing ecotec / 839592_09 positioning of appliance for final installation – above worktop, foreseeable obstructions etc. This appliance is deemed to be a one person lift when removed from the carton. Fit bracket securely onto wall before lifting appliance into...

  • Page 19

    19 instructions for installation and servicing ecotec / 839592_09 4.2.2 unpack the boiler to unpack the boiler, cut both plastic carton straps, open box and lift out the polystyrene top packing. Lift the cardboard box upwards. Note care should be taken not to scratch the white surface of the boiler ...

  • Page 20

    20 instructions for installation and servicing ecotec / 839592_09 4.5 installing the flue system • install the flue system (refer to the seperate air/flue duct installation instructions). 4.6 fitting the boiler • lift the boiler (3) up to the wall so that it is slightly above the hanging bracket (1)...

  • Page 21

    21 instructions for installation and servicing ecotec / 839592_09 • fit the union nut (2) and the compression olive (3) to the gas connection pipe (1) of the boiler. • fit the union nut (6) and the compression olive (5) to the pre-formed tail provided with ecotec plus appli- ances (7). • fully inser...

  • Page 22

    22 instructions for installation and servicing ecotec / 839592_09 7 d soakaway c 6 5 gulley a internal stackpipe 3 4 3 b internal discharge system 1 2 fig. 4.8 installing the condensate drain pipe (picture shows ecotec plus combination boiler) the condensate discharge pipe must terminate in a suit- ...

  • Page 23

    23 instructions for installation and servicing ecotec / 839592_09 bar 1 2 3 4 5 fig. 4.10 heating flow and return connection for ecotec pro combination boiler ecotec plus system boiler • insert a seal (1) and fit the service valves (2) to the flow and return connection of the appliance. • fit a unio...

  • Page 24

    24 instructions for installation and servicing ecotec / 839592_09 current edition of the etci (electro-technical council for ireland) rules. The boiler is supplied for connection to 230 v, ~ 50 hz supply fused at 3 a rating. Connection to the mains supply shall be made via a fused 3 pin plug to an u...

  • Page 25

    25 instructions for installation and servicing ecotec / 839592_09 4.14.3 electric board layout burner cable harness hydraulic cable harness connection for external ebus controller room thermostat 24 v: connection 7, 8 and 9 no bi-directional interface (analogue only) room thermostat 230 v/50 hz (rem...

  • Page 26

    26 instructions for installation and servicing ecotec / 839592_09 x 2 bus — + 24v 7 8 9 230v l n 3 4 5 x 20 x40 x3 1 x12 x41 electronic control box aqua sensor ecotec plus only: ntc hot water outlet fan unit ignition electrode ntc flow diverter valve gas valve assembly water pressure sensor ntc retu...

  • Page 27

    27 instructions for installation and servicing ecotec / 839592_09 x 2 bus 24v 7 8 9 — + 230v l n 3 4 5 x 20 x40 x3 1 x12 x41 electronic control box fan unit ignition electrode ntc flow gas valve assembly hot water contact c1/c2 water pressure sensor ntc return x 20/5 red x 20/7 black x 20/7 black x ...

  • Page 28

    28 instructions for installation and servicing ecotec / 839592_09 4.15 controls 4.15.1 vaillant controls and accessories controller item no. Connection vrc 400 (1-circuit controller, weather-controlled) 00 2001 0843 installation in electronics box (plug-and-play) vrt 360 (room temperature controller...

  • Page 29

    29 instructions for installation and servicing ecotec / 839592_09 4.17 frost protection the boiler has an integral frost thermostat which is designed for protection of the boiler. To protect remote or exposed parts of the heating system or property additional frost protection measures must be taken ...

  • Page 30

    30 instructions for installation and servicing ecotec / 839592_09 5 commissioning part i 5.1 preliminary electrical checks check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity. 5.2 gas supply the complete gas...

  • Page 31

    31 instructions for installation and servicing ecotec / 839592_09 the ecotec plus combination boiler will be delivered with a filling loop. • insert the double check valve (1) of the filling pipe at the cold water shutoff valve and secure the double check valve with the spring clip (2). • to fill, f...

  • Page 32

    32 instructions for installation and servicing ecotec / 839592_09 5.6 filling the condensate siphon 1 fig. 5.4 filling the condensate siphon danger! Note that if the boiler is run with an empty condensate trap there is a danger that fumes might escape into the room and cause poison- ing. For this re...

  • Page 33

    33 instructions for installation and servicing ecotec / 839592_09 5.9.2 gas inlet working pressure check the inlet pressure as described below: • remove the front case from the boiler. • close the gas shutoff valve fitted to the boiler. 1 2 fig. 5.13 checking the gas supply pressure • loosen the sea...

  • Page 34

    34 instructions for installation and servicing ecotec / 839592_09 5.10 refitting the case 1 2 fig. 5.14 refitting the case • hook the top of the front casing over the lip on the top of the boiler chassis and push the bottom of the front casing into place. • ensure the spring retaining clips (2) enga...

  • Page 35

    35 instructions for installation and servicing ecotec / 839592_09 6 functional checks (commissioning part ii) 6.1 functional checks 6.1.1 procedure after installing and checking the gas supply pressure, perform a function check before commissioning the appliance and handing over to the user. • commi...

  • Page 36

    36 instructions for installation and servicing ecotec / 839592_09 • release water from the system until the system design pres- sure of 1.0 bar is attained. (the actual reading on the digital pressure gauge should ideally be 0.5 bar plus an additional pressure corresponding to the highest point of t...

  • Page 37

    37 instructions for installation and servicing ecotec / 839592_09 always perform the following steps after completing any inspection tasks: • open the service valves in the heating flow and return and in the cold water inlet (combination boilers only). • if necessary, refill the device with cold wat...

  • Page 38

    38 instructions for installation and servicing ecotec / 839592_09 7.1.4 functional check of boiler operation • carry out a functional check of the boiler operation as previously detailed. • remove the appliance casing as detailed and operate the boiler. • inspect the burner operation through the vie...

  • Page 39

    39 instructions for installation and servicing ecotec / 839592_09 3 4 1 2 fig. 7.3 cleaning the integral condensation heat exchanger • dismantle the burner module as described under 7.2.1. Caution! Risk of damaging the primary heat exchanger! Do not attempt to loosen nor retighten the four screws (1...

  • Page 40

    40 instructions for installation and servicing ecotec / 839592_09 • reconnect the ht lead (5) and earth lead (6) to the spark electrode. • insert the cables (8) on the fan motor and the cable (7) on the gas fitting. 2 3 1 fig. 7.7 refitting the gas supply • reconnect the gas supply (3) to the gas va...

  • Page 41

    41 instructions for installation and servicing ecotec / 839592_09 • ensure the boiler ch service valves are closed. • release the pressure from the boiler. • remove valve cap from expansion vessel charge point. • check that the internal charge pressure of the expan- sion vessel is between 0.75 and 0...

  • Page 42

    42 instructions for installation and servicing ecotec / 839592_09 8.1.2 diagnostic codes display meaning heating mode (all models): s. 0 no heat demand s. 1 fan running s. 2 water pump running s. 3 ignition sequence s. 4 burner ignited s. 5 fan and pump running s. 6 fan over run s. 7 pump over run s...

  • Page 43

    43 instructions for installation and servicing ecotec / 839592_09 display meaning display value/adjustable value d. 0 heating part load adjustable heating part load in kw (factory setting: max. Output) d. 1 water pump over run time for heating mode 2 - 60 min (factory setting: 5 min) d. 2 max. Burne...

  • Page 44

    44 instructions for installation and servicing ecotec / 839592_09 second diagnostic level • as described above in the first diagnostic level, scroll through the diagnostic number d.97. • change the displayed value to 17 (password) and press the “i” button. You are now in the second diagnostic level ...

  • Page 45

    45 instructions for installation and servicing ecotec / 839592_09 display meaning display value/adjustable value d.78 storage charging temperature limit (target flow tem- perature in storage mode, system boilers only) adjustment range in °c 55 to 90 (factory setting: 80) d.80 heating operating hours...

  • Page 46

    46 instructions for installation and servicing ecotec / 839592_09 code meaning cause f. 0 flow–ntc open circuit ntc broken, ntc cable broken, defective connection at ntc, defective connection at electronics f. 1 return–ntc open circuit ntc broken, ntc cable broken, defective connection at ntc, defec...

  • Page 47

    47 instructions for installation and servicing ecotec / 839592_09 8.4 test programs special functions can be triggered on the appliances by activating various test programs. These programs are given in detail in the table 8.5. • the test programs p.0 to p.6 will be started when “power on” is turned ...

  • Page 48

    48 instructions for installation and servicing ecotec / 839592_09 • remove the air intake pipe (fig. 7.1, pos. 2). • loosen the gas supply pipe on the gas fitting (fig. 7.2, pos. 3). 1 3 2 4 fig. 9.2 dismantling fan with gas fitting • pull out the plug (4) from the gas valve. • pull out the plug (3)...

  • Page 49

    49 instructions for installation and servicing ecotec / 839592_09 9.5 replacing primary heat exchanger danger! Before replacing the component, comply with the safety instructions in section 9.1. 1 2 3 4 fig. 9.5 replacing primary heat exchanger • disconnect the appliance from the mains as described ...

  • Page 50

    50 instructions for installation and servicing ecotec / 839592_09 appliance device specific number ecotec plus 612 0 ecotec plus 615 1 ecotec plus 618 2 ecotec plus 624 3 ecotec plus 630 4 ecotec plus 637 5 ecotec plus 824 6 ecotec plus 831 7 ecotec plus 837 8 ecotec pro 24 7 ecotec pro 28 0 table 9...

  • Page 51

    51 instructions for installation and servicing ecotec / 839592_09 appendix appendix.

  • Page 52

    Benchmark gas boiler commissioning checklist.

  • Page 56

    839592_09 gb 05 2008.