Vaillant ecoTEC plus 806 VU GB 806/5-5, Installation And Maintenance Instructions Manual

Page 1: ...maintenance instructions ecoTEC plus VU GB 5 5 GB IE Installation and maintenance instructions Publisher manufacturer Vaillant GmbH Berghauser Str 40 D 42859 Remscheid Tel 49 21 91 18 0 Fax 49 21 91...

Page 2: ...ng installation 20 7 12 Flushing the heating installation for the first time cold 21 7 13 Filling the condensate trap 21 7 14 Checking and adjusting the gas ratio setting 21 7 15 Checking leak tightne...

Page 3: ...l start up checklist 45 G 1 Initial start up checklist 45 H Commissioning Checklist 48 I Opening of the flue pipe 51 I 1 Positioning of the opening of a fan supported flue gas guiding 51 I 2 Text from...

Page 4: ...tion and main tenance conditions listed in the instruc tions Intended use also covers installation in ac cordance with the IP class Any other use that is not specified in these instructions or use bey...

Page 5: ...ces re quired for correct installation Install the necessary safety devices in the system Observe the applicable national and inter national laws standards and guidelines 1 3 8 Risk of injury during t...

Page 6: ...lead to corrosion on the product and in the air flue pipe Ensure that the supply of combustion air is always free of fluorine chlorine sulphur dust etc Ensure that no chemical substances are stored a...

Page 7: ...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 lations The Benchmark Checklist can be used to demon...

Page 8: ...e total overpressure Tmax e g 85 C Max flow temperature 230 V 50 Hz Electric connection Information on the identification plate Meaning e g 260 W Max electrical power consumption IP e g X4D Level of p...

Page 9: ...e is not required however you can also remove the side sections if there is sufficient space at the side approx 200 mm in order to facilitate maintenance or re pair work Where units are installed in c...

Page 10: ...n site 1 1 Install the hanging bracket 1 on the wall 2 Suspend the product on the hanging bracket from above using the suspension bracket 4 8 Removing installing the front casing 4 8 1 Removing the fr...

Page 11: ...area 4 Install the upper casing Page 10 5 Fold up the electronics box 5 Installation Danger Risk of explosion or scalding caused by incorrect installation Stresses in the supply line can cause leaks M...

Page 12: ...l damage due to heat trans fer during soldering Only solder connection pieces if the con nection pieces are not yet screwed to the service valves The product should be connected using a Vaillant pump...

Page 13: ...are not exceeded in the pip ing Select the plate heat exchanger according to output Depending on your choice of pump group the following re maining feed heads are available in the unit supply Power De...

Page 14: ...vant section 5 2 6 Connecting the expansion relief valve Note The product is delivered with a 6 bar expansion relief valve which must be installed on the product and must be guided to a secure but vis...

Page 15: ...tronics box 1 forward 3 Undo the clips 3 from the brackets 4 Fold up the cover 2 5 4 1 2 Closing the electronics box 1 Close the cover 2 by pushing downwards on the elec tronics box 1 2 Ensure that al...

Page 16: ...dy this if necessary 10 Plug the ProE plug into the associated PCB slot 11 Secure the cable in the electronics box using the strain reliefs 5 4 4 Connecting the pump group X18 230 V X22 1 Open the ele...

Page 17: ...hen operating with liquid gas 5 4 8 Actuating the circulation pump according to requirements 1 Connect the wiring in the same way as described in Connecting controllers to the electronic system Page 1...

Page 18: ...tary water Treating the filling and supplementary water Observe all applicable national regulations and technical standards when treating the filling and supplementary water Provided the national regu...

Page 19: ...setting by pressing OK 7 5 5 Heating partial load The heating partial load of the product is set to Auto at the factory This means that the product independently determines the optimum heating output...

Page 20: ...in pressure determine and eliminate the cause 7 11 Filling and purging the heating installation 1 Flush the heating installation thoroughly before filling it 2 Select the check programme P 06 The pump...

Page 21: ...ng due to escaping flue gas An empty or insufficiently filled condensate trap may allow flue gas to escape into the room air Fill the condensate trap with water before starting up the product 2 1 1 Re...

Page 22: ...stat Wait at least 5 minutes until the boiler has reached its operating temperature Ensure that all other gas appliances in the property are turned off Measure the gas flow rate at the gas meter Compa...

Page 23: ...Install the front casing Page 10 Disconnect the product from the power mains You must not start up the boiler Conditions Gas flow pressure in the permissible range End the check programme P 01 Allow t...

Page 24: ...rvice Install the front casing Page 10 7 15 Checking leak tightness Check the gas line the heating circuit and the hot water circuit for leak tightness Check the flue gas pipe for correct installation...

Page 25: ...par tial load you can set a value under D 000 which equates to the product output in kW If the product is operated in cascade you must raise the fan speed of the unit partial load to 1500 rpm D 050 wh...

Page 26: ...the maintenance interval the message that the product must be serviced appears in the display together with the maintenance symbol after a configurable number of burner operating hours The display on...

Page 27: ...Maintenance Maintenance is required in order to eliminate any deviations of the actual condition from the target condition This is nor mally done by cleaning setting and if necessary replacing indivi...

Page 28: ...ated fan Air intake pipe Gas valve Burner 1 Switch off the product using the on off button 2 Disconnect the product from the power mains 3 Close the gas isolator cock 4 Remove the front casing Page 10...

Page 29: ...rmer Note The cable is firmly connected to the ignition electrode 9 Remove the plugs 12 and 13 from the fan motor by pushing in the latching lug 10 Remove the plug from the gas valve 10 11 Remove the...

Page 30: ...l the new electrodes only after first installing the gas air mixture unit 1 Remove the electrodes 1 from the burner door from above 2 Insert the new electrodes with new seals Torque 2 8 Nm 9 9 Cleanin...

Page 31: ...0 kW and 120 kW Torque 2 8 Nm Warning Risk of poisoning and fire caused by es caping gas Gas can escape through leaks Check the gas tightness at the gas con nection using leak detection spray 12 Open...

Page 32: ...press the fault clearance key Operating instructions If you are unable to remedy the fault and the fault recurs despite several fault clearance attempts contact Vaillant Service 10 4 Querying the fau...

Page 33: ...burner door 4 Turn the insulation protection plate 1 to remove it 5 Remove the insulating mat 2 6 Undo the nuts 3 on the burner 7 Use a suitable socket with extension to ensure that the burner mat do...

Page 34: ...crews on the fan evenly The fan must not be at an angle 10 10 5 Replacing the heat exchanger 1 Drain the product Page 31 2 Remove the gas air mixture unit Page 28 3 Unscrew the flow and return line in...

Page 35: ...Specific Numbers DSN Device Spe cific Number for the product types Product type number 806 VU GB 806 5 5 82 1006 VU GB 1006 5 5 81 1206 VU GB 1206 5 5 80 Confirm your setting The electronics are now s...

Page 36: ...Target flow temp Appliance config Language DHW temperature Back Select Target flow temp Appliance config Language DHW temperature Back Select Appliance config Test programs Installer level Fault list...

Page 37: ...elect Heating partial load Appliance config Accessory relay 2 Accessory relay 1 Back Select Heating partial load Appliance config Accessory relay 2 Contact data Back Select Heating partial load Applia...

Page 38: ...justable D 011 Status of external heating pump 0 Off 1 100 On Not ad justable D 014 Pump speed target value high efficiency pump Heating circuit pump target value in 0 Auto 1 53 2 60 3 70 4 85 5 100...

Page 39: ...temperature Actual value in C Not ad justable D 041 Return temperature Actual value in C Not ad justable D 044 Digitised ionisation value Display field 0 to 1020 800 no flame 400 good flame Not ad ju...

Page 40: ...le D 096 Default setting Reset all adjustable parameters to factory setting 0 No 1 Yes C Inspection and maintenance work Overview Note The table below lists the manufacturer requirements with respect...

Page 41: ...ting installation to 1 0 4 5 bar depending on the static height of the heating installation and start the purging programme P 00 X 19 Perform a test operation of the product and heating installation i...

Page 42: ...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 casi...

Page 43: ...ot reset incorrect cable harness liquid gas coding resistor and DSN do not match F 73 Water pressure sensor signal in the wrong range too low Interruption short circuit of water pressure sensor interr...

Page 44: ...al sensor Flow sensor optional DCF connection Earth Earth Contact thermostat burner off Ext room th 3 4 contact 24 V Bus connection Controller room th digital Accessory output Select via D 26 Charging...

Page 45: ...loor heating circuits Radiator heating circuits Ventilator heating circuits Water hardness when starting up mol m or mg l CaCO System volume l Added additive Designation amount Gas supply Type of gas...

Page 46: ...mp in the return required When using a third party pump Pump connected to BMU signal and voltage required Pump characteristic line at least in accordance with the instructions required Hot water suppl...

Page 47: ...alled correctly signal available Start up default settings CO content at max via P 1 before adjustment Vol CO content at max via P 1 after adjustment Vol Gas flow pressure at nominal heat loading max...

Page 48: ...coTEC plus 0020134823_04 H Commissioning Checklist Heating and Hotwater Industry Council HHIC www centralheating co uk Benchmark Commissioning and Servicing Section It is a requirement that the boiler...

Page 49: ...th the appropriate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Optimum start control Fitted Fitted Fitted Fitte...

Page 50: ...g system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND AND SERVICE 02 AND AND SERVICE 03 AND AND SERVICE 04 AND AND...

Page 51: ...pipes 75 mm 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 ba...

Page 52: ...al should be exten ded as shown Dimension H This clearance may be reduced to 25 mm without adversely affecting the performance of the boiler How ever in order to ensure that the condensate vapour plum...

Page 53: ...tion water volume with reference to T 23 K 2 990 l h 3 740 l h 4 485 l h Approx condensate rate pH value 3 5 4 0 in 40 30 C heating mode 12 8 l h 16 0 l h 19 2 l h Remaining feed head of the modulatin...

Page 54: ...9 0 vol 9 0 vol CO content max volume 9 0 vol 9 0 vol 9 0 vol Boiler dimension width 480 mm 480 mm 480 mm Boiler dimension height 960 mm 960 mm 960 mm Boiler dimension depth 603 mm 603 mm 603 mm Appro...

Page 55: ...asing 10 Front casing closed 4 Frost 6 Function menu 27 G Gas connection 11 Gas conversion 21 Gas ratio setting 21 Gas valve 33 Gas air mixture unit 28 30 H Heat exchanger 29 34 Heating flow 12 Heatin...

Page 56: ...23_04 Self test 27 Service message 32 Service partner 32 Setting the pump output 26 Side section 11 Spare parts 27 Status codes 17 41 Switching on 19 T Target feed temperature 19 Test programmes 17 To...

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Page 60: ...ire DE56 1JT Telephone 0330 100 3461 info vaillant co uk www vaillant co uk These instructions or parts thereof are protected by copyright and may be reproduced or distributed only with the manufactur...