Vaillant ecoTEC plus SERIES User guide

Instructions for installation and servicing
ecoTEC plus
Wall hung open vent condensing boiler
GB
For the installer

Instructions for installation and servicing ecoTEC plus / 0020020828_052
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on the documentation. . . . . . . . . . . . . . . . 3
1.1.1 Other instructions supplied with this appliance. . . 3
1.1.3 Safety instructions and symbols. . . . . . . . . . . . . 3
1.2 ecoTEC plus boilers . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 General information . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.1 Gas category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.2 Gas safety (installation and use) regulations. . 4
1.4.3 Gas testing and certification . . . . . . . . . . . . . . . . 4
1.4 4 Control of substances hazardous to health . . . 4
1.4.5 Insulation pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.7 Manual handling guidance . . . . . . . . . . . . . . . . . . 4
1.4.8 Gas leak or fault. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.9 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.10 Sheet metal parts . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.11 Sealed components . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.12 Electrical supply failure . . . . . . . . . . . . . . . . . . . . 5
1.4.13 Protection against freezing . . . . . . . . . . . . . . . . . 5
1.4.14 Boilers installed in a compartment or cupboard 5
1.4.15 Boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.16 Condensate drain. . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 .17 Pluming from flue terminal . . . . . . . . . . . . . . . . . 5
1.4.18 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.19 Maintenance and servicing . . . . . . . . . . . . . . . . . 5
1.4.20 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Statutory requirements . . . . . . . . . . . . . . . . . . . . 6
1.6 Regulations, rules and guidelines. . . . . . . . . . . . 6
1.7 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8 Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.9 Gas council numbers. . . . . . . . . . . . . . . . . . . . . . . 6
2 Boiler specifications . . . . . . . . . . . . . . . . . . . . 7
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 General requirements. . . . . . . . . . . . . . . . . . . . . 9
3.1 Preliminary remarks for room sealed appliances. 9
3.2 Related documents . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.1 Flue termination. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.2 Internal flue installation . . . . . . . . . . . . . . . . . . . . 11
3.6 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Cupboard or compartment ventilation . . . . . . . 11
3.8 Domestic hot water cylinder . . . . . . . . . . . . . . . . 12
3.8.1 Unvented hot water cylinder. . . . . . . . . . . . . . . . 12
3.9 Condensate drain. . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.10 Heating system controls. . . . . . . . . . . . . . . . . . . . 12
3.11 Draining tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.12 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.13 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.14 Pump specification . . . . . . . . . . . . . . . . . . . . . . . . 12
3.15 Cleanser and inhibitor. . . . . . . . . . . . . . . . . . . . . . 12
3.16 Open vented heating system. . . . . . . . . . . . . . . . 13
3.17 Sealed water systems. . . . . . . . . . . . . . . . . . . . . . 14
3.17.1 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.17.2 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.17.3 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.17.4 Water make up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.17.5 Filling a sealed water system . . . . . . . . . . . . . . . 14
4 Boiler installation sequence. . . . . . . . . . . . . . 15
4.1 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.1 Sheet metal parts . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.2 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.3 Timber frame buildings. . . . . . . . . . . . . . . . . . . . . 15
4.1.4 Contents included with delivery . . . . . . . . . . . . . 15
4 .2 Flue exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.1 Other flue options . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Fitting the boiler hanging bracket . . . . . . . . . . . 16
4.3.1 Boiler fixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.2 Removing the front casing. . . . . . . . . . . . . . . . . . 16
4.3.3 Gas connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.4 Water connections. . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.5 Condensate trap and siphonic drain connection 17
4.3.6 Installing the flue system. . . . . . . . . . . . . . . . . . . 17
4.4 Electrical connections. . . . . . . . . . . . . . . . . . . . . . 17
4.4.1 Connection to the main supply . . . . . . . . . . . . . . 18
4.4.2 Wiring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.3 Electrical board layout . . . . . . . . . . . . . . . . . . . . . 19
4.4.4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.5 External electrical controls . . . . . . . . . . . . . . . . . 21
4.4.6 Connection details for external switches and .
boiler terminal strip. . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.7 Vaillant optional plug in timer accessories. . . . 21
4.4.8 Connection details using the VR 65 control
centre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Commissioning (Part I). . . . . . . . . . . . . . . . . . 22
5.1 Preliminaries - all systems . . . . . . . . . . . . . . . . . . 22
5.1.1 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.2 Initial Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.3 Ignition problems. . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.4 Flue problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.5 Testing - gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Natural gas to LPG conversion . . . . . . . . . . . 24
7 Functional checks commissioning (part II). . 25
7.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 Domestic hot water (If optional VR65, uniSTOR
cylinder and Vaillant control are installed). . . . 25
7.4 Pump exercise programme . . . . . . . . . . . . . . . . . 25
7.5 Final flush of the heating system (hot) . . . . . . . 25
7.6 Handing over to the user . . . . . . . . . . . . . . . . . . . 26
7.7 Vaillant warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Inspection and maintenance . . . . . . . . . . . . . 27
8.1 Initial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.3 Functional check of boiler operation . . . . . . . . . 27
8.1.4 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Contents

3Instructions for installation and servicing ecoTEC plus / 0020020828_05
1 Introduction
1.1 Notes on the documentation.
To ensure clarity of information in instructions a new
European standard of advice and symbols is being
introduced. To ensure compliance with this new standard
the following details are included.The following informa-
tion is intended to help you through-out the boilers
entire instruction pack. We assume no liability for any
damage caused by non-observance of these instructions.
1.1.1 Other instructions supplied with this appliance.
For the owner:
Instructions for use no. 0020020829
Short operating instructions no. 838404
Warranty card with return envelope no. 802922
For the installer/service engineer:
Flue installation instructions no. 834449
The instructions for any accessories and controllers
used also apply.
The Benchmark gas boiler commissioning checklist
(in this manual) should be completed by the installer
and/or the commissioning engineer.
If, after reading these instructions, you have any
questions on the operation of the boiler, please contact
either your installer or Vaillant Technical Department.
1.1.2 Retention of documents
Please retain this literature and all related documents
so that they are available whenever they are required.
If you move please pass on the documents to the buyer.
1.1.3 Safety instructions and symbols
Please observe the safety instructions in this literature
for the operation of the appliance.
dDanger!
Immediate risk of serious injury or death.
eDanger!
Risk of death from electric shock!
HDanger!
Risk of burns or scalding!
aCaution!
Potentially dangerous situations for the
product and environment.
hNote!
Useful information and instructions.
• Symbol for a necessary task
Introduction 1
8.1.5 Spark electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1.6 Removing the burner . . . . . . . . . . . . . . . . . . . . . . 29
8.1.7 Combustion chamber and heat exchanger. . . . 30
8.1.8 Condensate drain. . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.9 Inner casing panel seal check . . . . . . . . . . . . . . . 31
8.1.10 Checking the expansion vessel (If fitted).. . . . . 31
8.1.11 Re commissioning the boiler . . . . . . . . . . . . . . . . 31
8.1.12 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9 Combustion analysis. . . . . . . . . . . . . . . . . . . . 32
9.1 Check CO2 content . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 33
10.1 Logical fault finding procedure. . . . . . . . . . . . . . 33
10.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.1.2 Diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.1.3 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.2 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.3 Resetting parameter to factory settings. . . . . . 37
11 Parts replacement . . . . . . . . . . . . . . . . . . . . . 38
11.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 38
11.2 Replacing the burner. . . . . . . . . . . . . . . . . . . . . . . 38
11.3 Replacing the gas valve . . . . . . . . . . . . . . . . . . . . 38
11.4 Replacing the fan. . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.5 Replacing the heat exchanger. . . . . . . . . . . . . . . 38
11.6 Replacing the condense trap and siphonic drain .39
11.7 Replacing electronics and display . . . . . . . . . . . 39
12 Recycling and disposal . . . . . . . . . . . . . . . . . . 40
12.1 Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
12.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
13 Vaillant service . . . . . . . . . . . . . . . . . . . . . . . . 40
14 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Instructions for installation and servicing ecoTEC plus / 0020020828_054
hNote!
This boiler must be installed and serviced by a com-
petent person in accordance with the GasSafety
(Installation and Use) Regulations 1998.In the UK
‘CORGI’ registered installers undertake the work in
compliance with safe and satisfactory standard.
1.2 ecoTEC plus boilers
The ecoTEC plus boilers are designed to provide central
heating from a fully pumped open-vented or sealed water
system. The central heating water temperature can be
adjusted on the boiler. The domestic hot water can only
be adjusted on the boiler if it is installed with a Vaillant
uniSTOR unvented cylinder and relevant controls. Once
the controls are set the boiler operates automatically.
A frost protection programme is also included.
Please read these instructions and follow them carefully
for the correct and economical use of your boiler. These
instructions are applicable to the following ecoTEC plus
boilers, available in Natural Gas. All ecoTEC plus boilers
can be converted to LPG.
Appliance Maximum output
ecoTEC plus 415 15 kW
ecoTEC plus 418 18 kW
ecoTEC plus 428 28 kW
ecoTEC plus 438 38 kW
1.3 General notes
The boiler has been designed for use with a open-vented
central heating system, and comes fully tested and
assembled. The boiler is easily mounted on any internal
wall and can be installed with either a horizontal or vertical
RSF (room sealed fan assisted) flue. The boiler uses a
standard flue system (100 mm or 125 mm outside diameter).
Flue extensions and additional bends and elbows are
available for the flue system to increase the flexibility. If
desired, an inhibitor may be used in the system. Guidance
on the use of inhibitors is contained in these instructions.
The boiler has a built in diagnostic system which indicates
the operational status of the boiler. This feature provides
key information to aid commissioning and fault finding.
The data badge is fitted to the combustion chamber
cover of the boiler. See text of General Requirements for
installation requirements or notes. The Valliant ecoTEC
plus boilers have been constructed in accordance with
recognised safety regulations. Nevertheless, danger to
the life and limb of the user or third parties can still occur
or the appliance or other material assets be damaged in
the event of improper use. The appliances are designed
for central heating systems. Any other use or extended
use is considered to be use other than intended. The
manufacturer/ supplier is not liable for any resulting
damage. Intended use includes the observance of the
operating and installation manual and the adherence to
the inspection and maintenance conditions.
aCaution!
Any incorrect use is forbidden. The appliances
must be installed by a competent person,
who is responsible for adhering to the existing
regulations, rules and guidelines.
1.4 General information
Thank you for choosing a Vaillant boiler. The information
given in this booklet will enable you to obtain the best
performance from this boiler.
1.4.1 Gas category
The boiler is supplied factory set for use on Natural Gas
(G20). The ecoTEC plus boilers can be field adjusted for
use on LPG (propane G31), see section 7 for instructions
or contact Vaillant Service, 0870 6060 777.
1.4.2 Gas safety (installation and use) regulations
In your own interests and that of safety, it is the Law that
ALL gas appliances are installed by a competent person in
accordance with the current issue of the above regulations.
1.4.3 Gas testing and certification
The boiler is tested and certificated for safety and per-
formance. It is, therefore, important that no alteration is
made to the boiler.
1.4 4 Control of substances hazardous to health
Under Section 6 of The Health and Safety at Work Act 1974,
we are required to provide information on substances haz-
ardous to health. The adhesives and sealants used in this
appliance are cured and give no known hazard in this state.
1.4.5 Insulation pads
These can cause irritation to skin, eyes and the respirato-
ry tract. If you have a history of skin complaint you may
be susceptible to irritation. High dust levels are usual
only if the material is broken. Normal handling should not
cause discomfort, but follow normal good hygiene and
wash your hands before eating, drinking or going to the
lavatory. If you do suffer irritation to the eyes or severe
irritation to the skin seek medical attention.
1.4.6 Spare parts
Only original Vaillant spare parts may be used.
1.4.7 Manual handling guidance
During the appliance installation and the replacement of the
heat exchanger it will be necessary to employ caution and
assistance whilst lifting as the appliance or component ex-
ceeds the recommended weight for a one man lift. In certain
situations it may be required to use a mechanical handling
aid. Take care to avoid trip hazards, slippery or wet surfaces.
dDanger!
Smell of gas. Risk of poisoning and explosion
due to a malfunction
1 Introduction

5Instructions for installation and servicing ecoTEC plus / 0020020828_05
1.4.8 Gas leak or fault
If you smell gas or suspect a gas leak:
• Do not switch lights on or off.
• Do not use any other electrical switches.
• Do not use a telephone in the hazardous area.
• Do not use naked flames, such as matches or cigarette
lighters.
• Do not smoke.
• Turn off the gas supply at the gas meter.
• Open the windows and doors.
• Warn other residents.
• Get out of the house.
• Consult your gas supplier, service agent or other
competent person.
Telephone the National emergency number 0800 111 99
1.4.9 Clearances
If fixtures are positioned close to the boiler, space must
be left as shown in fig 4.1. Enough space must also be
left in front of the boiler to allow for servicing.
1.4.10 Sheet metal parts
This boiler contains metal parts (components) and care
should be taken when handling and cleaning, with par-
ticular regard to edges.
1.4.11 Sealed components
Under no circumstances must the User interfere with any
sealed component as this could result in a potentially
dangerous situation arising.
eDanger!
This boiler must be earthed.
1.4.12 Electrical supply failure
The boiler will not work without an electrical supply. Normal
operation of the boiler should resume when the electrical
supply is restored. Reset any external controls to resume
normal operation of the central heating. If the boiler does
not resume normal operation. (The burner fails to ignite
after five attempts). The overheat thermostat may have
operated. Automatic ignition can only take place after you
manually reset the fault, refer to section 5.1.3. to reset.
1.4.13 Protection against freezing
The boiler has a built in frost protection programme as long
as the electricity and gas are left switched on. This device
operates the burner and system pump when the tempera-
ture inside the boiler falls to 3°C. Any other exposed areas
of the system should be protected by a separate frost ther-
mostat. If the mains electricity and gas are to be turned off
for any long periods during severe weather, it is recom-
mended that the whole system, including the boiler, should
be drained to avoid the risk of freezing. Make sure that, if
fitted, the immersion heater in the cylinder is switched off.
If you have a sealed water system contact your installation/
servicing company as draining, refilling and pressurising
MUST be carried out by a competent person.
As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the
condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe. The
boiler should then restart. Contact your installation/
servicing company if the fault persists.
1.4.14 Boilers installed in a compartment or cupboard
If the boiler is fitted into a compartment or cupboard it
does not require ventilation openings.
Do not use the compartment or cupboard for storage.
1.4.15 Boiler casing
Do not remove or adjust the casing in any way, as incor-
rect-fitting may result in incorrect operation or failure
to operate at all.
1.4.16 Condensate drain
The condensate drain must not be modified or blocked.
1.4 .17 Pluming from flue terminal
All condensing boilers produce a plume of water vapour
from the flue terminal. This is due to the high efficiency
and hence low flue gas temperature. This may increase
in wet, damp weather but this is completely normal and
indicates that the boiler is operating correctly.
1.4.18 Cleaning
This appliance contains metal parts and care should be
taken when handling and cleaning with particular regard
to edges. The boiler casing can be cleaned using a mild
liquid detergent with a damp cloth, then a dry cloth to
polish. Do not use any form of abrasive or solvent clean-
er as you may damage the paint work.
1.4.19 Maintenance and servicing
For the continued efficient and safe operation of the boiler
it is recommended that it is checked and serviced at regular
intervals. The frequency of servicing will depend upon the
installation conditions and usage, but in general, once a year
should be enough.
If this appliance is installed in a rented property there is a
duty of care imposed on the owner of the property by the
current issue of the Gas Safety (Installa
tion and Use) Regu-
lations, Section 35. Servicing/maintenance
should be carried
out by a competent person in accordance with the rules in
force in the countries of destination.
Please be advised that on completion of commissioning and
servicing you should complete the Benchmark gas boiler
commissioning checklist.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded there.
1.4.20 Technical data
Al dimensions are given in millimetres (except as noted). The
data label is positioned on the combustion chamber cover.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is:
All ecoTEC plus boilers : Class ‘A’. The value is used in the
Introduction 1

Instructions for installation and servicing ecoTEC plus / 0020020828_056
UK Government’s Standard Assessment Procedure (SAP)
for energy rating of dwellings. The test data from which it
has been calculated has been certified by B.S.I.
1.5 Statutory requirements
The appliance is suitable only for installation in GB and IE
and should be installed in accordance with the rules in force.
In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:
- The manufacturer’s instructions supplied
- The Gas Safety (Installation and Use) Regulations
- The appropriate Buildings Regulations either
- The Building Regulations
- The Building Regulations (Scotland)
- The Building Regulations (Northern Ireland)
-
The Water Fittings Regulations or Water bye laws in Scotland
- The Health and Safety at Work Act, Control of Sub-
stances Hazardous to Health (COSHH)
- The Current I.E.E. Wiring Regulations
Where no specific instructions are given, reference
should be made to the relevant British Standard Code of
Practice. In IE, the installation must be carried out by a
competent person and installed in accordance with the
current edition of I.S.813 “Domestic Gas Installations”, the
current Building Regulations and reference should be
made to the current ETCI rules for Electrical Installation.
In GB the following Codes of Practice apply:
BS 4814, BS 6891
BS 6798 BS 6700
BS 5440 Part 1 and 2 BS 7074 Part 1 and 2
BS 5546 Part 1 BS 7593
BS 5449 BS 7671
In IE:
I.S.813 BS 5546
BS 7074 BS 5449
BS 7593
Manufacturer’s instructions must not be taken as over-
riding statutory requirements.
hNote!
For further information, see the current issue of
the Building Regulations, approved document L1
(in the UK) and the current issue of the following:
• Central heating system specification (CheSS)
• Controls for domestic central heating system
and hot water. BRECSU.
Certification
This boiler certificated to the current issue of EN 483 for
performance and safety. It is important that no alteration
is made to the boiler, without permission, in writing, from
Vaillant. Any alteration that is not approved by Vaillant,
could invalidate the warranty and could also infringe the
current issue of the Statutory Requirements.
1.6 Regulations, rules and guidelines.
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efficiency) Regulations, and there-
fore is deemed to meet the requirements of Directive
92/42/EEC on the efficiency requirements for new hot
water boilers fired with liquid or gaseous fuels. Type
test for purposes of Regulation 5 certified by: Notified
body 0087. Product/production certified by: Notified
body 0086.
1.7 CE label
The CE label on this appliance shows compliance with:
- Directive 90/396/EEC on the approximation of the laws
of the Member States relating to appliances burning
gaseous fuels.
- Directive 73/23/EEC on the harmonisation of the Laws
of the Member States relating to electrical equipment
designed for use within certain voltage limits.
- Directive 89/336/EEC on the approximation of the Laws
of the Member States relating to electromagnetic
compatibility.
1.8 Benchmark
hNote!
Vaillant Ltd. support the Benchmark initiative
At the rear of the installation manual, you will
find a Benchmark gas boiler commissioning
checklist. It is very important that this is com-
pleted correctly at the time of installation,
commissioning and hand over to the user.
1.9 Gas council numbers
Appliance Gas council numbers
ecoTEC plus 415 41 - 044 - 53
ecoTEC plus 418 41 - 044 - 54
ecoTEC plus 428 41 - 044 - 55
ecoTEC plus 438 41 - 044 - 57
1 Introduction

7Instructions for installation and servicing ecoTEC plus / 0020020828_05
2 Boiler specifications
2.1 Technical data
Description ecoTEC plus 415 ecoTEC plus 418 ecoTEC plus 428 ecoTEC plus 438 Unit
Maximum CH heat input (net) 15.3 18.9 28.6 38.4 kW
CH heat output (80/60 °C) 5.0 - 15.0 5.0 - 18.6 5.3 - 28.2 6.3 - 38.0 kW
CH heat output (50/30 °C) 5.3 - 16.2 5.3 - 20.0 5.7 - 30.6 6.8 - 41.0 kW
SEDBUK Band A A A A
SAP Seasonal Efficiency 90.5 90.4 90.6 90.8 %
NOx Class 5 5 5 5
"lP rating" IPX4D IPX4D IPX4D IPX4D
Inlet gas working pressure required
(natural gas) 20 20 20 20 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 37.8 37.8 37.8 MJ/m3
Maximum gas rate 1.61 2.0 3.02 4.06 M3/h
Minimum gas rate 0.53 0.53 0.56 0.71 M3/h
Burner % CO2 (Case on) 9.3 + 0.2 - 0.5 9.3 + 0.2 - 0.5 9.3 + 0.2 - 0.5 9.0 + 0.2 - 0.5 %
Gas connection (compression) 15 15 15 15 mm
Water connections (compression) 22 22 22 22 mm
Condensate drain (internal diameter) 19 min. 19 min. 19 min. 19 min. mm
Main PCB 2 2 2 2 A
Minimum flow rate of water
through the boiler 10.8 12.9 20.3 27.2 L/min.
Weight 31 31 33 33 kg
Electrical supply 230/~50 230/~50 230/~50 230/~50 V~/HZ
External fuse 3 3 3 3 A
Power input 60 60 60 60 W
Case height 600 600 600 600 mm
Case width 375 375 375 375 mm
Case depth 340 340 340 340 mm
Boiler specifications 2

Instructions for installation and servicing ecoTEC plus / 0020020828_058
2.1.2 Dimensions
48
26
33
176 160
340
113
375
133
30
53
161
610
1
2
37
4
5
6
8
56
Fig. 2.1 Dimensions in mm
1 Heating return pipe Ø 22
2 Heating flow pipe Ø 22
3 Gas connection Ø 15
4 Hanging bracket
5 Flue hole - flue system 303 933
6 Flue pipe connection
7 Condensate drain outlet connection (Ø 21)
8 Outside wall face
2.1.3 Installation
Fig. 2.2 Function elements of boiler
1 Flue pipe connection
2 Fan
3 Gas valve
4 Electronics box
5 Burner module
6 Ignition electrode
7 Condense trap
2 Boiler specifications

9Instructions for installation and servicing ecoTEC plus / 0020020828_05
3 General requirements
3.1 Preliminary remarks for room sealed appliances
This appliance should only be installed with a Vaillant flue
system. Install the flue system as detailed in the separate
flue installation instructions supplied with this boiler.
3.2 Related documents
The installation of the boiler must be in accordance with the
relevant requirements of Gas Safety (Installation and Use)
Regulations 1998, Health and Safety Document No. 635
(The Electricity at Work Regulations 1989), BS7671 (IEE
Wiring Regulations) and the Water Supply (Water Fitting)
Regulations 1999, or The Water Bylaws 2000 (Scotland).
It should also be in accordance with the relevant require-
ments of the Local Authority, Building Regulations, The
Building Regulations (Scotland), The Building Regulations
(Northern Ireland) and the relevant recommendations of
the following British Standards:
BS 6700: Services supplying water for domestic use within
buildings and their curtilages. BS 6798: Specification for
installation of gas fired boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pressure
gas pipe work up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water
central heating systems. Institute of Gas Engineers
Publication
IG/UP/7 Edition 2: “Gas installations in timber framed
and light steel framed buildings“.
IGE/UP1: Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2: Gas installation pipe work, boosters and
compressors on industrial and commercial premises.
IGE/UP10: Installation of gas appliances in industrial
and commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating systems.
BS. 5440: Installation and maintenance of flues and
ventilation for gas appliances of rated input not exceeding
70 kW net (1st, 2nd and 3rd family gases).
Part 1 Specification for installation of flues.
Part 2 Specification for installation and maintenance
of ventilation for gas appliances. European
installation directive
aCaution!
The appliance must be installed and serviced by
a competent person as stated in the Gas Safety
(Installation and Use) Regulations 1998. In IE,
the installation must be in accordance with the
current edition of I.S.813 ‘Domestic Gas Instal-
lations’, the current Building Regulations and
reference should be made to the current ETCI
rules for electrical installation.
aCaution!
When tightening or slackening screwed connec-
tions always use suitable open-ended spanners
(not pipe wrench, or extensions, etc.). Incorrect
use and/or unsuitable tools can lead to damage
being caused (e.g. gas or water leakage)!
3.3 Installation site
The location chosen for the boiler must permit the provision
of a satisfactory flue termination. The location must also pro-
vide adequate space for servicing and air circulation around
the boiler. The boiler may be installed in any room, although
particular attention is drawn to the requirements of BS 7671
(IEE Regulations), the electrical provisions of the Building
Standards (Scotland) Regulations, and in IE the current edi-
tion of IS 813 and the current ETCI rules, in respect of the in-
stallation of a boiler in a room containing a bath or shower.
hNote!
If a room sealed boiler is installed in a room
with a bath or shower, electrical switches or
boiler controls using the mains power supply
must be placed at locations that cannot be
reached by the person in the bath or shower.
If the boiler is installed in an unusual location, special proce-
dures may be necessary and BS 5546 and BS 6798 give
detailed guidance on this aspect. The boiler must be mount-
ed on a flat, vertical wall, which must be sufficiently robust
to take the weight of the boiler. The boiler may be installed
on a combustible wall, subject to the requirements of the
Local Authorities and Building Regulations. A compartment
used to enclose the boiler must be designed and constructed
specifically for this purpose. (An existing cupboard or com-
partment may be used provided that it is modified for the
purpose). Details of essential features of cupboard/compart-
ment design including airing cupboard installations are given
in BS 6798. If the boiler is to be fitted in a timber framed
building, it should be fitted in accordance with Institute of
Gas Engineers Publication IG/UP/7 Edition 2 “Gas installa-
tions in timber framed and light steel framed buildings“.
Please note the safety instructions below before deciding
where to install the boiler:
aCaution!
Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance must be operated independent of
the ambient air.
General requirements 3

Instructions for installation and servicing ecoTEC plus / 0020020828_0510
When choosing the place of installation and while operating the
appliance, make sure that the air supply is free of chemical
substances containing fluorine, chlorine, sulphur etc. Sprays,
solvents and cleaning agents, paints, adhesives etc. contain the
kind of substances that can lead to corrosion even in the ex-
haust system when the appliance is operated depending on the
ambient air in the worst case scenario. Particularly in hair-cut-
ting salons, lacquering and finishing, cleaning facilities, the ap-
pliance must be operated independent of the ambient air! Oth-
erwise, a separate installation room is required to guarantee
that the air supply is free of the above mentioned substances.
3.4 Gas supply
The gas supplier should ensure the availability of an ade-
quate supply of gas. A gas meter may only be connected
to the service pipe by the supplier of gas or their contrac-
tor. An existing meter should be checked to ensure that it
is capable of passing the rate of gas supply required. In-
stallation pipes should be fitted in accordance with BS
6891. In IE the current edition of IS 813. Pipe work from
the meter to the boiler must be of an adequate size. Do
not use pipes of a smaller size than the boiler gas con-
nection (15 mm). The complete installation must be
checked for leaks and purged as described in BS 6891.
dDanger!
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. You will find a list of genu-
ine flue pipes in the Vaillant installation manual
for flue pipes. The CE mark is valid only if the
appliance is operated with Vaillant flue pipes.
3.5 Flue options
There are various flue systems to choose from, as follows:
60/100 standard horizontal air/flue duct, see fig 3.1.
60/100 telescopic horizontal air/flue duct, see fig 3.2.
60/100 Vertical air/flue duct and terminal, see fig 3.3.
80/125 horizontal air/flue duct, see fig 3.4.
80/125 Vertical air/flue duct and terminal, see fig 3.5.
Flue extensions are available to extend the length, both
90° bends and 45° elbows are also available. Refer to
flue system installation instructions for full details.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at
least 3° to allow condensate to run out via the drain.
667
Fig. 3.1 Art. No. 30 39 33
Fig. 3.2 Art. No. 30 39 36
Fig. 3.3 Art. No. 30 39 00
Fig. 3.4 Art. No. 30 32 09
Fig. 3.5 Vertical Flue System Art. No. 30 32 00
3 General requirements

11Instructions for installation and servicing ecoTEC plus / 0020020828_05
3.5.1 Flue termination
The following details refer to both flue systems.
a.The terminal must be located where the combustible
substances can escape freely at all times.
b.A plume of water vapour will sometimes be visible
from the flue terminal. Positions where this could be a
nuisance should be avoided.
c. If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people
have access then a suitable terminal guard must be
provided and fitted (made by Tower Flue Components,
Tonbridge, TN9 1TB, Model K3, plastic coated).
hNote!
Vertical flues must not terminate within
600mm of an openable window, air vent or any
other ventilation opening.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
Fig. 3.6 Terminal locations
hNote!
Vertical flues must not terminate within
600mm of an openable window, air vent or any
other ventilation opening.
Terminal position mm
ADirectly below an opening, above an opening or hori-
zontal to an opening, air brick, opening window, etc. 300
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
JFrom an opening in the car port (e.g. door, window)
into the dwelling 1200
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent wall for vertical Flue 500
Tabelle 3.1 Flue terminal position for a fan assisted concentric flue
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
hNote!
In addition, the terminal should not be located
closer than 150 mm from a wallopening provided
for e.g. a window. Boundary flue terminations
must as a minimum comply with Building regu-
lation part „J“ 600 mm and should also be in
accordance with the Guide to Condensing Boiler
Installation which recommends 2.5 m from wall,
fence or boundary.
Where a plume diverter terminal is used this is
measured in the direction of the flow of products.
BS 5440–1: It is recommended that the fanned flue ter-
minal should be positioned as follows:
a.at least 2 m from an opening in the building directly
opposite, and
b.so that the products of combustion are not directed
to discharge across a boundary.
1. Dimensions B, C and D: These clearances may be re-
duced to 25 mm without affecting the performance of
the boiler. In order to ensure that the condensate
plume does not affect adjacent surfaces the terminal
should be extended as shown in Fig. 3.7.
2. Dimension F: This clearance may be reduced to 25
mm without effecting the performance of the boiler.
However, in order to ensure that the condensate
plume does not affect adjacent surfaces a clearance
of 300 mm is preferred. For IE, recommendations are
given in the current edition of IS 813.
Fig. 3.7 Flue termination under balcony/eves
3.5.2 Internal flue installation
The flue can be installed from inside the building when
access to the outside wall face is not practicable.
3.6 Air supply
Detailed recommendations for air supply are given in
BS 5440: Part 2. It is not necessary to have an air vent in
the room or internal space in which the boiler is installed.
3.7 Cupboard or compartment ventilation
The boilers are very high efficiency appliances.
General requirements 3

Instructions for installation and servicing ecoTEC plus / 0020020828_0512
As a consequence the heat loss from the appliance
casing during operation is very low. For cupboard or
compartment installations it is therefore not necessary
to provide any high or low level permanent air vents
for cooling purposes.
3.8 Domestic hot water cylinder
aCaution!
Single feed indirect cylinders are not suitable.
The domestic hot water cylinder must be of the
double feed fully indirect coil type. It must be
suitable for working at a gauge pressure of
0.35 bar above the safety valve setting.
3.8.1 Unvented hot water cylinder
The ecoTEC plus can be connected to an unvented hot
water cylinder. Vaillant offer a range of cylinders called
uniSTOR with capacities from 125 litres to 310 litres. All
unvented domestic hot water cylinders must be installed
by a competent person to the current building regula-
tions and water regulations at the time of installation.
For building regulations refer to G3 and for water regu-
lations guidance G17 to G24 and recommendation R17
to R24. For Ireland: The current issue of BS5546 and
BS6700. If fitting to an existing system the local author-
ity should be informed.
3.9 Condensate drain
A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the
internal household draining system. If this is not
practical, discharge can be made externally into the
household drainage system or a purpose designed soak
away, see Section 4.3.5 for more details.
3.10 Heating system controls
It is recommended that a programmer and room ther-
mostat control the boiler. Vaillant have a range of op-
tional easy fit controls available.
Thermostatic radiator valves must be installed, however
they must not be fitted in a room where the room ther-
mostat is located.
hNote!
All systems must have at least one radiator
not fitted with a thermostatic valve.
hNote!
For further information, see the current issue
of the Building Regulations, approved document
L1, and the following current issues of:
1. Central heating system specification (CheSS)
2. Controls for domestic central heating system
and hot water. BRECSU.
3.11 Draining tap
A draining tap must be provided at all the lowest points
of the system, which will allow the entire system and
hot water system to be drained. Draining taps shall be
to the current issue of BS 2879.
3.12 Safety valve
A safety valve need not be fitted to an open-vented system.
3.13 Bypass
A system bypass will be required fitted at least 1.5 metres
away from the boiler, refer to the current issue of central
heating system specifications (CHeSS).
3.14 Pump specification
The pump should be fitted on the flow pipe from the
boiler and have isolating valves each side.
3.15 Cleanser and inhibitor
In the case of an existing installation, it is essential that
prior to installing the new boiler the system is thorough-
ly flushed. For optimum performance after installation
of a new system, the boiler and its associated central
heating system should also be flushed. Flushing should
be carried out in accordance with BS7593: 1992 using
a cleanser such as Sentinel X300 or X400, or Fernox
Superfloc. For long-term corrosion protection, after
flushing, an inhibitor suitable for stainless steel heat
exchangers should be used, refer to the current issue of
BS 5449 and BS 7593 on the use of inhibitors in central
heating systems. Examples are Sentinel X100 and Fernox.
aCaution!
It is essential that the cleanser is fully
removed from the system after flushing and
before adding inhibitor. Take care to ensure
that all low points in the system are fully drained.
For all systems follow the manufacture’s instructions,
but where new radiators are fitted do not leave the
cleanser in the system for longer than 24 hours.
For optimum performance the boiler and its associated
central heating system should be flushed in accordance
with BS7593: 1992 using a cleanser.
For advice on the application of system cleansers and
inhibitors contact either;
Fernox, Alpha-Fry Technologies
Tandem House
Marlow Way, Beddington Farm Road
Croydon CR0 4XS
Telephone: [phone]
Fernox technical help line: 01799 550811 or:
Sentinel, GE Betz
Widnes, Cheshire, WA8 8UD
Telephone: [phone].
3 General requirements

13Instructions for installation and servicing ecoTEC plus / 0020020828_05
ecoTEC plus 415 pressure loss graph
Water pressure loss (metres head of water)
Flow Rate (litres/hour)
646 l/hr = 20 diff @ 12 kW
Fig. 3.8.1 Pressure loss ecoTEC plus 415
ecoTEC plus 418 pressure loss graph
Water pressure loss (metres head of water)
Flow Rate (litres/hour)
773.86 l/hr = 20 diff @ 18 kW
Fig. 3.8.2 Pressure loss ecoTEC plus 418
ecoTEC plus 428 pressure loss graph
Water pressure loss (metres head of water)
Flow Rate (litres/hour)
1220 l/hr = 20 diff @ 30 kW
Fig. 3.8.3 Pressure loss ecoTEC plus 428
ecoTEC plus 438 pressure loss graph
Water pressure loss (metres head of water)
Flow Rate (litres/hour)
1633 l/hr = 20 diff @ 38 kW
Fig. 3.8.4 Pressure loss ecoTEC plus 438
3.16 Open vented heating system
The boiler must be supplied from an unrestricted water
supply taken from a feed and expansion cistern situated
at a maximum height of 27 metres (90ft) above the boiler.
The cold feed must be 15mm minimum size. The vent
must rise continuously and be unrestricted. It is impor-
tant that the relative positions of the pump, cold feed
and open vent are as shown in fig 3.9.
Open (vented) system.
Recommended
relationship between
pump, cold feed and vent.
22 mm (min.)
vent feed and
expansion cistern
15 mm (min.) cold feed
15 mm (min.)
automatic by-pass
450 mm
(min.)
height
1000 mm
(min.)
boiler 150 mm (max.)
return
cylinder
flow
pump
heating
Fig. 3.9 Open vented system
General requirements 3

Instructions for installation and servicing ecoTEC plus / 0020020828_0514
3.17 Sealed water systems
The installation must comply with the appropriate
requirements of the current issue of BS4814, BS5449,
BS6759, BS6798 and BS7074 Part 1 and 2. For IE your
attention is drawn to the current edition of IS 813. See
fig 3.10 for a suggested layout.
3.17.1 Safety valve
A safety valve must be fitted to a sealed system. It shall
be preset, non-adjustable with a lift pressure of 3-bar,
incorporating seating of a resilient material, a test device
and a connection for drain. The safety valve discharge
pipe must be routed to outside the building, must not
discharge above an entrance or window or any type of
public access area, be clear of any electrical fittings and
positioned so that any discharge can be seen.
3.17.2 Expansion vessel
A diaphragm type expansion vessel, conforming to the
current issue of BS4814 (see also BS7074 Part 1 and 2).
For IE the current edition of IS 813, must be connected
at a point close to the inlet side of the circulating pump,
see the Typical installation, Fig. 3.10. unless laid down
differently by the manufacturer. The expansion vessel
volume depends on the total water system volume and
the initial system design pressure. For any system an
accurate calculation of vessel size is given in the current
issue of BS5449 and BS7074 Part 1. Example: For an
initial design pressure of 0.7 bar, the minimum total
vessel volume required is 0.063 x Total System Volume.
hNote!
A higher initial design pressure requires a larger
volume expansion vessel.
The charge pressure must not be less than the static
head of the system, that is, the height of the highest
point of the system above the expansion vessel.
3.17.3 Pressure gauge
A pressure gauge with a set pointer and covering at least
0 to 4 bar (0 to 60 lb/in2) shall be fitted permanently to
the system in a position where it can be seen when filling
the system.
3.17.4 Water make up
Provision should be made for replacing water loss from
the system using a make up bottle mounted in a position
higher than the top point of the system, connected
through a non-return valve to the return side of either
the heating circuit or the hot water cylinder. Alternatively,
provision for make up water should be made using a
proprietary filling loop.
3.17.5 Filling a sealed water system
Provision for filling the system at low level must be
made. This can be achieved by the use of a proprietary
filling loop.
3 General requirements
3 litres (o.66 gals) make-up bottle (if required)
flow control valve 'A' air release point
filling point
circulating pump
pressure
gauge
expansion vesselboilerdrain cock
make-up alternatives
flow
return
flow control valve 'A'
auto air vent
non-return
valve
heating
circuit
automatic
bypass
valve 'B'
safety valve
Fig. 3.10 Typical installation

15Instructions for installation and servicing ecoTEC plus / 0020020828_05
4 Boiler installation sequence
4.1 Boiler location
hNote!
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although
particular attention is drawn to the installation
of a boiler in a room containing a bath or shower
where reference must be made to the relevant
requirements. This boiler is suitable for instal-
lation in bathroom zones 1, 2 and 3.
4.1.1 Sheet metal parts
aCaution!
When installing the appliance, care should be
taken to avoid any possibility of personal injury
when handling sheet metal parts.
In GB this is the current I.E.E. WIRING REGULATIONS
and BUILDING REGULATIONS. In IE reference should
be made to the current edition of I.S.813 “Domestic Gas
Installations” and the current ETCI rules. The boiler must
be mounted on a flat wall, which is sufficiently robust to
take its total weight, see boiler specifications 2.1.
4.1.2 Clearances
Fig. 4.1 Distance during installation
* A removable compartment door can be placed at least 5 mm
in front of the appliance
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see fig 4.1.
Additional clearances may be beneficial around the boiler for
installation and servicing. For flue installations where external
access is not practicable, consideration should be given for
the space required to insert the flue internally, which may
necessitate clearance larger than those specified in fig 4.1.
4.1.3 Timber frame buildings
If the boiler is to be installed in a timber frame building it
should be fitted in accordance with the Institute of Gas En-
gineers document IG/UP/7 Edition 2 “Gas installations in
timber framed and light steel framed buildings“. If in doubt
seek advice from the local gas undertaking or Vaillant.
4.1.4 Contents included with delivery
The Vaillant ecoTEC plus is delivered pre-mounted in a
package unit. Check that all the parts have been delivered
intact (see fig. 4.2 and table 4.1. Do not remove the boiler
from the polystyrene base at this stage. Place aside the
flue adaptor and connections pack until required.
Fig. 4.2 Contents included with delivery
Item Quantity Description
1 1 Boiler
2 1 Hanging bracket
3 1 Flue connection adaptor
4 1 Instruction booklets
5 2 Guarantee card and envelope
6 1 Template
7 1 Screws/wallplugs
81
Gas service valve, compression couplers
and condense drain pipe coupler
Table 4.1 Contents included with delivery
hNote!
Care should be taken not to scratch the white
surface of the boiler casing.
Boiler installation sequence 4

Instructions for installation and servicing ecoTEC plus / 0020020828_0516
4 .2 Flue exit
Refer to flue system installation instructions for full details.
dDanger!
Vaillant appliances are certified only for use with ge-
nuine Vaillant flue pipes. Only use genuine Vaillant
flue pipes. Malfunctions can occur if you use other
accessories. These may result in damage and injury.
You will find a list of genuine flue pipes in the Vaillant
installation manual for flue pipes. The CE mark is valid
only if the appliance is operated with Vaillant flue pipes.
4.2.1 Other flue options
Flue instructions for other flue systems such as vertical
RSF flues, flues run to the side of the boiler and the use
of additional bends etc. are detailed in the flue installa-
tion instructions.
4.3 Fitting the boiler hanging bracket
Reposition the wall template over the flue hole ensuring the
template is vertical and mark the position of the fixing holes
for the hanging bracket, see fig 4.3. Mark and drill the fixing
holes and secure the hanging bracket. Fix the hanging bracket
to the wall using the screws supplied. Ensure the uppermost
set of screw positions are used (it may be necessary to use
additional or alternative fixings to ensure adequate support).
wall plug (4 off)
wall template
hanging bracket
screw n° 12 x 50 mm (4 off)
160
Fig. 4.3 Boiler hanging bracket
hNote!
If the boiler is to be fitted in a timber framed
building ensure that the bracket is secured to
a substantial part of the timber frame capable
of taking the weight of the boiler.
4.3.1 Boiler fixing
Lift the boiler into position in the following manner: Lean
the top of the boiler slightly to the wall and position just
above the hanging bracket. Allow the boiler to slowly
move downwards until engaged in the hanging bracket.
4.3.2 Removing the front casing
Remove the front casing securing screws then lift the case
upwards off the two top retaining dowels, see fig 4.4.
hNote!
Take care not to damage the front casing.
4.3.3 Gas connection
retaining dowel (2 off)
front casing
screw (2 off)
Fig. 4.4 Removing front casing
dDanger!
The gas connection may only be made by a
competent person. The legal directives and the
local regulations for gas supply companies
must be observed.
aCaution!
Ensure a stress-relief assembly of the gas
pipes to avoid leakages!
aCaution!
The gas regulating block may be tested for leakage
only with a maximum pressure of 150 mbar! High-
er testing pressures can damage the gas fitting.
aCaution!
When making final connection to the boiler, if using
soldered fittings, extra care should be taken to avoid
damage to isolation valves through heat transfer.
Before connection check the supply of local gas.
hNote!
Ensure the gas supply pipe work is adequately
sized so that a 20 mbar gas pressure is available
at the boiler inlet at full flow rate.
• Tighten all connections.
• Check the gas connection with leak indicator
spray for leakage.
The gas supply can be connected from below, or through the
wall at the rear of the boiler. See fig 4.5. and refer to section 3.4.
The whole of the gas installation, including the meter,
should be inspected, tested for soundness and purged
in accordance with the current issue of BS6891 and in IE
the current edition of I.S.813 “Domestic Gas Installations”.
4 Boiler installation sequence

17Instructions for installation and servicing ecoTEC plus / 0020020828_05
union
cennector
condensate
trap
gas supply in
coupling
spigot
condensate
drain pipe
internal
discharge
system
soakawaygulley
internal
stack pipe
1
2
3
4
5
6
ab
cd
3
Fig. 4.5 Gas and condense connections
4.3.4 Water connections
aCaution!
When making final connection to the boiler, if
using soldered fittings, extra care should be
taken to avoid damage through heat transfer.
Flow
Return
22 mm compression
is the recommended
fixing for servicing.
Fig. 4.6 Water connections
Provision is made for the water connections to be made
from above the boiler, see fig 4.6 (using the two 22mm
compression couplers supplied). The position is shown
on the wall template. Flush out the domestic hot water
and the heating systems before connecting to the boiler.
4.3.5 Condensate trap and siphonic drain connection
Refer to fig 4.5. The condensate drain connection is at the un-
derside rear of the boiler. The condense drain is suitable for use
with standard "Push fit" overflow pipe and couplings do not use
adhesive when connecting to the spigot (1) The condense drain
pipe (2) should be non corrosive plastic. The drain pipe should
have a continuous fall of a least (45mm per metre) away from
the boiler. Condensate should, if possible be discharged into the
household internal drainage system. The condensate is discharged
periodically in ‘slugs’ by siphonic action. It is not necessary to
provide air breaks or extra traps in the discharge pipe as there is
already a 75mm high trap inside the boiler. Fitting an extra trap
may cause the boiler siphon to work incorrectly. Refer to
BS5546 or BS6798 for advice on disposal of boiler condensate.
(a ) Preferably the drain pipe should run and terminate inter-
nally to the house soil and vent stack at least 450mm
above the invert of the stack. There must be an air break
in the discharge pipe upstream of the trap. This should be
designed so that the condensate cannot be discharged into
the house if the condensate drain pipe becomes blocked.
(b) Connecting into the internal discharge branch
(e.g. sink waste or washing machine) with an external
termination, the condensate drain pipe should have a
minimum diameter of 22mm with no length restriction
and should incorporate a trap with a 75mm (3) seal.
The connection should preferably made down stream
of the sink waste trap, if the connection is only possible
up stream, then an air break is needed between the
two traps. This is normally provided by the sink waste.
(c) Termination in a gully (5) below grid level (6) and
above the water level. The external pipe length
should be kept as short as possible to minimise the risk
of freezing and should not be more than 3 metres.
(d) At a condensate absorption point (soak away) (7). The
external pipe length should not be more than 3 metres.
Refer to the latest issue of BS 6798 Specification for
installation of gas fired boilers of rate input not exceed-
ing 70kW net for further information. Before operating
the boiler the condensate trap must be filled with water.
4.3.6 Installing the flue system
• Install the flue system (refer to the separate air/flue
duct installation instructions).
4.4 Electrical connections
eDanger!
This appliance must be earthed. Electrocution
caused by touching live parts can be fatal.
Before working on the appliance, turn off the
power supply and secure against restart.
• The boiler must be earthed.
• All system components shall be of an approved type
and all wiring to current I.E.E. wiring regulations.
• External wiring must be correctly earthed, polarised
and in accordance with the relevant standards.
- In GB this is BS 7671.
- In IE this is the current edition of I.S.813 “Domestic
Gas Installations”.
• The boiler must be connected to a permanent 230V ac,
50Hz supply.
•
Connection of the whole electrical system of the boiler,
inclu-ding any heating controls, to the electrical supply
must be through one common isolator and must be fused
3 Amp maximum.
• Isolation should be by a double pole switched fused
spur box, with a minimum gap of 3 mm for both poles.
The fused spur box should be readily accessible and
Boiler installation sequence 4

Instructions for installation and servicing ecoTEC plus / 0020020828_0518
preferably adjacent to the appliance. It should be
identified as to its use.
• Alternatively connection can be made through an un-
switched shuttered socket and 3A fused 3-pin plug both
to the current issue of BS 1363 may be used, provided
they are not used in a room containing a bath or shower.
• A 3 core flexible cord according to BS6500 tables 6,
8 or 16 (3 x 0.75 to 3 x 1.5mm2) should be used.
aCaution!
This appliance must be wired in accordance
with these instructions. Any fault arising from
incorrect wiring cannot be put right under the
terms of the Vaillant guarantee.
eDanger!
Mains connection terminals L and N remain live
“unless isolated at the fused spur or electrical
outlet supplying the boiler”.
aCaution!
Do not connect any mains 230V power to the
connections 7-8-9 or BUS (+,-).
hNote!
Ensure that all cables pass through grommets
in the outer casing and are securely fixed by
the cable clamps in the rear of the electronics
box. Ensure that the power supply is connected
such that the current carrying conductors
become taut before the earth conductor should
the supply cable slip from the cable clamp.
4.4.1 Connection to the main supply
• Lower the electronics box, see fig. 4.7.
unclip
electronics box
Fig. 4.7 Mains Supply Connection
Opening the electronics box
• Unclip the bottom of the electronics box cover and
hinge back to reveal the connection plugs.
• Feed the power supply flex into the appliance and the
electronics box through the cable clamps provided.
4.4.2 Wiring system
• Connect the mains supply to the terminal block, see fig
4 .8.1 the pump can be connected directly to the termi-
nal block or alternatively as shown in diagram 4 .8.2 .
Fig 4.8.1 Mains Supply Connection
mains supply
connection
pump
connecticon
red link *
CH pump junction box
3 amp fuse
double pole isolator
230 Vac 50 Hz
permanent
supply
230 Vac system controls
• zone valve
• programmer
• room thermostat
• cylinder thermostat
* Remove red link if
external 230V controls
are to be fitted
Note: All cables connected
to the appliance should be
permanently fixed to the wall
Fig. 4.8.2 Mains supply and alternative pump switch live connection
Green/yellow (earth) wire – boiler terminal Earth sign
Blue (neutral) wire – boiler terminal N
Brown (live) wire – boiler terminal L
aCaution!
Do not connect any mains 230V power to the
connections 7-8-9 or BUS (+,-).
hNote!
Ensure that the wires are securely fixed in
the terminal block.
• Refit the electronics box cover by pushing
into place until it clips back into position.
• Raise the electronics box.
• Check the electrical installation by carrying out short
circuit, earth continuity and resistance to earth tests
and a check for correct polarity.
4 Boiler installation sequence

19Instructions for installation and servicing ecoTEC plus / 0020020828_05
4.4.3 Electrical board layout
X20 X2 -+
BUS 24V 230V
789 LN 345
X40 X41
X31
Caution:
Do not connect
supply voltage!
Risk of damage
to electronics!
Room thermostat 24V:
Connection 7, 8 and 9
No bi-directional
interface (analogue only)
Mains supply: 230V / 50Hz
Room thermostat 230V / 50Hz
(remove bridge on connection)
Heating pump
2A fuse, slow
Igniter
Connection: 230V
Su
pp
ly for accessory module
eBUS accessory connection
Burner cable harness
Accessory module connection
Diagnosis via eBUS
vrnet DIALOG
outer probe
ext. flow or return probe
Hydraulic cable harness
Connection for external
eBUS controller
ext. flow or return probe
X12
Fig. 4.9 Connection wiring
Boiler installation sequence 4

Instructions for installation and servicing ecoTEC plus / 0020020828_0520
NTC return NTC flow
X 20/5 red
X 20/7 black
X 20/8 blue
black link
Ignition electrode
Fan unit
Gas valve assembly
X 20/18 red (24 Vdc)
X 20/9 blue (earth)
Chassis earth
green/ yellow
pump connection
red red
fuse T2E
250 Volts
Electronic control box
green/yellow
green/ yellow
bus 24 V 230 V
X20
black
X2
X 20/16 blue (earth)
X 20/4 grey (PWM)
X 20/3 black (hall signal)
X 20/17 red (24 Vdc)
Fig. 4.10 Mains Supply Connection
4 Boiler installation sequence