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Vaillant ecoTEC exclusive 838 User Manual

Vaillant ecoTEC exclusive 838
68 pages
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Installation and maintenance instructions
For the heating engineer
GB, IE
Installation and maintenance instructions
ecoTEC exclusive
ecoTEC exclusive 832
ecoTEC exclusive 838

Table of Contents

Questions and Answers:

Vaillant ecoTEC exclusive 838 Specifications

General IconGeneral
Boiler typeCondensing
MountingWall-mounted
Output38 kW
Efficiency94%
ErP RatingA
ERP efficiency94%
Warranty5 years
DHW output38.0 kW
FuelNatural gas
TypeCombination boiler

Summary

Notes on the documentation

Storage of the documents

Instructions for the plant operator regarding document retention.

Symbols used

Explanation of symbols used in the manual for danger and required actions.

Validity of the manual

Specifies the part numbers for which this installation manual is applicable.

CE label

Information on directives and standards the appliance complies with.

Gas council numbers

Provides gas council numbers for specific appliance models.

Identification plate

Location of the appliance's identification plate.

Description of the appliance

Design

Diagram and legend of the functional elements of the ecoTEC exclusive appliance.

Type overview

Summary table of appliance types, designated countries, gas types, and heat ratings.

Safety

Warnings

General information on observing safety instructions and warning notes.

Intended use

Specifies the correct and incorrect uses of the Vaillant ecoTEC boiler.

General safety instructions

Provides crucial safety instructions and regulations to be observed.

What to do in an emergency if you smell gas

Procedure to follow in case of a gas leak detection.

What to do in an emergency if you smell flue gas

Procedure to follow in case of flue gas detection.

Material damage caused by corrosion

Precautions to prevent corrosion to the unit and flue installation.

Preventing frost damage

Measures to prevent frost damage during power cuts or low temperatures.

Maintaining operation in the event of a power cut

Guidance on using an emergency power generator for heating.

Material damage due to improper use and/or unsuitable tools

Warnings about using incorrect tools causing material damage.

Changes to the surroundings of the boiler

Prohibits changes to specific boiler components and surroundings.

Important note on operation with liquid gas

Specific instructions for operating the boiler with liquid gas.

Installation below ground level

Regulations for installing the boiler in rooms below ground level.

Avoid incorrect gas types

Warning against using incorrect gas types and its consequences.

General requirements

General prerequisites for installing and commissioning the appliance.

Assembly

Scope of delivery

Checklist for verifying completeness of delivered appliance and accessories.

Transporting the appliance

Manual handling regulations and recommendations for lifting and moving the appliance.

Unpacking of appliance from carton

Instructions and recommendations for safely unpacking the appliance.

Positioning of Appliance for Final Installation - no obstructions

Guidelines for positioning the appliance, considering weight and clearance.

Positioning of Appliance for Final Installation - above worktop, foreseeable obstructions etc.

Instructions for positioning the appliance above worktops with obstructions.

Positioning of Appliance for Final Installation - within compartment etc. restricting installation.

Guidelines for positioning the appliance within restricted compartments.

Positioning of Appliance for Final Installation - in roof space restricting installation.

Instructions for positioning the appliance in a roof space, including risk assessment.

Dimensioned drawing and dimensions for connection

Diagram showing appliance dimensions and connection points with measurements.

Installation site

Requirements for selecting the installation location, including safety and environmental factors.

Required minimum gaps/assembly clearances

Diagram illustrating required clearances around the appliance for installation.

Mounting the appliance

Step-by-step instructions for mounting the boiler onto the wall bracket.

Removing the front case

Procedure for safely removing the front casing of the appliance.

Installation

General instructions for the heating system

Important safety caution regarding flushing the heating system before connection.

Connecting up the gas line

Detailed instructions and safety warnings for connecting the gas supply line.

Connecting hot and cold water pipes

Procedure for connecting the hot and cold water pipes, including safety warnings.

Connecting the heating flow and heating return

Instructions for connecting the heating flow and return pipes, including safety warnings.

Pressure Relief Valve

Instructions for fitting the pressure relief valve and filling loop.

Fitting the air/flue gas duct

Safety warnings and instructions for fitting the air/flue gas duct.

100 mm standard flue pipe

Details and availability of the 100mm standard flue pipe.

Optional 125 mm flue pipe

Information on the optional 125mm concentric flue pipe system.

Termination of the flue pipe

Guidelines for positioning flue terminals to ensure safety and prevent issues.

Air connection

Recommendations for air connection and ventilation requirements for enclosures.

Condensate discharge

Instructions for connecting the condensate drain pipe and suitable termination points.

Connecting the unit to the electricity supply

Safety warnings and instructions for connecting the appliance to the electrical supply.

Establishing the mains connection

Details on the factory-fitted connection cable and plug requirements.

Connecting controllers, accessories and external installation components

Instructions for connecting external controllers and accessories to the boiler's electronics.

External electrical controllers (non eBUS)

Information on connecting external controllers like timers or room thermostats.

Details for the connection of an external timer to the connection rail

Diagram and instructions for connecting an external timer to the boiler's connection rail.

Optional plug-in timers by Vaillant

List of optional Vaillant timers and accessories with their item numbers and connections.

Wiring diagrams

Diagrams illustrating electrical connections for various components and accessories.

Start-up

Filling the system

Instructions for filling the heating system.

Conditioning the heating water

Guidelines for treating heating water to prevent corrosion and ensure compatibility.

Filling and venting the unit and the heating system

Procedure for filling the boiler and heating system and venting air.

First flushing of the system

Instructions for flushing the entire heating system before boiler startup.

Filling and bleeding from the hot water side

Procedure for filling and venting the hot water side of the system.

Filling the condense trap

Instructions for filling the condensate siphon to prevent flue gas escape.

Checking the gas setting

Procedure for checking the gas setting and ensuring correct operation.

Checking for tightness of the flue gas installation and flue gas recirculation

Checking flue gas system integrity and recirculation for safety.

Checking the gas flow rate

Procedure for measuring and verifying the boiler's gas flow rate.

Checking the gas inlet working pressure

Procedure for checking the gas inlet working pressure at the reference test point.

Checking the equipment function

Steps to check the overall function of the boiler's heating and hot water systems.

Heating

Procedure to check the heating function and status codes.

Hot water function

Procedure to check the hot water function and status codes.

Subsequent flushing through of the heating system ("hot")

Instructions for flushing the system after reaching operating temperature.

Handing over the appliance to the owner

Instructions for handover, including controller settings, safety, and maintenance advice.

Adapting the appliance to the heating system

Selection and setting the parameters

Guide to navigating and setting various diagnostic parameters on the appliance.

Overview of the settable installation parameters

Table listing adjustable parameters, their meaning, and default settings.

Setting the heating partial load

Instructions for setting the heating partial load using diagnosis point 'd.0'.

Setting the pump overrun time

Adjusting pump overrun time for heating operation and different modes.

Setting the maximum flow temperature

Setting the maximum feed temperature for the heating system.

Setting the return temperature control

Changing temperature regulation from feed to return for underfloor heating.

Setting the burner anti-cycle time

Adjusting the burner anti-cycle time to prevent frequent switching.

Determination of the maintenance interval/maintenance display

Setting the appliance's maintenance interval and how the service signal is displayed.

Setting the pump output

Adjusting the pump output in five steps for optimal system performance.

Adjusting the bypass valve

Instructions for adjusting the bypass valve to regulate pressure.

Inspection and maintenance

Inspection and maintenance intervals

Details on required inspection and maintenance frequency and safety warnings.

General inspection and maintenance instructions

General guidelines for inspection, maintenance, and use of genuine spare parts.

Safety instructions

Crucial safety warnings regarding electrical shock and proper procedure before maintenance.

Checking the CO2 concentration

Procedure for measuring CO2 concentration to check combustion performance.

Adjusting the CO2 concentration (or the air ratio)

Step-by-step guide for adjusting CO2 concentration using the main throttle screw.

Inspection and maintenance work steps

Table detailing specific inspection and maintenance activities and their frequency.

Filling/draining the heating installation

Procedures for filling and draining the heating system.

Filling the unit and heating installation

Refers to Section 6.1 for filling the appliance and heating system.

Draining the unit

Procedure for closing maintenance cocks and opening drain valves.

Draining the entire installation

Steps for draining the entire heating system, including radiators.

Servicing the compact thermal module

Introduction to servicing the compact thermal module.

Dismantle compact thermal module

Safety warnings and procedure for dismantling the compact thermal module.

Cleaning the heat exchanger

Instructions and safety precautions for cleaning the heat exchanger.

Checking the burner

Procedure for checking the burner for damage and replacement.

Thermo-Kompaktmodul einbauen

Safety instructions for reassembling the Thermo-Kompaktmodul.

Maintaining the secondary heat exchanger

Safety warnings and procedure for removing and cleaning the secondary heat exchanger.

Cleaning the condense trap

Instructions for cleaning the condensate trap and refilling it with water.

Checking the expansion vessel

Procedure for checking the pressure in the expansion vessel.

Checking the connection pressure (gas inlet working pressure)

Reference to Section 6.2.3 for checking gas inlet working pressure.

Checking CO2 content and adjusting if necessary

Reference to Section 8.1.3 for checking the air figure (CO2 concentration).

Test operation

Checks to perform after completing any inspection or maintenance task.

Troubleshooting

Diagnostics

Guide to obtaining error codes (F.xx) and status codes (S.xx) for troubleshooting.

Status codes

Explanation of status codes displayed by the appliance indicating operating conditions.

Diagnosis codes

Instructions for accessing and navigating diagnosis levels for parameter adjustment.

Error codes

List of error codes displayed by the appliance when faults occur.

Error memory

Instructions for accessing the appliance's error memory.

Test programs

Details on various test programs (P.0-P.6) for checking appliance functions.

Resetting parameter to factory settings

Procedure for resetting all adjustable parameters to their factory default settings.

Replacing components

Safety instructions

Essential safety warnings regarding electrical shock and proper procedure before component replacement.

Replacing burner

Safety warnings and step-by-step instructions for replacing the burner.

Replacing fan or gas fittings

Safety warnings and instructions for replacing the fan or gas fittings.

Replacing primary heat exchanger

Safety warnings and procedure for replacing the primary heat exchanger.

Replacing electronics and display

Instructions for replacing electronics or display, including setting appliance variant.

Vaillant service

Vaillant service

Recommendation for arranging a Maintenance Agreement with Vaillant Service Solutions.

Recycling and disposal

Recycling and disposal

Guidelines for disposing of the appliance and packaging responsibly.

Technical data

Technical data

Comprehensive table of technical specifications for the ecoTEC exclusive models.

Appendix

EC declaration of conformity

Document detailing the appliance's compliance with relevant EU directives and standards.

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