Vaillant ECOTEC EXCLUSIVE 627 VU 256/5-7 Installation And Maintenance Instructions Manual
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Vaillant ECOTEC EXCLUSIVE 627 VU 256/5-7 Installation And Maintenance Instructions Manual

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Installation and maintenance instructions
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40
D-42859 Remscheid
Tel. +49 21 91 18‑0
Fax +49 21 91 18‑2810
info@vaillant.de
www.vaillant.de
ecoTEC exclusive
627 (VU 256/5‑7 (H-GB))
GB, IE

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Summary of Contents for Vaillant ECOTEC EXCLUSIVE 627 VU 256/5-7

  • Page 1 Installation and maintenance instructions ecoTEC exclusive 627 (VU 256/5‑7 (H-GB)) GB, IE Publisher/manufacturer Vaillant GmbH Berghauser Str. 40 D-42859 Remscheid Tel. +49 21 91 18‑0 Fax +49 21 91 18‑2810 info@vaillant.de www.vaillant.de...

  • Page 2: Table Of Contents

    Contents Contents Flushing the heating installation for the first time ("cold") ............20 7.10 Filling the heating installation ......20 Safety ..............4 7.11 Purging the heating installation ......20 Action-related warnings ......... 4 7.12 Filling the condensate trap ........20 Intended use ............
  • Page 3 Contents Index ................... 59 0020193966_01 ecoTEC exclusive Installation and maintenance instructions...

  • Page 4: Safety

    1 Safety Safety this document shall be considered improper use. Any direct commercial or industrial use Action-related warnings is also deemed to be improper. Classification of action-related warnings Caution. The action-related warnings are classified in Improper use of any kind is prohibited. accordance with the severity of the possible danger using the following warning signs and General safety information...
  • Page 5 Safety 1 ▶ Ensure that the product is supplied with phone once you are outside of the build- ing. sufficient combustion air. 1.3.3 Risk of death from leaks if the 1.3.8 Risk of poisoning caused by product is installed below ground insufficient combustion air supply level Conditions: Open-flued operation...

  • Page 6: Regulations (Directives, Laws, Standards)

    1 Safety 1.3.13 Risk of injury due to the heavy Regulations (directives, laws, weight of the product standards) ▶ Make sure that the product is transported ▶ Observe the national regulations, stand- by at least two people. ards, guidelines and laws. 1.3.14 Risk of material damage caused by using an unsuitable tool ▶...

  • Page 7: Notes On The Documentation

    41-694-02 ecoTEC exclusive Benchmark Vaillant is a licensed member of the Benchmark Scheme. Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved...

  • Page 8: Information On The Identification Plate

    4 Set-up Information on the identification plate Energy Saving Trust Endorsed Products The identification plate is mounted on the underside of the product in the factory.   Information on the Meaning identification plate Only the most energy efficient products can carry the ‘Energy Saving Trust Endorsed Product’...

  • Page 9: Transporting The Product

    Set-up 4 Transporting the product Dimensions 4.3.1 General ▶ Hold the load as close as possible to your body. Do not twist your body – instead, reposition your feet. ▶ If the unit is being lifted by two persons, ensure your movements are coordinated during lifting.

  • Page 10: Minimum Clearances

    4 Set-up Wall-mounting the product The product's installation depth B can be found in the tech- nical data in the appendix. Minimum clearances Minimum clearance 165 mm: Air/flue pipe, 60/100 mm diameter 275 mm: Air/flue pipe, 80/125 mm diameter 180 mm; optimum approx. 250 mm Check whether the wall has sufficient load-bearing ca- 5 mm;...

  • Page 11: Removing The Front Casing

    Installation 5 Removing the front casing Removing the side section Caution. ▶ Risk of material damage caused by mech- Remove the front casing as shown in the illustration. anical deformation. Removing both side sections may cause mechanical distortion in the product, which may cause damage to the piping, for ex- ample, and potentially result in leaks.

  • Page 12: Installation Requirements

    5 Installation ▶ If, during gas leak-tightness tests, you 5.1.1 Information on liquefied petroleum gas also place the gas lines and the gas valve operation in the product under pressure, use a max. In the as-delivered condition, the product is preset for opera- test pressure of 11 kPa (110 mbar).

  • Page 13: Installing The Gas Connection

    Installation 5 Installing the gas connection Connecting the condensate drain pipework Danger! Risk of death from escaping flue gases! The condensate drain pipework of the con- densate trap must not be connected tightly to waste-water piping because, otherwise, the internal condensate trap may be drained fully and flue gas may escape.

  • Page 14: Installing The Discharge Pipe On The Expansion Relief Valve

    5 Installation ▶ 5.8.2 Replacing the connection piece for the Ensure that the condensate drain pipework terminates in a suitable location. Further information can be obtained air/flue pipe as required from BS 6798 Specification for installation of gas–fired Replace the connection piece for the air/flue pipe as boilers of rated input not exceeding 70 kW net.
  • Page 15 Installation 5 5.9.1 Opening the electronics box 5.9.3 Establishing the power supply Caution. Risk of material damage due to high con- nected voltage. At mains voltages greater than 253 V, elec- tronic components may be damaged. ▶ Make sure that the rated voltage of the mains is 230 V.

  • Page 16: Operation

    6 Operation Open the electronics box. (→ Page 15) When starting up in the installation assistant or retro- actively via diagnostics code D.087, set the correct gas Detach the ProE plug from the PCB slot for the mains type. connection (X1). Unscrew the ProE plug for the factory-installed power 5.9.7 Connecting additional components...

  • Page 17: Live Monitor (Status Codes)

    Start-up 7 ▶ Live Monitor (status codes) Also briefly press ▶ Press and hold until the display shows the Menu → Live monitor language setting option. ▶ Status codes in the display provide information on the pro- Select the required language. duct's current operating mode.

  • Page 18: Restarting The Installation Assistants

    7 Start-up Restarting the installation assistants Note Green iQ mode is a special operating mode Menu → Installer level → Start inst. assistant that can be used to save energy. If this mode You can restart the installation assistant at any time by call- is activated, the product operates in the heat- ing it up in the menu.

  • Page 19: Preventing Low Water Pressure

    Start-up 7 Checking the quality of the heating water No incompatibility with our products has been detected to ▶ date with proper use of the following additives. Remove a little water from the heating circuit. ▶ ▶ Check the appearance of the heating water. When using additives, follow the manufacturer's instruc- ▶...

  • Page 20: Flushing The Heating Installation For The First Time ("Cold")

    7 Start-up Flushing the heating installation for the first Open all thermostatic radiator valves in the heating in- stallation. time ("cold") If necessary, check that both service valves on the Note product are open. The complete heating system must be flushed Slowly open the filling and drainage tap so that the wa- at least twice: Once with cold water and once ter flows into the heating system.

  • Page 21: Gas Inspection

    Start-up 7 7.13 Gas inspection 7.13.3 Checking the gas flow pressure 7.13.1 Checking the leak-tightness of the flue gas Ensure that the gas inlet working pressure can be obtained with all other gas appliances in the property installation and flue gas recirculation working.
  • Page 22 7 Start-up ▶ During the calibration and when measur- 13. Remove the pressure gauge. ing the CO₂ content, you must operate the 14. Tighten the screw on the measuring nipple (1). product with the front casing installed and 15. Open the gas isolator cock. closed, and with the flue pipe completely 16.

  • Page 23: Checking Leak-Tightness

    Start-up 7 ▶ In the next few minutes, measure the CO/CO₂ content Note and the gas flow at maximum load. Calibration is not complete and the CO/CO₂ ▶ to end check programme P.01. content and gas flow cannot be measured. ▶...

  • Page 24: Thoroughly Flushing The Heating Installation ("Hot")

    8 Adapting the unit to the heating installation 7.15 Thoroughly flushing the heating installation Calling up diagnostics codes ("hot") The settings options for more complex systems can be found in the Diagnostics menu. Operate the appliance until the boiler and the heating system are up to temperature.

  • Page 25: Setting The Maintenance Interval

    Adapting the unit to the heating installation 8 8.2.2 Resetting the remaining burner anti-cycling 8.4.1 Remaining pump head time 8.4.1.1 Pump characteristic line 627 (VU 256/5-7) Alternatives 1 / 2 ▶ Navigate to Menu → Reset anti-cycl. time. ◁ The current burner anti-cycling time appears in 100% the display.

  • Page 26: Handing The Product Over To The Operator

    9 Troubleshooting ◁ The measuring probes must be rinsed and must not Pres- be contaminated by a previous measurement. Position of the sure Notes/application adjusting screw in MPa ▶ Check for recirculation at the air test point. The following (mbar) measured values are indicators of recirculation.

  • Page 27: Eliminating Faults

    Troubleshooting 9 Eliminating faults Replacing defective components ▶ 9.7.1 Replacing the burner If fault messages (F.XX) appear, eliminate the fault by referring to the table in the appendix or using the Remove the compact thermal module. (→ Page 31) Function menu (→ Page 30) and the Check programmes (→...
  • Page 28 9 Troubleshooting Unscrew both screws to secure the gas valve assembly to the fan. Remove the plug (1) from the fan. Reinstall the new gas valve assembly in the reverse order. Use new seals for this. Unscrew the three screws between the mixture pipe and the fan flange.
  • Page 29 To make the installation easier, use only the lubricant that may be included with the Vaillant spare part. If no lubricant is included with the Vaillant spare part, use only water or commercially available soft soap. 18. Ensure that the clamps on the heat exchanger's con- nections are seated correctly.

  • Page 30: Completing Repair Work

    10 Inspection and maintenance 9.7.6 Replacing the PCB or the display 9.7.8 Replacing the all-gas sensor Note If you only replace one component, when the product is switched on, the new component ad- opts the parameters that were previously set from the component that was not replaced.

  • Page 31: Electronics Self-Test

    Inspection and maintenance 10 Test Display Action programme T.06 Check external Switch the external pump on pump and off. T.08 Checking the Product starts up and burner switches to minimum load. The flow temperature is shown in the display. 10.2 Electronics self-test Menu →...

  • Page 32: Cleaning The Condensate Trap

    10 Inspection and maintenance 10.3.2 Cleaning the heat exchanger 10.3.4 Installing the compact thermal module Protect the folded down electronics box against sprayed water. Never undo the four nuts on the stud bolt (1) or tighten them. Clean the heating coil (3) of the heat exchanger (4) us- ing water or, if required, vinegar (to a maximum of 5% acid).

  • Page 33: Draining The Product

    Maintenance Agreement. (→ Page 29). Please contact Vaillant Service Solutions for further details: Fill the heating installation. (→ Page 20) Telephone: 0330 100 3461 Purge the heating installation. (→ Page 20) 10.7...

  • Page 34: Appendix

    Appendix Appendix Installer level – Overview Setting level Values Default Unit Increment, select, explanation setting Min. Max. Installer level → – – Enter code 1 (competent person code 17) Installer level → Fault list → F.XX – F.XX¹ – – –...
  • Page 35 Appendix Setting level Values Default Unit Increment, select, explanation setting Min. Max. – Accessory relay 1 1 = Circulation pump 2 = External pump 3 = Cylinder charging pump 4 = Extractor hood 5 = External solenoid valve 6 = External fault message 7 = Solar pump (not active) 8 = eBUS remote control (not active) 9 = Legionella protection pump (not active)

  • Page 36: B Overview Of Diagnostics Codes

    Appendix Setting level Values Default Unit Increment, select, explanation setting Min. Max. – Accessory relay 1 1 = Circulation pump 2 = External pump 3 = Cylinder charging pump 4 = Extractor hood 5 = External solenoid valve 6 = External fault message 7 = Solar pump (not active) 8 = eBUS remote control (not active) 9 = Legionella protection pump (not active)
  • Page 37 Appendix Values Default Code Parameter Unit Increment, select, explanation setting setting Min. Max. – D.007 Cylinder temperature tar- Current value °C Only products with no integrated Not ad- get value hot water generation and with a justable connected cylinder Comfort mode target value Only products with integrated hot water generation –...
  • Page 38 Appendix Values Default Code Parameter Unit Increment, select, explanation setting setting Min. Max. D.020 Max. DHW temperature °C Max. setting for cylinder target target value value – – D.022 DHW demand Current value Domestic hot water requirement via Not ad- C1/C2, impeller or APC justable 0: Off...
  • Page 39 Pump mode 0 = Relay with disable facility 1 = PWM with disable facility – D.047 Current outside temperat- Current value °C (with Vaillant weather-compensated Not ad- control) justable – D.050 Offset min. speed 3000 Nominal value set in factory –...
  • Page 40 Appendix Values Default Code Parameter Unit Increment, select, explanation setting setting Min. Max. D.075 Max. cylinder charging Max. charging time for domestic time hot water cylinder without inde- pendent control system – – D.076 Device Specific Number Current value (Device specific number = DSN) Not ad- justable D.077...

  • Page 41: C Status Codes - Overview

    Appendix Values Default Code Parameter Unit Increment, select, explanation setting setting Min. Max. – D.095 Software version: PeBUS Current value 0: BMU participant 1: AI 2: APC 3: SMU – – D.096 Reset to factory settings? 0: No 1: Yes –...
  • Page 42 Appendix Status code Parameter Meaning S.19 DHW mode: Measuring program DHW mode: Measuring programme Cylinder charging mode S.20 DHW demand Domestic hot water requirement DHW mode: Fan start-up S.21 DHW mode: Fan start-up S.22 DHW mode: Pump pre-run DHW mode: Pump prerun S.23 DHW mode: Ignition DHW mode: Ignition...

  • Page 43: D Overview Of Fault Codes

    Flow/return sensor test running, heating demands are S.98 Flow/return temperature sensor self-test blocked. S.99 Vaillant self-test Self-test Overview of fault codes Note Since the code table is used for various products, some codes may not be visible for the product in question.
  • Page 44 Appendix Code Parameter Possible causes F.33 Pressure switch Check: Cable harness, vacuum hose (blockage), supply air/flue gas route (blockage), panel (correct type), flue pipe (length), air pressure sensor, settings (if necessary, switch D.132 to multiple-flue configura- tion), pressure switch, fan. F.35 Fault: Air/flue gas duct Check the entire air/flue pipe for:...
  • Page 45 Appendix Code Parameter Possible causes F.70 Fault: Invalid Device Specific Number If spare parts fitted: Display and PCB replaced at same time and DSN not reset, incorrect or missing output range coding resistance F.71 Fault: Flow sensor Flow temperature sensor signalling constant value: –...

  • Page 46: E Wiring Diagram

    Appendix Wiring diagram Installation and maintenance instructions ecoTEC exclusive 0020193966_01...
  • Page 47 Appendix +24V Hallsignal Masse X100 X40 X51 X100 230V~ X101 X101 0020193966_01 ecoTEC exclusive Installation and maintenance instructions...

  • Page 48: F Inspection And Maintenance Work - Overview

    Appendix Main PCB Bus connection (digital room thermostat/control) Operator control panel PCB Prioritising diverter valve All-gas sensor Water pressure sensor Gas valve assembly Cylinder temperature sensor Outdoor temperature sensor, flow temperature Cylinder contact "C1/C2" sensor (optional, external), DCF receiver Internal heating circuit flow rate sensor Circulation pump remote control Internal pump Return temperature sensor...
  • Page 49 Appendix Mainten- ance Inspection (must be Work (annual) carried out at regular intervals) Ensure that no gas, flue gas, domestic hot water or condensate is leaking from the product. Restore leak-tightness if necessary. Record the inspection/maintenance work carried out. 0020193966_01 ecoTEC exclusive Installation and maintenance instructions...

  • Page 50: G Commissioning Checklist

    Appendix Commissioning Checklist Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the completed in full. www.centralheating.co.uk © Heating and Hotwater Industry Council (HHIC) Installation and maintenance instructions ecoTEC exclusive 0020193966_01...
  • Page 51 Appendix GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
  • Page 52 Appendix SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ²...
  • Page 53 Appendix PRIOR TO CO AND COMBUSTION RATIO CHECK NOTE The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas THE AIR GAS RATIO VALVE IS FACTORY supply pressure/rate checked as required prior to commissioning. SET AND MUST NOT BE ADJUSTED As part of the installation process, especially where a flue has been fitted by persons other than the DURING COMMISSIONING UNLESS THIS boiler installer, visually check the integrity of the whole flue system to confirm that all components are...

  • Page 54: H Opening Of The Flue Pipe

    Appendix Opening of the flue pipe D, E Positioning of the opening of a fan-supported flue gas pipe Minimum dimen- Installation site sions Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm Horizontally to an opening, air bricks, opening windows, etc., that can be opened.

  • Page 55: I Horizontal Terminal Positioning

    Appendix Horizontal terminal positioning BS 5440-1 recommends that fanned flue chimney terminals 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 directly across a boundary if the products are likely to cause a nuisance to a neighbour or discharge over a walkway or patio.
  • Page 56 Appendix (VU 256/5‑7 (H-GB)) ecoTEC exclusive Gas flow rate at 15 °C 2.35 kg/h and 1013 mbar (based on hot water generation, if applicable), G31 Min. flue gas mass rate 1.47 g/s (G20) Min. flue gas mass rate 1.81 g/s (G31) Max.
  • Page 57 Appendix (VU 256/5‑7 (H-GB)) ecoTEC exclusive Nominal heat output range P at 50/30 °C * … 26.7 kW Nominal heat output range P at 80/60 °C * … 24.7 kW Maximum heat output for 30.0 kW hot water generation Maximum heat input for 30.3 kW hot water generation Maximum heat input,...
  • Page 58 Appendix (VU 256/5‑7 (H-GB)) ecoTEC exclusive Standby electrical power < 1.9 W consumption Level of protection IP X4 D Test symbol/registration CE‑ 0085CM0320 Installation and maintenance instructions ecoTEC exclusive 0020193966_01...
  • Page 59 Index Index Electricity ................5 Electronics box, closing............15 Air ratio setting .............. 22–23 Electronics box, opening ............. 15 Electronics self-test ............. 31 Air/flue pipe, connecting ............14 Air/flue pipe, installed ............5 Ending, installation assistant ..........18 Expansion vessel, replacing..........29 Air/flue pipe, installing ............
  • Page 60 Index Side section, removing ............11 Maintenance interval, setting..........25 Spare parts................27 Maintenance work ............30, 48 Starting, installation assistants ..........18 Maintenance work, completing..........33 Status codes..............17, 41 M-gas, setting..............18 Switching off, product ............33 Minimum clearance ............. 10 Switching on/off ..............
  • Page 64 0020193966_01 0020193966_01 14.08.2017 Supplier Vaillant Ltd. Nottingham Road Belper Derbyshire 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 manufacturer's written consent. We reserve the right to make technical changes.

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