Vaillant ecoTEC exclusive 627 Installation And Maintenance Instructions Manual
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Summary of Contents for Vaillant ecoTEC exclusive 627
- Page 1 VU 256/5‑7 (H-GB) ecoTEC exclusive 627 en Installation and maintenance instructions...
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Page 2: Table Of Contents
Installation and maintenance Restarting the installation assistants ....25 Test programmes..........25 instructions Using check programmes ........25 Contents Checking and treating the heating water/filling and supplementary water ........25 Filling the condensate siphon ......26 Safety ..............4 Preventing low water pressure ......26 Intended use ............ - Page 3 Recycling and disposal........41 Appendix ................42 Inspection and maintenance work ....42 Installer level – Overview ........43 Overview of diagnostics codes ......45 Status codes – Overview ........50 Overview of fault codes ........52 Check programmes – Overview ....... 55 Function menu –...
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Page 4: Safety
Safety Qualification The person carrying out the work described Intended use here must have completed professional train- The product is intended as a heat generator ing. The competent person must demon- for sealed heating installations and for do- strably have all of the knowledge, skills and mestic hot water generation. - Page 5 ▶ Do not use any electrical switches, mains To ensure that the combustion air supply is plugs, doorbells, telephones or other com- sufficient during open-flued operation: munication systems in the building. ▶ Ensure that the air supply to the product's ▶...
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Page 6: Regulations (Directives, Laws, Standards)
To prevent material damage: ▶ Do not install the product in rooms prone to frost. You can find a list of relevant standards at: https://www.vaillant.co.uk/standards 1.3.11 Safety devices ▶ Install the necessary safety devices in the installation. 1.3.12 Risk of death from leaks if the... -
Page 7: Guarantee And Customer Service
To register your Vaillant appliance visit: https://self-service.vaillant.co.uk/warranty-registration 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 at the time by the Health and... -
Page 8: Technical Data
Technical data VU 256/5‑7 (H-GB) Technical data – General ecoTEC exclusive 627 VU 256/5‑7 Nominal heat output 3.4 to 26.7 kW (H-GB) range P at 50/30 °C * ecoTEC Nominal heat output exclusive 627 3.0 to 24.7 kW range P at 80/60 °C * Designated country (des- GB (United Maximum heat output for... -
Page 9: Notes On The Documentation
Hot Water Association Level of protection IP X4 D Vaillant is a full member of the Hot Water Association and promotes the scheme in association with its cylinder range. Details are available on the web site www.vaillant.co.uk Notes on the documentation ▶... -
Page 10: Product Design
Reset any external controls, to resume normal operation of the central heating. If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this call your Installation/Servicing company or Vaillant service. 5.7.2 Overheating Safety The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens. -
Page 11: Set-Up
Set-up Dimensions Scope of delivery Check that the scope of delivery is complete and intact. Num- Designation Heat generator Installation kit containing the following: - Product bracket - Expansion relief valve connection pipe - Gas stopcock - Gas connection pipe, dia. 15 mm - Service valve - Heating flow/return connection pipe - Bag with small parts... -
Page 12: Installation Site
Installation site Air/flue pipe 6.6.1 Regulation This boiler is not suitable for outdoor installation. This boiler may be installed in any room. However if the boiler is being Different flue outlet configurations can be carried out. installed in a room containing a bath or shower it must only be installed in zones 2 or 3. - Page 13 6.6.2 Position of the air/flue terminal 6.6.2.1 Positioning the terminal of a fan-supported flue system Dimen- Installation site sions Adjacent to a boundary. 300 mm The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang.
- Page 14 Dimen- Installation site sions Below eaves. 200 mm Below gutters, pipe and drains. 75 mm The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant. Above adjacent ground or balcony.
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Page 15: Using The Installation Template
6.6.3.3 Vertical Concentric Flue ⌀ 60/100 mm or 6.6.3 Flue Configuration Description ⌀ 80/125 mm (C33 type installation) 6.6.3.1 Horizontal Concentric Flue ⌀ 60/100 mm or ⌀ 80/125 mm (C13 type installation) Gasket (fitted) Consult the separate installation manual for air/flue gas sys- Note tems supplied with your appliance for all possibilities and as- If the terminal is at less than 1.80 m from the... -
Page 16: Removing/Installing The Front Casing
6.10 Removing/installing the side section Note the total weight of the product. Only use fixing material that is permitted for the wall. 6.10.1 Removing the side section If required, ensure that mounting apparatus on-site has sufficient load-bearing capacity. Wall-mount the product as shown in the illustration. Removing/installing the front casing 6.9.1 Removing the front casing... -
Page 17: Installation
Installation Condition: The volume of the installed expansion vessel is insufficient ▶ Install an additional expansion vessel, connected as Installation requirements close to the product as possible, in the heating return. 7.1.1 Information on liquefied petroleum gas Install the connection pipes such that they are free from operation mechanical stress. -
Page 18: Connecting The Heating Flow And Heating Return
Connecting the heating flow and heating return ▶ Establish the heating connections (1) in accordance with the relevant standards. Installing the drain pipe on the expansion relief valve The product is equipped with a condensate siphon (1). (The filling height is 145 mm). The condensate siphon collects the Install the drain pipe for the expansion relief valve in condensate that has formed in a vessel with a volumetric ca- such a way that it does not interfere with the removal... - Page 19 discharge pipe as there is already a trap inside the boiler. 7.8.1.4 Internal termination into combined sink Fitting an extra trap may cause the boiler siphon to work in- waste correctly. Refer to BS5546 or BS6798 for further advice on disposal of boiler condensate.
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Page 20: Flue Installation
Flue installation Open end of pipe direct into gulley below ground level but above water level 7.9.1 Installing and connecting the air/flue pipe Susceptible to siphonage, must terminate in a gulley You can find out which air/flue pipes may be used by consulting the enclosed set-up instructions for the 7.8.1.7 External termination into rain water down air/flue system. -
Page 21: Electrical Installation
7.9.2.2 Installing the connection piece for the air/flue pipe, 80/125 mm diameter Remove the connection piece for the air/flue pipe. 30 mm ≤ (→ Page 20) Insert the alternative connection piece. In doing so, pay Strip the flexible line as shown in the figure. In doing so, attention to the latching lugs. - Page 22 7.10.4 Installing the product in a wet room For multi-circuit controls, change D.018 from Eco (inter- mittently operating pump) to Comfort (continuously op- Danger! erating pump). (→ Page 31) Risk of death from electric shock! 7.10.6 Replacing the gas family coding resistor, if If you install the product in a room with high required levels of moisture, e.g.
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Page 23: Operation
Operation Operating concept The operating concept and the read-off and setting facilities of the operator level are described in the operating instruc- tions. An overview of the reading and setting options for the in- staller level is included in the table in the appendix. Installer level –... -
Page 24: Start-Up
▶ Start-up Fill the heating installation. (→ Page 27) 9.3.3 Purging Carrying out the initial start-up Unlike in the Check programs menu, to purge the sys- Initial start-up must be carried out by a customer service tem, start check programme P.00 by pressing technician or an authorised competent person using the Benchmark Checklist. -
Page 25: Restarting The Installation Assistants
9.3.8 Auxiliary relay and multi-functional module Using check programmes Menu → Installer level → Test programs → Check pro- If you have connected additional components to the product, assign these components to the individual re- grams lays. Display Meaning In each case, confirm by pressing P.00 Purging check programme: The internal pump is cyclically actuated. -
Page 26: Filling The Condensate Siphon
Treating the filling and supplementary water Additives for frost protection intended to remain ▶ permanently in the installation Observe all applicable national regulations and technical – rules when treating the filling and supplementary water. Adey MC ZERO – Fernox Antifreeze Alphi 11 Provided the national regulations and technical rules do not –... -
Page 27: Filling The Heating Installation
9.10 Filling the heating installation 9.11 Flushing the heating installation for the first time ("cold") Note The complete heating system must be flushed at least twice: Once with cold water and once with hot water in accordance with the following instructions. - Page 28 9.13.2 Checking the gas flow rate The gas flow rate has been set during production and does not require adjustment. With the front casing fitted check the gas flow rate of the boiler as follows: ▶ Start up the product with the check programme P.01. ▶...
- Page 29 Start up the product. Condition: Gas flow pressure not in the permissible range Caution. Note Risk of material damage and operating Since the combustion can be continuously faults caused by incorrect gas connec- monitored by the product, you do not need to check the combustion.
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Page 30: Checking Leak-Tightness
◁ ▶ Do not measure the CO/CO₂ content or the gas flow If required, open all of the draw-off point and allow during calibration (status S.93). the domestic hot water cylinder to cool. ◁ ▶ If the heat generator permanently switches from If required, carry out calibration and measurement status S.93 to status S.04 after approximately five again. -
Page 31: Adapting The Unit To The Heating Installation
Note Set maximum burner anti-cycling time [min] Flow (tar- The actual reading on the digital pressure get) gauge should ideally be 0,05 MPa (0,5 bar) [°C] plus an additional pressure corresponding 10.0 13.0 16.5 19.5 to the highest point of the system above the base of the boiler –... -
Page 32: Setting The Pump Output
Guideline value for burner operating hours until the Number next inspection/maintenance Heat de- of per- work is due for an average mand sons operating time of one year (dependent upon the system type) 3 ‑ 4 2600 h 20.0 kW 4 ‑... - Page 33 ▶ Inform the end user that they must not store or use explo- sive or highly flammable substances (such as petrol, pa- per or paint) in the installation room of the product. ▶ Complete and sign off the Benchmark commissioning check list.
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Page 34: 12 Inspection And Maintenance
12 Inspection and maintenance 12.6 Electronics self-test Menu → Installer level → Test programs → Electronics 12.1 Complete Service Interval Record section self-test ▶ After servicing, complete the relevant Service Interval You can use the electronics self-test to check the PCB. Record section of the Benchmark Checklist located on the inside back pages of this document. - Page 35 12.8.2 Cleaning the heat exchanger Protect the hinged down electronics box against spray- ing water. Unscrew the retaining screw (2) and remove the air intake pipe (1) from the intake stub. Unscrew the cap nut from the gas valve (3). Never undo the four nuts on the stud bolt (1) or tighten them.
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Page 36: Clean The Condensate Siphon And Check The Condensate Discharge Pipe
12.8.4 Installing the compact thermal module 12.10 Draining the product Close the service valves of the product. Start the check programme P.06 (diverter valve mid- position). Open the drain valves. Make sure that the cap of the automatic air vent on the internal pump is open so that the product can be drained fully. -
Page 37: 12.15 Checking The Product For Leak-Tightness
12.15 Checking the product for leak-tightness 13.2 Checking service messages ▶ ▶ Check that the product is leak-tight. (→ Page 30) To obtain further information, call up the Live monitor. (→ Page 23) Condition: S.40 is displayed 13 Troubleshooting The product is in Comfort protection mode. The product has detected a temporary fault and continues to run with restric- 13.1 Comfort protection mode for the heat cell... -
Page 38: Resetting Parameters To Factory Settings
13.5 Resetting parameters to factory settings 13.7.2 Replacing the gas valve assembly Navigate to Menu → Installer level → Diagnostics Switch off heating mode and domestic hot water gener- menu → D.096 Reset to factory settings? and con- ation (→ Operating instructions). firm by pressing Press to set the value to 1 and confirm by pressing... - Page 39 After installing the new gas valve assembly, carry out a leak-tightness test (→ Page 30). Close the front casing. 10. Switch on the product. 11. Navigate to Menu → Installer level → Diagnostics menu → D.052 Min. gas valve steps offset and con- firm by pressing 12.
- Page 40 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.
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Page 41: Completing Repair Work
Dispose of the packaging correctly. ▶ Observe all relevant regulations. ▶ For detailed information refer to www.vaillant.co.uk. Remove the air intake pipe; see Removing the compact thermal module (→ Page 34). Undo the screws (3) just enough so that you can pull out the all-gas sensor (1) by the cable. -
Page 42: Appendix
Appendix Inspection and maintenance work The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If na- tional regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed. Each time inspection and maintenance work is carried out, carry out the required preparatory and com- pletion work. -
Page 43: B Installer Level - Overview
Maintenance work Interval Checking the CO/CO₂ content following maintenance work Annually Checking leak-tightness Annually 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 →... - Page 44 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)
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Page 45: C Overview Of Diagnostics Codes
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 46 Values Factory 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 domestic hot water generation and justable with a connected cylinder Comfort mode target value Only products with integrated do- mestic hot water generation –...
- Page 47 Values Factory Code Parameter Unit Increment, select, explanation setting setting Min. Max. – – D.022 DHW demand Current value Domestic hot water requirement via Not ad- C1/C2, impeller or APC justable 0: Off 1: On – – D.023 Heating mode status Current value Summer/winter mode (heating Not ad-...
- Page 48 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 49 Values Factory Code Parameter Unit Increment, select, explanation setting setting Min. Max. – – D.076 Device Specific Number Current value (Device specific number = DSN) Not ad- justable D.077 DHW partial load Output-range- Adjustable cylinder charging output 100 % specific D.078 DHW max.
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Page 50: D Status Codes - Overview
Values Factory Code Parameter Unit Increment, select, explanation setting setting Min. Max. – – D.118 CO sensor fault number Current value 1: Heater short circuit Not ad- justable 2: Heater open circuit 3: Heater temperature control fault 4: Heater temperature plausibility check not OK 5: Sensor short circuit/open circuit 6: Reference resistance measure-... - Page 51 Return temperature sensor self-test blocked. Water pressure sensor test running, heating demands S.97 Water pressure sensor self-test are blocked. Flow/return sensor test running, heating demands are S.98 Flow/return temperature sensor self-test blocked. S.99 Vaillant self-test Self-test 0020193966_04 ecoTEC exclusive Installation and maintenance instructions...
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Page 52: E Overview Of Fault Codes
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. Code Parameter Possible causes F.00 Interruption: Flow sensor NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC defective F.01 Interruption: Return sensor... - Page 53 Code Parameter Possible causes F.35 Fault: Air/flue gas duct Check the entire air/flue pipe for: – Permitted design – Restriction or blockage in the air/flue pipe caused by obstructions – Damage The air/flue pipe must be installed in accordance with the recognised rules If the combustion air supply (air pipe) or discharge of flue gas (flue pipe) occurs with no problems, reset the product using...
- Page 54 Code Parameter Possible causes Flow/return NTC temperature difference too great → flow and/or return F.72 Fault: Flow/return sensor temperature sensor defective F.73 Fault: Water press. sensor Interruption/short circuit of water pressure sensor, interruption/short circuit to GND in supply line to water pressure sensor or water pressure sensor defective F.74 Fault: Water press.
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Page 55: F Check Programmes - Overview
Check programmes – Overview Check programme Meaning P.00 Purging The internal pump is cyclically actuated. The heating circuit and domestic hot water circuit are purged adaptively by automatically switching the circuits via the automatic air vent (the cap for the automatic air vent is loosened at the factory). -
Page 56: H Wiring Diagram
Wiring diagram +24V Hallsignal Masse X100 X40 X51 X100 230V~ X101 X101 Installation and maintenance instructions ecoTEC exclusive 0020193966_04... - Page 57 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...
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Page 58: Commissioning Checklist
Commissioning Checklist Benchmark Commissioning & Warranty Validation Service Record It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. - Page 59 GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s)) Weather compensation...
- Page 60 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER Date: SERVICE/INTERIM WORK ON BOILER...
- Page 61 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER Date: SERVICE/INTERIM WORK ON BOILER...
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Page 62: J Commissioning Flow Chart
Commissioning Flow Chart 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... -
Page 63: Index
Index Electronics self-test ............. 34 Expansion vessel, replacing..........40 Air ratio setting .............. 29–30 Fan, replacing..............39 Air/flue pipe, connecting ............20 Fault codes..............37, 52 Air/flue pipe, horizontal wall duct......... 15 Fault memory, checking ............37 Air/flue pipe, installing ............20 Fault memory, deleting............ - Page 64 PCB or display, replacing ............ 40 Power supply............... 21 Pre-charge pressure for the internal expansion vessel, checking ................36 Preparing, maintenance work..........34 Preparing, repair work ............38 Product dimensions............. 11 Product, draining ..............36 Product, switching off ............41 Propane................
- Page 68 Supplier Vaillant Ltd. Nottingham Road Belper Derbyshire DE56 1JT Telephone 0330 100 3461 info@vaillant.co.uk www.vaillant.co.uk 0020193966_04 Publisher/manufacturer Vaillant GmbH Berghauser Str. 40 D-42859 Remscheid Tel. +492191 18 0 Fax +492191 18 2810 info@vaillant.de www.vaillant.de © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.