Vaillant ecoTEC exclusive 627, Installation And Maintenance Instructions Manual

Page 1: ...en Installation and maintenance instructions ecoTEC exclusive VU 256 5 7 H GB ecoTEC exclusive 627 0020193966_04 29 07 2020 ...

Page 2: ...hecking and treating the heating water filling and supplementary water 25 9 8 Filling the condensate siphon 26 9 9 Preventing low water pressure 26 9 10 Filling the heating installation 27 9 11 Flushing the heating installation for the first time cold 27 9 12 Purging the heating installation 27 9 13 Gas inspection 27 9 14 Checking leak tightness 30 9 15 Checking the heating mode 30 9 16 Thoroughly...

Page 3: ...dix 42 A Inspection and maintenance work 42 B Installer level Overview 43 C Overview of diagnostics codes 45 D Status codes Overview 50 E Overview of fault codes 52 F Check programmes Overview 55 G Function menu Overview 55 H Wiring diagram 56 I Commissioning Checklist 58 J Commissioning Flow Chart 62 Index 63 ...

Page 4: ...Any direct use in industrial or commercial processes Any use other than those described in these instructions and any use that goes beyond what is described here 1 2 Qualification The person carrying out the work described here must have completed professional train ing The competent person must demon strably have all of the knowledge skills and capabilities that are required in order to carry out...

Page 5: ...supply Unsuitable or insufficient combustion and room air may lead to material damage but also to life threatening situations To ensure that the combustion air supply is sufficient during open flued operation Ensure that the air supply to the product s installation room is permanently unobstruc ted and sufficient in accordance with the relevant ventilation requirements This also applies in particu...

Page 6: ...rone to frost 1 3 11 Safety devices Install the necessary safety devices in the installation 1 3 12 Risk of death from leaks if the product is installed below ground level Liquid gas accumulates at floor level If the product is installed below ground level liquid gas may accumulate at floor level if there are any leaks In this case there is a risk of explosion Make sure that liquid gas cannot esca...

Page 7: ... vaillant group com Spares Enquiries Telephone 01773 596 615 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...

Page 8: ... nominal heat output may be higher than the value in the technical data depending on the design of the system and the current operating status VU 256 5 7 H GB ecoTEC exclusive 627 Nominal heat output range P at 50 30 C 3 4 to 26 7 kW Nominal heat output range P at 80 60 C 3 0 to 24 7 kW Maximum heat output for hot water generation 30 0 kW Maximum heat input for hot water generation 30 3 kW Maximum...

Page 9: ...Available for Boilers Heating controls and chemical inhib itors the Energy Saving Trust endorsed product brandmark gives consumers confidence that a product will cost less to run help lower energy bills and reduce carbon emissions About the Energy Saving Trust Energy Saving Trust is an independent and impartial organ isation that provides trusted energy saving advice to em power millions of people...

Page 10: ...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 To restart the boiler press the reset button on the boiler interface If the boiler fails to resume normal operation and all exte...

Page 11: ...Condensate discharge hose 1 Mounting template 1 Enclosed documentation 6 2 Dimensions 620 20 720 A B 125 180 130 440 80 188 160 100 100 55 55 12 1 3 4 5 3 5 11 4 6 7 8 9 2 10 1 Air flue pipe wall duct 2 Unit mounting bracket 3 Heating flow 4 Gas connection 5 Heating return 6 Connection for the heating expansion relief valve drain pipework 7 Condensate siphon connection 8 Condensate siphon 9 Cylind...

Page 12: ...nt ventilation is not required if the product is fitted with a concentric flue system 6 6 Air flue pipe 6 6 1 Regulation Different flue outlet configurations can be carried out Consult the installation manual for air flue gas systems for more information about the other possibilities and associated accessories Minimum fall 44 mm m Standard flue terminal kits have an in built fall back to the boile...

Page 13: ...clearance to noncombustible building material Vertical flue clearance to combustible building material 500 mm 1 500 mm J Above below and either side of an opening door air vent or opening window 300 mm K Diagonally to an opening door air vent or opening window 600 mm L 2 To an internal or external corner 200 mm M Below a Velux window Above or to either side of the Velux window 2 000 mm 600 mm N Fr...

Page 14: ...need to be increased to avoid wall staining and nuisance from pluming depending on site conditions Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fixings Installations in car ports are not recommended The flue cannot be lower than 1 metre from the top of ...

Page 15: ...me into con tact with the terminal or the terminal could be subject to dam age If a terminal guard is required it must be positioned to provide minimum of 50 mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in the figure 6 6 3 3 Vertical Concentric Flue 60 100 mm or 80 125 mm C33 type installation Consult the separate installatio...

Page 16: ...tration 6 9 2 Installing the front casing Refit the components in the reverse order 6 10 Removing installing the side section 6 10 1 Removing the side section 2x B A C D Caution Risk of material damage caused by mech 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 Depress...

Page 17: ...e Check whether the gas type that is available at the in stallation site and the gas type that is set in the product are the same To do this check the setting for diagnostics code D 087 Page 31 7 2 Preparing for installation 1 Make sure that the existing gas meter is capable of passing the rate of gas supply required 2 Consider the maximum heat output given in DHW mode 3 Install a system separator...

Page 18: ...ctly Follow the instructions listed here and observe directives and local regulations on condensed water discharge If you cannot guarantee that the materials from which the condensate discharge pipe is made are suitable install a system to neutralise the condensate Connect the condensate discharge 2 to a condensate discharge pipe 3 that has a minimum internal diameter of 19 mm 30 mm internal diame...

Page 19: ...oil and vent stack Ø22mm Ø 32mm 3 m 7 8 1 3 External termination to gulley or hopper Ø22mm Ø 32mm 3 m Best practice 7 8 1 4 Internal termination into combined sink waste Ø32mm Ø22mm 3 m 100mm Preferred option for external termination 7 8 1 5 External termination into soakaway 500 mm 100 mm 300 mm 50 25 25 25 25 Ø12 Ø32mm 3 m 1 2 3 4 5 6 1 Ground either or 2 Seal 3 Plastic tube 100 mm diameter 4 Bo...

Page 20: ...l Condition Installation in damp rooms You must connect the product to a room sealed air flue system The combustion air must not be taken from the installation room Caution Risk of poisoning due to escaping flue gas Mineral oil based greases can damage the seals Instead of grease use only water or com mercially available soft soap to aid install ation 3 Install the air flue pipe using the set up i...

Page 21: ...s resulting from loose individual wires fit conductor end sleeves on the stripped ends of the conductors 7 Screw the respective plug to the connection cable 8 Check whether all conductors are sitting mechanically securely in the terminals of the plug Remedy this if necessary 9 Plug the plug into the associated PCB slot see the wir ing diagram in the appendix 7 10 3 Establishing the power supply Ca...

Page 22: ...eady a bridge Condition Connecting a low voltage control 24 V Remove the bridge and connect the control to the 24 V RT connection X100 or X106 Condition Connecting 230 volt controller Connect the switched live supply with the terminal marked RT at X1 beside the LNPE connections then remove the link at X100 do NOT connect 230 volt to any other terminal than the RT connection Condition Connecting a ...

Page 23: ... in staller level is included in the table in the appendix Installer level Overview Page 43 8 2 Calling up the installer level 1 Only call up the installer level if you are a competent person 2 Press and at the same time 3 Navigate to Menu Installer level and confirm by pressing 4 Set the value 17 code and confirm by pressing 8 3 Live Monitor status codes Menu Live monitor Status codes in the disp...

Page 24: ...the same time Also briefly press Press and hold and until the display shows the language setting option Select the required language Confirm twice by pressing 9 3 2 Filling mode Filling mode check programme P 06 is activated automatic ally in the installation assistant for as long as the filling mode appears on the display Fill the heating installation Page 27 9 3 3 Purging 1 Unlike in the Check p...

Page 25: ... Purging check programme The internal pump is cyclically actuated The heating circuit and 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 Hot water circuit active or Heating circuit active display 1 x Start purging 1 x Cancel End purge programme Note The duration of the purge pr...

Page 26: ...ability for the compatibility of any additive or its effectiveness in the rest of the heating system Additives for cleaning measures subsequent flushing required Adey MC3 Adey MC5 Fernox F3 Sentinel X 300 Sentinel X 400 Additives intended to remain permanently in the installation Adey MC1 Fernox F1 Fernox F2 Sentinel X 100 Sentinel X 200 Additives for frost protection intended to remain permanentl...

Page 27: ...he radiator valves and the drain valves so that the water can drain quickly Start at the next point in the installation and open the purging valves on the radiators so that the contaminated water can completely drain 4 Close the draining cocks 5 Refill the heating system with water 6 Check that the expansion relief valve of the heating system is functioning correctly by turning the handle on the v...

Page 28: ...aximum gas flow rate onto the Benchmark gas boiler commissioning checklist 9 13 3 Checking the gas flow pressure 1 Ensure that the gas inlet working pressure can be obtained with all other gas appliances in the property working 2 Close the gas stopcock 1 2 3 Use a screwdriver to undo the sealing screw of the test nipple 1 at the gas valve assembly 4 Connect a manometer 2 to the test nipple 1 5 Ope...

Page 29: ...luence the calibration of the gas air mixture During the calibration and when measur ing the CO content you must operate the product with the front casing installed and closed and with the flue pipe completely installed 1 Start up the product Note Since the combustion can be continuously monitored by the product you do not need to check the combustion 2 Ensure that the maximum heat volume can be t...

Page 30: ...e P 01 6 Alternatives 1 Ensure that there is a heat demand at the domestic hot water cylinder If required open all of the draw off point and allow the domestic hot water cylinder to cool If required carry out calibration and measurement again 6 Alternatives 2 Check the installation and if required carry out cal ibration and measurement again with the correct in stallation Condition The domestic ho...

Page 31: ...lement default setting 20 mins 10 2 1 Setting the burner anti cycling time 1 Navigate to Menu Installer level Diagnostics menu D 002 Max anti cycl time Heating and con firm by pressing 2 Set the burner anti cycling time and confirm by pressing TFlow tar get C Set maximum burner anti cycling time min 1 5 10 15 20 25 30 30 2 0 4 0 8 5 12 5 16 5 20 5 25 0 35 2 0 4 0 7 5 11 0 15 0 18 5 22 0 TFlow tar ...

Page 32: ... 035 350 If the radiators do not heat up sufficiently at the default setting In this case you must set the pump to the maximum speed Mid position 5 turns to the left 0 025 250 Default setting 5 further turns to the left from the mid position 0 017 170 If noises are produced in the radiators or radiator valves Install the front casing 11 Handing over to the end user At the time of commissioning com...

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 Complete and sign off the guarantee documentation ...

Page 34: ...off The fan runs at maximum rotational speed T 04 Check cylinder charge pump Switch the cylinder charging pump on and off T 05 Check circula tion pump Switch the circulation pump on and off T 06 Check external pump Switch the external pump on and off T 08 Checking the burner Product starts up and switches to minimum load The flow temperature is shown in the display 12 6 Electronics self test Menu ...

Page 35: ...back wall of the heat exchanger If you notice any signs of damage replace the relevant insulating mat 12 8 2 Cleaning the heat exchanger 1 Protect the hinged down electronics box against spray ing water 1 2 3 4 2 Never undo the four nuts on the stud bolt 1 or tighten them 3 Clean the spiral immersion heater 3 of the heat ex changer 4 using water or if required vinegar to a maximum of 5 acid Allow ...

Page 36: ...ing the product 1 Close the service valves of the product 2 Start the check programme P 06 diverter valve mid position 3 Open the drain valves 4 Make sure that the cap of the automatic air vent on the internal pump is open so that the product can be drained fully 12 11 Checking the pre charge pressure for the internal expansion vessel 1 Close the service valves and drain the product 2 Measure the ...

Page 37: ...on mode Check and if required replace the all gas sensor 13 2 Checking service messages To obtain further information call up the Live monitor Page 23 Condition S 40 is displayed The product is in Comfort protection mode The product has detected a temporary fault and continues to run with restric ted comfort The product switches back to the normal operat ing mode To establish whether or not a comp...

Page 38: ...y of the product and it will therefore no longer comply with the applicable standards We strongly recommend that you use original spare parts from the manufacturer as this guarantees fault free and safe operation of the product To receive information about the available original spare parts contact the contact address provided on the back page of these instructions If you require spare parts for m...

Page 39: ...hermal module Page 34 3 Remove the left side section 4 Detach the condensate discharge hose from the heat exchanger 2 3 4 1 5 Remove the clamps 2 and 3 from the flow connec tion and the return connection 6 Undo the union nut 4 on the pump s return connection and remove the pipe from the return connection on the heat exchanger 7 Remove the pipe from the flow connection on the heat exchanger 8 Remov...

Page 40: ...allation 13 7 6 Replacing the PCB or the display 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 1 Open the electronics box Page 21 2 Replace the PCB or display according to the assembly and installation instructions supplied X31 X12 1 3 If you are replacing the PCB rem...

Page 41: ...s stopcock 13 9 Checking the product for leak tightness Check that the product is leak tight Page 30 14 Decommissioning 14 1 Temporarily decommissioning the product Press the on off button The display goes out Close the gas stopcock For products with domestic hot water generation and products with a connected domestic hot water cylinder you must also close the cold water isolation valve 14 2 Perma...

Page 42: ...ndition of the product and if required eliminate any faults that are found Annually 11 Calibrating the heat generator and measuring the CO CO content and gas flow in heating mode Annually 29 12 Logging the CO content air ratio and CO CO ratio Annually 13 Check the product s recirculation at the supply air test point on the air flue pipe If required inspect the entire air flue system and if necessa...

Page 43: ...T 01 Internal pump On Off T 02 3 way valve On Off T 03 Fan On Off T 04 Cylinder charging pump On Off T 05 Circulation pump On Off T 06 External pump On Off T 08 Burner On Off Installer level Test programs Electronics self test Self test Yes No Installer level Appliance config Language Languages available for selection Country specific Target flow temp 30 75 1 DHW temperature 30 60 1 Product with h...

Page 44: ...ls Phone num ber 0 9 Auto Factory setting On Off Installer level Diagnostics menu D XXX D XXX Current value Installer level Start inst assistant Language Languages available for selection Country specific Filling mode 3 way valve is in mid position 0 2 0 Normal operating mode 1 Mid position parallel operation 2 Permanent heating mode position Purge program Select circ using Automatic adaptive purg...

Page 45: ... faults have occurred C Overview of diagnostics codes Note Since the code table is used for various products some codes may not be visible for the product in question Code Parameter Values Unit Increment select explanation Factory setting Own setting Min Max D 000 Heating partial load Output range specific kW Adjustable partial heat load Auto Product automatically adjusts max partial load to curre...

Page 46: ... On Not ad justable D 014 Pump speed target value Target value of internal high effi ciency pump Possible settings 0 Auto 1 53 2 60 3 70 4 85 5 100 0 Auto D 015 Pump speed actual value Current value High efficiency pump Not ad justable D 016 Controller 24 V DC Heat ing mode Current value Heating mode 0 Off 1 On Not ad justable D 017 Control type 0 1 Heating flow return temperature control changeov...

Page 47: ... ive 9 Anti legionella pump not act ive 10 Solar valve not active 2 D 027 Accessory relay 1 1 10 Switching of relay 1 on the VR 40 2 in 7 multi functional module 1 Circulation pump 2 External pump 3 Cylinder charging pump 4 Extraction hood 5 External solenoid valve 6 External fault message 7 Solar pump not active 8 eBUS remote control not act ive 9 Anti legionella pump not act ive 10 Solar valve n...

Page 48: ...cts with integrated do mestic hot water generation 0 Solar post heating deactivated 3 Domestic hot water activated min target value 60 C 0 D 060 Number of safety therm shut downs Current value Number of safety cut out switch off sequences Not ad justable D 061 No of shut downs in ign flame controller Current value Not ad justable D 064 Avg ignition time Current value s Not ad justable D 065 Max ig...

Page 49: ...tenance messages 0 1 0 Off 1 On 1 D 087 Set the type of gas 0 2 0 Natural gas 1 Propane 50 mbar 2 Propane 30 37 mbar Fit the correct coding resistor for gas family X24 Natural gas factory setting Yellow Liquefied petroleum gas Grey 0 D 088 Min DHW flow rate 0 1 Switch on delay for domestic hot water draw off detection via im peller combination products only 0 1 5 l hr no delay 1 3 7 l hr 2 s delay...

Page 50: ...e Fan start up S 02 Heating mode Pump pre run Heating mode Pump prerun S 03 Heating mode Ignition Heating mode Ignition S 04 Heating mode Burner on Heating mode Burner on S 05 Heating mode Pump fan overrun Heating mode Pump fan overrun S 06 Heating mode Fan overrun Heating mode Fan overrun S 07 Heating mode Pump overrun Heating mode Pump overrun S 08 Heating mode Anti cycling time Heating mode Rem...

Page 51: ... with accessory VR40 or condensate pump defective heat requirement is blocked S 46 Comfort protection Minimum load loss of flame Comfort protection mode flame loss at minimum load S 53 Waiting time Water shortage Product is within the waiting period of the modulation block operating block function as a result of water defi ciency flow return spread too large S 54 Waiting time Water shortage Produc...

Page 52: ...nt water in the product water pressure sensor defective cable to pump or water pressure sensor loose not connected defective F 23 Safety switch off Temp spread too large Pump blocked insufficient pump output air in product flow and return NTC connected the wrong way round F 24 Safety switch off Temp incr too fast Pump blocked insufficient pump output air in product system pressure too low non retu...

Page 53: ...value exceeded A component in the combustion regulation is defective Contact fault at the gas valve assembly plug not plugged in cor rectly or not plugged in plug defective slot is defective loose con nection If the fault occurs again after being reset The gas valve assembly is defective F 57 Fault Measuring program Active comfort protection mode has detected a regulation fault Ignition electrode ...

Page 54: ...ylinder sensor Air in the actoSTOR pump Inspect cable harness for pump Check the impeller sensor and or limiter in the product Prioritising diverter valve defective Secondary heat exchanger blocked Pump defective F 82 Fault Ext current anode External current anode not connected X43 edge connector with bridge missing from the PCB External current anode connected Power supply to the external current...

Page 55: ...Reset eGas Calling up the programme deletes all of the CH offsets central heating that have been saved from previous calibration processes The products then starts by fully calibrating the combustion regulation status S 09 P 06 Filling mode The prioritising diverter valve is moved to the mid position The burner and pump are switched off to fill or drain the product G Function menu Overview Functio...

Page 56: ... 3 2 4 1 2 3 L N L N L N X16 L N 1 2 3 1 2 3 19 1 20 8 17 7 18 6 4 3 1 M C1 C2 16 4 3 17 5 7 8 5 4 2 1 Masse PWM Hallsignal 24V Burner Off BUS RT 24V X100 4 2 10 11 2 3 1 5 8 1 6 8 3 5 1 2 4 1 2 3 5 6 7 8 X30 X40 X51 X35 X31 X22 X90 2 1 T2 Fuse X12 X25 X21 X2 Opt X16 Fan X11 TL Pump X13 X18 CH Pump B off RT BUS X100 X24 X20 X101 X41 5 X51 11 15 2 1 9 18 18 21 20 4 3 17 16 13 14 12 11 10 7 15 6 8 2...

Page 57: ...e control 7 Return temperature sensor 8 Flow temperature sensor 9 Fan 10 Contact thermostat burner off 11 24 V DC room thermostat 12 Bus connection digital room thermostat control 13 Prioritising diverter valve 14 Water pressure sensor 15 Cylinder temperature sensor 16 Cylinder contact C1 C2 17 Internal heating circuit flow rate sensor 18 Internal pump 19 Gas family coding resistor 20 Additional r...

Page 58: ...sumer and they should be made aware it is ultimately their responsibility to register with the manufacturer within the allotted time period It is essential that the boiler is serviced in line with the manufacturers recommendations at least annually This must be carried out by a competent Gas Safe registered engineer The service details should be recorded on the Benchmark Service and Interim Boiler...

Page 59: ...put left at factory settings Yes No If no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar C Central heating return temperature C System correctly balanced rebalanced Yes COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No Water scale reducer softener pre existing Fitted Not required Brand Product Yes No If yes DHW expansion v...

Page 60: ...OILER delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO undertaken in accordance with manufacturers instructions and readings are correct yes Gas rate m3 h OR ft3 h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken in accordance with BS 7593 and boiler...

Page 61: ...OILER delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO undertaken in accordance with manufacturers instructions and readings are correct yes Gas rate m3 h OR ft3 h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken in accordance with BS 7593 and boiler...

Page 62: ...ot specify how to set boiler to minimum rate contact Technical Helpline for advice CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE With boiler still set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording NOTE If no flue gas sampling point is present and the correct procedure is not specified in the manual consult boiler manufacturer for gu...

Page 63: ...ing 41 Decommissioning temporarily 41 Diagnostics codes calling up 31 Disposal packaging 41 Disposing of the packaging 41 Documents 9 Draining product 36 E Electronics box closing 21 Electronics box opening 21 Electronics self test 34 Expansion vessel replacing 40 F Fan replacing 39 Fault codes 37 52 Fault memory checking 37 Fault memory deleting 37 Fault messages 37 Filling 27 Filling mode 24 Flu...

Page 64: ... fan 39 Replacing gas family coding resistor 22 Replacing gas valve assembly 38 Replacing heat exchanger 39 Replacing PCB and display 40 Replacing PCB or display 40 Replacing unit connection piece for the air flue pipe 20 Resetting burner anti cycling time 31 S Safety devices 10 Scope of delivery 11 Self test 34 55 Serial number 9 10 Service message 37 Setting bypass valve 32 Setting gas type 25 S...

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Page 68: ...blisher 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 Subject to technical modifications 0020193966_04 ...