Vaillant VUW 246/5-3 (H-GB), Installation And Maintenance Instructions Manual

Page 1: ...en Installation and maintenance instructions ecoTEC pro VUW 6 5 3 0020244995_04 29 07 2020 ...

Page 2: ...e product on and off 28 9 5 Using check programmes 28 9 6 Preventing low water pressure 28 9 7 Flushing the heating installation for the first time cold 28 9 8 Filling the heating installation 28 9 9 Purging the heating installation 29 9 10 Filling and purging the hot water system 29 9 11 Gas inspection 29 9 12 Thoroughly flushing the heating installation hot 31 9 13 Checking leak tightness 31 10 ...

Page 3: ...rview of diagnostics codes 41 C Status codes Overview 45 D Overview of fault codes 46 E Check programmes Overview 48 F Wiring diagrams 49 F 1 Product connection diagram with integrated hot water generation 49 G Commissioning Checklist 50 H Commissioning Flow Chart 54 Index 55 ...

Page 4: ... 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 th...

Page 5: ... accessory 200 mm To ensure that the seals are not damaged Instead of grease use only water or com mercially available soft soap to aid installa tion 1 3 3 Electricity The power supply terminals L and N remain live To prevent electric shocks proceed as fol lows before working on the product Disconnect the product from the power supply by switching off all power supplies at all poles electrical par...

Page 6: ...cessary safety devices in the installation 1 3 11 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 escape from the product or the gas pipe under any circ...

Page 7: ...illant 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 co...

Page 8: ...tural gas flow pressure 2 0 kPa 20 0 mbar 2 0 kPa 20 0 mbar G31 propane gas flow pressure 3 7 kPa 37 0 mbar Gas flow rate at 15 C and 1013 mbar based on domestic hot water generation if applicable G20 2 5 m h 2 9 m h Gas flow rate at 15 C and 1013 mbar based on domestic hot water generation if applicable G31 2 2 kg h Min flue gas mass flow rate G20 2 47 g s 2 47 g s Min flue gas mass flow rate G31...

Page 9: ...ry at 40 30 C 107 0 107 0 Nominal heat input ef ficiency stationary at 50 30 C 106 0 106 0 Nominal heat input ef ficiency stationary at 60 40 C 101 0 101 0 Nominal heat input ef ficiency stationary at 80 60 C 98 0 98 0 Technical data Power loading G31 VUW 286 5 3 P GB ecoTEC pro 28 Nominal heat output range P at 50 30 C 7 9 to 25 3 kW Nominal heat output range P at 80 60 C 7 2 to 24 0 kW Maximum h...

Page 10: ... Hot water handling mode VUW 246 5 3 H GB ecoTEC pro 24 VUW 286 5 3 H GB ecoTEC pro 28 VUW 286 5 3 P GB ecoTEC pro 28 Lowest water volume 2 0 l min 2 0 l min 2 0 l min Water volume at ΔT 30 K 11 2 l min 13 l min 13 l min Water volume at ΔT 35 K 9 6 l min 11 1 l min 11 1 l min Water volume at ΔT 42 K 8 0 l min 9 3 l min 9 3 l min Permitted overpressure 1 0 MPa 10 0 bar 1 0 MPa 10 0 bar 1 0 MPa 10 0...

Page 11: ...tion that provides trusted energy saving advice to em power millions of people to lead affordable low energy life styles For more information visit energysavingtrust org uk 5 3 Hot Water Association 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 5 4 Information on the ide...

Page 12: ...aillant 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 external controls are calling for heat then call your Installation Servi cing company or Vaillant service 5 7 3 Fr...

Page 13: ...unting template 1 Condensate discharge hose 1 Enclosed documentation 6 2 Dimensions 720 20 624 160 125 188 100 100 35 35 440 A 338 180 125 2 1 3 5 7 9 8 4 6 6 4 7 11 10 3 5 12 1 Air flue pipe wall duct 2 Unit mounting bracket 3 Heating flow 22 1 5 diameter 4 Domestic hot water connection 15 1 5 diameter 5 Gas connection 15 1 5 diameter 6 Cold water connection 15 1 5 diameter 7 Heating return 22 1 ...

Page 14: ...As a consequence the heat loss from the appliance casing during operation is very low Compartment ventilation is not required as the products are only certified and can only be 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 p...

Page 15: ...arance 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 From ...

Page 16: ...void 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 a lightwell due to the bu...

Page 17: ...uard is required if persons could come 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 installat...

Page 18: ... Consult the separate installation manual for air flue gas sys tems supplied with your appliance for all possibilities and as sociated accessories and how to install the flue system 6 7 Using the installation template Use the installation template to ascertain the locations at which you need to drill holes and make breakthroughs 6 8 Wall mounting the product 1 Check the load bearing capacity of th...

Page 19: ...ed 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 Always only remove one side section never both side sections at the same time Remove the side section as shown in the illustration 6 10 2 Installing the side section Refit the components in the reverse order ...

Page 20: ...itional expansion vessel connected as close to the product as possible in the heating return Condition External expansion vessel installed and warm start active Install a non return valve in the product outlet heating flow or decommission the internal expansion vessel in order to prevent the warm start function from being increasingly activated due to backflow 6 Install the connection pipes such t...

Page 21: ...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 1 to a condensate discharge pipe 3 that has a minimum internal diameter of 19 mm 30 mm internal diameter f...

Page 22: ...nd vent stack Ø22mm Preferred option 7 7 1 2 Direct connection to external soil and vent stack Ø22mm Ø 32mm 3 m 7 7 1 3 External termination to gulley or hopper Ø22mm Ø 32mm 3 m Best practice 7 7 1 4 Internal termination into combined sink waste Ø32mm Ø22mm 3 m 100mm Preferred option for external termination 7 7 1 5 External termination into soakaway 500 mm 100 mm 300 mm 50 25 25 25 25 Ø12 Ø32mm 3...

Page 23: ...not be taken from the installation site 3 Install the air flue pipe using the set up instructions 7 8 2 Replacing the connector for the air flue pipe as required 1 Replace the connector for the air flue pipe as required The product specific standard equipment is listed under Technical data 2 Remove the connection piece for the air flue pipe this is installed at the factory Page 23 3 If required in...

Page 24: ...l 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 9 3 Establishing the power supply Caution Risk of material damage due...

Page 25: ...via eBUS Connect the controller to the eBUS connection Bridge the 24 V RT connection X100 or X106 if there is not already a bridge Condition Connecting a low voltage controller 24 V Remove the bridge and connect the controller 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 connection...

Page 26: ...d appear in the display 4 Set the value 17 code and confirm by pressing 5 Press to access the check programmes P and the fault codes F and to return to the diagnostics codes D 6 Use or to set the required value and confirm by pressing 7 Confirm by pressing 8 Press to cancel a setting or exit the installer level 8 4 Live Monitor status codes Menu Live monitor Status codes in the display provide inf...

Page 27: ...ons and technical rules do not stipulate more stringent requirements the following applies You must treat the heating water in the following cases If the entire filling and supplementary water quantity dur ing the operating life of the system exceeds three times the nominal volume of the heating installation or If the guideline values listed in the following table are not met or If the pH value of...

Page 28: ...ater in accordance with the following instructions 1 Check whether all thermostatic radiator valves and both service valves on the product are open 2 Connect a hose to the drain valve that is located at the lowest position in the heating system 3 Open the 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...

Page 29: ...a in the appendix Call Vaillant Service 0330 1003 143 Do not start up the product Condition The product design is compatible with the local gas group Proceed as described below 9 11 2 Checking the air flue pipe flue gas recirculation 1 Check the flue gas installation is intact in accordance with the latest gas safe technical bulletin and informa tion supplied in the installation instructions 2 For...

Page 30: ...any and proceed as follows End the check programme P 01 Allow the boiler to cool down by allowing pump overrun to operate for a minimum of two minutes Close the gas stopcock Remove the pressure gauge and retighten the sealing screw 1 for the measuring nipple Open the gas stopcock Check the test nipple for gas tightness Close the gas stopcock Install the front casing Disconnect the product from the...

Page 31: ...bar is attained Note The actual reading on the digital pressure gauge should ideally be 0 05 MPa 0 5 bar plus an additional pressure corresponding to the highest point of the system above the base of the boiler 10 m head equals an ad ditional 1 bar reading on the pressure gauge The minimum pressure should not be less than 0 1 MPa 1 bar in any installation If the system is to be treated with an inh...

Page 32: ...ating hours until the next maintenance work is due and confirm by pressing Heat de mand Number of per sons Guideline value for burner operating hours until the next inspection maintenance work is due for an average operating time of one year dependent upon the system type 5 0 kW 1 2 1050 h 2 3 1150 h 10 0 kW 1 2 1500 h 2 3 1600 h 15 0 kW 2 3 1800 h 3 4 1900 h Heat de mand Number of per sons Guidel...

Page 33: ...ich requests that the user reads the instructions to the front of the product in the end user s language Draw attention to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK Explain to the end user how the safety devices work and where they are located Inform the e...

Page 34: ...gas connections Correctness of the water pressure The condition of the whole system in particular the con dition of radiator valves evidence of leakage from the heating system and dripping taps Correct any faults before proceeding 12 4 Preparing the maintenance work 1 Switch off the product 2 Disconnect the product from the power grid 3 Remove the front casing Page 18 4 Close the gas stopcock 5 Cl...

Page 35: ...water or if required vinegar to a maximum of 5 acid Allow the vinegar to act on the heat exchanger for 20 minutes 4 Rinse away any loose dirt with a sharp jet of water or use a plastic brush Do not point the water jet directly at the insulating mat 2 on the back of the heat ex changer The water flows out of the heat exchanger through the condensate siphon 12 7 Checking the burner 1 2 3 1 Check the...

Page 36: ...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 12 Checking the pre charge pressure for the internal expansion vessel 1 Close the service valves and drain the product 2 Measure the pre charge pressure of the expansion ves sel at the vessel valve Condition Pre charge pressure 0 075 MPa 0 75 bar Ideally you shou...

Page 37: ...s To delete the entire fault list navigate to diagnostics code D 094 in the installer level Set the diagnostics code to 1 and confirm by pressing 13 4 Resetting parameters to factory settings 1 Navigate to diagnostics code D 096 in the installer level 2 Set the diagnostics code to 1 and confirm by pressing 13 5 Preparing the repair work 1 Decommission the product 2 Disconnect the product from the ...

Page 38: ...e installa tion work has been completed 13 Refit the entire fan gas valve unit in reverse order You must use a new seal 5 for this 14 Ensure that the order in which the three screws are screwed in between the fan and the mixture pipe cor responds to the numbering 3 2 and 4 15 Tighten the cap nut 2 on the gas valve and the cap nut 8 between the gas pipes In the process secure the gas pipe against t...

Page 39: ...ics box Page 24 2 Replace the PCB and display according to the assembly and installation instructions supplied 3 Close the electronics box 4 Press the on off button on the product Page 28 You are automatically taken to D 093 to set the device specific number 5 Set the correct value for the relevant product type in ac cordance with the table below and confirm by pressing Product type number VUW 246...

Page 40: ... Carry out the combustion analysis Measure the CO content CO content and the CO CO ratio For products with a rear air flue connection The combustion analysis can only be carried out when the unit casing has been removed it is not necessary to test these products for flue gas recir culation Annually 12 Check the product s recirculation at the supply air test point on the air flue pipe If required i...

Page 41: ... value In C Not ad justable D 005 Heating target flow temperature In C the maximum value that is set in D 071 and is restricted by means of an eBUS control if such a control is connected Not ad justable D 006 Outlet temperature target value 35 to 65 Not ad justable D 007 Comfort mode target value APC target value Cylinder temperature target value Product with integrated domestic hot water generati...

Page 42: ... hot water mode stage 2 2 Automatic heating mode pump prerun overrun stage 1 domestic hot water mode stage 2 3 Always stage 2 4 Automatic heating mode pump prerun overrun stage 1 domestic hot water mode stage 1 2 D 020 Max DHW temperature target value Adjustment range 50 70 C actoSTOR 65 C 65 C D 022 DHW demand On Off Not ad justable D 023 Heating mode status Heating on heating off summer mode Not...

Page 43: ...44 Ionisation value actual value Display field 0 to 1020 800 no flame 400 good flame Not ad justable D 046 Pump mode 0 Relay with disable facility 1 PWM with disable facility 0 Relay with disable facility D 047 Current outside temperature with Vaillant weather compensated control Actual value in C Not ad justable D 050 Offset min speed In rpm adjustment range 0 to 3000 Nominal value set in factory...

Page 44: ... hours In hours h Not ad justable D 081 DHW operating hours In hours h Not ad justable D 082 Heating burner starts Number of burner start ups Not ad justable D 083 DHW burner starts Number of burner start ups Not ad justable D 084 Maintenance in Adjustment range 0 to 3000 hrs and for deactivated D 088 Min DHW flow rate Switch on delay for domestic hot water draw off detec tion via impeller only pr...

Page 45: ...ated S 17 DHW mode Pump over run The pump overrun for domestic hot water mode is activated S 20 DHW demand The domestic hot water demand is activated S 21 DHW mode Fan start up The fan start up for domestic hot water mode is activated S 22 DHW mode Pump pre run The pump prerun for domestic hot water mode is activated S 23 DHW mode Ignition The ignition for domestic hot water mode is activated S 24...

Page 46: ... the code table is used for various products some codes may not be visible for the product in question Message Possible cause Measure F 00 Interruption Flow sensor Flow temperature sensor de fective or not connected Check Flow temperature sensor plug cable harness PCB F 01 Interruption Return sensor Return temperature sensor de fective or not connected Check Return temperature sensor plug cable ha...

Page 47: ...cording sensor e g ionisation electrode for an unstable signal electronics F 65 Fault Electronics temp Electronics defective or too hot due to external influences 1 Check PCB 2 If required reduce the environmental temperature F 67 Fault Electronics flame Implausible flame signal Check Cable harness flame monitor PCB F 68 Fault Flame signal un stable Flame monitor reports an un stable flame signal ...

Page 48: ...ot water circuit are ad aptively purged by automatically switching the circuits using the automatic air vent the automatic air vent s cap must be loose The active circuit is shown in the display Press once to start purging the heating circuit Press once to end the purge programme Note The purge programme runs for 7 5 min per circuit and then terminates Purging the heating circuit Prioritising dive...

Page 49: ...Fuse X12 X2 X18 CH Pump B off RT BUS X106 X20 X1 X41 X51 L RT N 2 1 8 16 12 13 14 11 10 9 6 15 4 5 7 17 3 1 Main PCB 2 Operator control panel PCB 3 Outside temperature sensor flow temperature sensor optional external DCF receiver 4 Circulation pump remote control 5 Gas valve 6 Return temperature sensor 7 Flow temperature sensor 8 Fan 09 Contact thermostat burner off 10 24 V DC room thermostat 11 B...

Page 50: ...er 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 Wo...

Page 51: ... 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 vess...

Page 52: ...ER 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 ma...

Page 53: ...ER 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 ma...

Page 54: ...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 guida...

Page 55: ...E Electronics box closing 24 Electronics box opening 24 F Factory settings restoring 37 Fan replacing 38 Fault codes 37 Fault memory calling up 37 Fault memory deleting 37 Fault messages 37 Filling 28 Flue pipe equipment connection piece 23 Frost protection 12 G Gas connection value 29 Gas conversion 29 Gas Council Number 11 Gas group 20 Gas setting 29 Gas type 20 Gas valve replacing 38 Guarantee ...

Page 56: ...delivery 13 Serial number 12 Service message 37 Setting CO content 30 Setting maintenance interval 32 Setting pump output 32 Side section installing 19 Side section removing 19 Spare parts 37 Status codes 26 Switching off 39 T Technical data 8 Treating the heating water 27 U Unit connection piece for the air flue pipe 80 125 mm diameter 23 Unit connection piece for the air flue pipe replacing 23 U...

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Page 60: ...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 0020244995_04 ...