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

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. [phone]‑0 Fax [phone]‑2810
[e-mail] www.vaillant.de

Contents

2 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

Contents

1 Safety .................................................................... 4

1.1 Action-related warnings ......................................... 4

1.2 Intended use.......................................................... 4

1.3 General safety information .................................... 4

1.4 Regulations (directives, laws, standards) .............. 6

2 Notes on the documentation .............................. 7

2.1 Observing other applicable documents ................. 7

2.2 Storing documents................................................. 7

2.3 Validity of the instructions ...................................... 7

2.4 Benchmark............................................................. 7

3 Product description............................................. 7

3.1 Product design....................................................... 7

3.2 Information on the identification plate.................... 8

3.3 CE label ................................................................. 8

3.4 Energy Saving Trust Endorsed Products .............. 8

3.5 Compartment Ventilation ....................................... 8

4 Set-up.................................................................... 8

4.1 Unpacking the product........................................... 8

4.2 Scope of delivery ................................................... 8

4.3 Transporting the product ....................................... 9

4.4 Dimensions............................................................ 9

4.5 Minimum clearances............................................ 10

4.6 Using the installation template............................. 10

4.7 Wall-mounting the product................................... 10

4.8 Removing the front casing................................... 11

4.9 Removing the side section .................................. 11

5 Installation.......................................................... 11

5.1 Installation requirements ..................................... 12

5.2 Installing the gas connection ............................... 13

5.3 Checking the gas line for leak-tightness.............. 13

5.4 Installing the cylinder connections....................... 13

5.5 Connecting the heating flow and heating

return ................................................................... 13

5.6 Connecting the condensate drain pipework ........ 13

5.7 Installing the discharge pipe on the expansion

relief valve............................................................ 14

5.8 Flue installation.................................................... 14

5.9 Electrical installation ............................................ 14

6 Operation............................................................ 16

6.1 Operating concept ............................................... 16

6.2 Calling up the installer level ................................. 16

6.3 Live Monitor (status codes) ................................. 17

7 Start-up ............................................................... 17

7.1 Carrying out the initial start-up............................. 17

7.2 Switching the product on/off ................................ 17

7.3 Running the installation assistants ...................... 17

7.4 Restarting the installation assistants ................... 18

7.5 Test programmes................................................. 18

7.6 Using check programmes.................................... 18

7.7 Checking and treating the heating water/filling

and supplementary water .................................... 18

7.8 Preventing low water pressure ............................ 19

7.9 Flushing the heating installation for the first

time ("cold") ......................................................... 20

7.10 Filling the heating installation .............................. 20

7.11 Purging the heating installation ........................... 20

7.12 Filling the condensate trap .................................. 20

7.13 Gas inspection ..................................................... 21

7.14 Checking leak-tightness ...................................... 23

7.15 Thoroughly flushing the heating installation

("hot")................................................................... 24

8 Adapting the unit to the heating

installation.......................................................... 24

8.1 Calling up diagnostics codes ............................... 24

8.2 Burner anti-cycling time ....................................... 24

8.3 Setting the maintenance interval ......................... 25

8.4 Setting the pump output....................................... 25

8.5 Setting the bypass valve...................................... 25

8.6 Handing the product over to the operator............ 26

9 Troubleshooting ................................................ 26

9.1 Comfort protection mode for the heat cell ........... 26

9.2 Checking service messages................................ 26

9.3 Eliminating faults.................................................. 27

9.4 Calling up/clearing the fault memory ................... 27

9.5 Resetting parameters to factory settings ............. 27

9.6 Preparing the repair work .................................... 27

9.7 Replacing defective components......................... 27

9.8 Completing repair work........................................ 30

10 Inspection and maintenance ............................ 30

10.1 Function menu ..................................................... 30

10.2 Electronics self-test.............................................. 31

10.3 Working on the compact thermal module ............ 31

10.4 Cleaning the condensate trap.............................. 32

10.5 Draining the product ............................................ 33

10.6 Checking the pre-charge pressure for the

internal expansion vessel .................................... 33

10.7 Completing inspection and maintenance work .... 33

11 Decommissioning.............................................. 33

11.1 Temporarily decommissioning the product.......... 33

11.2 Decommissioning the product ............................. 33

12 Recycling and disposal..................................... 33

13 Customer service............................................... 33

Appendix ............................................................................ 34

A Installer level – Overview .................................. 34

B Overview of diagnostics codes........................ 36

C Status codes – Overview .................................. 41

D Overview of fault codes .................................... 43

E Wiring diagram................................................... 46

F Inspection and maintenance work –

Overview............................................................. 48

G Commissioning Checklist................................. 50

H Opening of the flue pipe.................................... 54

H.1 Positioning of the opening of a fan-supported

flue gas pipe ........................................................ 54

I Horizontal terminal positioning........................ 55

J Technical data.................................................... 55

Contents

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 3

Index ................................................................................... 59

1 Safety

4 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

1 Safety

1.1 Action-related warnings

Classification of action-related warnings

The action-related warnings are classified in
accordance with the severity of the possible
danger using the following warning signs and
signal words:

Warning symbols and signal words

Danger!

Imminent danger to life or risk of
severe personal injury

Danger!

Risk of death from electric shock

Warning.

Risk of minor personal injury

Caution.

Risk of material or environmental
damage

1.2 Intended use

There is a risk of injury or death to the user or
others, or of damage to the product and other
property in the event of improper use or use
for which it is not intended.

The product is intended as a heat generator
for closed heating installations and for hot
water generation.

Depending on the gas-fired boiler type, the
products referred to in these instructions
must only be installed and operated in con­junction with the air/flue pipe accessories lis­ted in the other applicable documents.

Intended use includes the following:

– observance of accompanying operating,

installation and servicing instructions for
the product and any other system compon­ents

– installing and fitting the product in accord-

ance with the product and system approval

– compliance with all inspection and main-

tenance conditions listed in the instruc­tions.

Intended use also covers installation in ac­cordance with the IP code.

Any other use that is not specified in these
instructions, or use beyond that specified in

this document shall be considered improper
use. Any direct commercial or industrial use
is also deemed to be improper.

Caution.

Improper use of any kind is prohibited.

1.3 General safety information

1.3.1 Risk caused by inadequate
qualifications

The following work must only be carried out
by competent persons who are sufficiently
qualified to do so:

– Set-up
– Dismantling
– Installation
– Start-up
– Inspection and maintenance
– Repair
– Decommissioning

▶ Observe all instructions that are included

with the product.

▶ Proceed in accordance with current tech-

nology.

▶ Observe all applicable directives, stand-

ards, laws and other regulations.

1.3.2 Risk of death from escaping gas

What to do if you smell gas in the building:

▶ Avoid rooms that smell of gas.
▶ If possible, open doors and windows fully

and ensure adequate ventilation.

▶ Do not use naked flames (e.g. lighters,

matches).

▶ Do not smoke.
▶ Do not use any electrical switches, mains

plugs, doorbells, telephones or other com­munication systems in the building.

▶ If it is safe to do so, close the emergency

control valve or the main isolator.

▶ If possible, close the gas isolator cock on

the product.

▶ Warn other occupants in the building by

yelling or banging on doors or walls.

▶ Leave the building immediately and ensure

that others do not enter the building.

▶ Notify the gas supply company or the Na-

tional Grid [phone] by tele-

Safety 1

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 5

phone once you are outside of the build­ing.

1.3.3 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 line under any
circumstance.

1.3.4 Risk of death due to blocked or
leaking flue gas routes

Installation errors, damage, tampering, unau­thorised installation sites or similar can cause
flue gas to escape and result in a risk of pois­oning.

What to do if you smell flue gas in the prop­erty:

▶ Open all accessible doors and windows

fully to provide ventilation.

▶ Switch off the product.
▶ Check the flue gas routes in the product

and the flue gas diversions.

1.3.5 Risk of poisoning and burns caused
by escaping hot flue gases

▶ Only operate the product if the air/flue pipe

has been completely installed.

▶ With the exception of short periods for

testing purposes, only operate the product
when the front casing is installed and
closed.

1.3.6 Risk of death due to explosive and
flammable materials

▶ Do not use the product in storage rooms

that contain explosive or flammable sub­stances (such as petrol, paper or paint).

1.3.7 Risk of death due to cabinet-type
casing

Cabinet-type casing can give rise to danger­ous situations when used on a product which
is operated with an open flue.

▶ Ensure that the product is supplied with

sufficient combustion air.

1.3.8 Risk of poisoning caused by
insufficient combustion air supply

Conditions: Open-flued operation

▶ Ensure that the air supply to the product's

installation room is permanently unobstruc­ted and sufficient in accordance with the
relevant ventilation requirements.

1.3.9 Risk of death due to lack of safety
devices

The schematic drawings included in this doc­ument do not show all safety devices re­quired for correct installation.

▶ Install the necessary safety devices in the

system.

▶ Observe the applicable national and inter-

national laws, standards and guidelines.

1.3.10 Risk of death from electric shock

There is a risk of death from electric shock if
you touch live components.

Before commencing work on the product:

▶ Disconnect the product from the power

supply by switching off all power supplies
at all poles (electrical partition with a con­tact gap of at least 3 mm, e.g. fuse or cir­cuit breaker).

▶ Secure against being switched back on

again.

▶ Wait for at least 3 minutes until the capa-

citors have discharged.

▶ Check that there is no voltage.

1.3.11 Risk of being burned or scalded by

hot components

▶ Only carry out work on these components

once they have cooled down.

1.3.12 Risk of death from escaping flue

gas

If you operate the product with an empty con­densate trap / siphon, then flue gas may es­cape into the room air.

▶ In order to operate the product, ensure that

the condensate trap / siphon is always full.

1 Safety

6 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

1.3.13 Risk of injury due to the heavy
weight of the product

▶ Make sure that the product is transported

by at least two people.

1.3.14 Risk of material damage caused by
using an unsuitable tool

▶ Use the correct tool to tighten or loosen

threaded connections.

1.3.15 Risk of material damage caused by
frost

▶ Do not install the product in rooms prone

to frost.

1.3.16 Risk of corrosion damage due to
unsuitable combustion and room
air

Sprays, solvents, chlorinated cleaning
agents, paint, adhesives, ammonia com­pounds, dust or similar substances may lead
to corrosion on the product and in the flue
gas guiding.

▶ Ensure that the supply of combustion air is

always free of fluorine, chlorine, sulphur,
dust, etc.

▶ Ensure that no chemical substances are

stored at the installation site.

▶ If you are installing the product in

hairdressing salons, painter's or joiner's
workshops, cleaning businesses or similar
locations, choose a separate installation
room in which the room air is technically
free of chemical substances.

1.3.17 Risk of damage to the flexible gas
pipe

The corrugated gas pipe may become dam­aged if weight is placed on it.

▶ Do not suspend the compact thermal

module on the flexible gas pipe, for
example during maintenance work.

1.4 Regulations (directives, laws,
standards)

▶ Observe the national regulations, stand-

ards, guidelines and laws.

Notes on the documentation 2

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 7

2 Notes on the documentation

2.1 Observing other applicable documents

▶ You must observe all the operating and installation in-

structions included with the system components.

2.2 Storing documents

▶ Pass these instructions and all other applicable docu-

ments on to the system operator.

2.3 Validity of the instructions

These instructions apply only to:

Product article number

Article num­ber

Gas Council
Number

627 (VU 256/5‑7 (H-GB))
ecoTEC exclusive

0010017063 41-694-02

2.4 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
at the time by the Health and Safety Executive and that it
meets the requirements of the appropriate Building Regu­lations. The Benchmark Checklist can be used to demon­strate compliance with Building Regulations and should be
provided to the customer for future reference.

Installers are required to carry out installation, commission­ing and servicing work in accordance with the Benchmark
Code of Practice which is available from the Heating and
Hotwater Industry Council who manage and promote the
Scheme.

Benchmark is managed and promoted by the Heating and
Hotwater Industry Council.

For more information visit www.centralheating.co.uk

3 Product description

3.1 Product design

The product does not require a minimum volume flow.

3

4

8

13

14

1112

17 16 15

19

18

5

6

9

10

7

1 2

1 Flue gas measuring

stub pipe

2 Connection for the flue

pipe

3 All-gas sensor

4 Expansion vessel

5 Compact thermal

module

6 Fan

7 Automatic air vent

8 Pressure gauge

9 Expansion relief valve

10 High-efficiency pump

11 Diverter valve

12 Electronics box

13 Bypass valve

14 Gas valve

15 Heat exchanger

16 Ignition electrode

17 Air intake pipe

18 Volume flow sensor

19 Water pressure sensor

4 Set-up

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3.2 Information on the identification plate

The identification plate is mounted on the underside of the
product in the factory.

Information on the
identification plate

Meaning

Read the instructions.

VU(W) ... Type designation

..6/5-7 Calorific value power/product generation

equipment

ecoTEC exclusive Product description

2H, G20 – 20 mbar
(2.0 kPa)

Gas group and gas connection pressure
as set at the factory

ww/yyyy Date of manufacture: Week/year

Cat. Approved unit categories

Types Approved gas-fired units

PMS Permissible total overpressure in heating

mode

PMW Permissible total overpressure during hot

water generation

T

max.

Max. flow temperature

ED 92/42 Current efficiency directive fulfilled with

4* rating

V Hz Mains voltage and mains frequency

W Max. electrical power consumption

IP Level of protection

Heating mode

Hot water generation

P Nominal heat output range

Q Heat input range

D Nominal hot water draw-off rate

Bar code with serial number,

7th to 16th digit = product article number

3.3 CE label

The CE label shows that the products comply with the basic
requirements of the applicable directives as stated on the
identification plate.

The declaration of conformity can be viewed at the manufac­turer's site.

3.4 Energy Saving Trust Endorsed Products

Only the most energy efficient products can carry the
‘Energy Saving Trust Endorsed Product’ brandmark making
it easy for consumers to choose products that have met strict
energy performance criteria.

Available for: Boilers, Heating controls and chemical inhib­itors, 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 organ­isation that provides trusted energy saving advice to em­power millions of people to lead affordable, low energy life­styles. For more information visit energysavingtrust.org.uk

3.5 Compartment Ventilation

The boilers are very high efficiency appliances.

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.

4 Set-up

4.1 Unpacking the product

1. Remove the product from its box.

2. Remove the protective film from all parts of the product.

4.2 Scope of delivery

Check that the scope of delivery is complete and intact.

Num­ber

Designation

1

Heat generator

1 Installation kit containing the following:

1 - Product bracket

1

- Expansion relief valve connection pipe

1 - Gas stopcock

1 - Gas connection pipe, dia. 15 mm

2 - Service valve

2 - Heating flow/return connection pipe

3 - Bag with small parts

1 - Gas family coding resistor

1 Mounting template

1

Enclosed documentation

Set-up 4

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 9

4.3 Transporting the product

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.

▶ Avoid bending your upper body – do not lean forwards or

to the side.

▶ Wear appropriate cut-resistant and non-slip gloves to

protect yourself against sharp edges and maintain a safe
and secure grip.

▶ If required, get somebody to assist you in this.

4.3.2 Unloading the box from the delivery van

▶ It is recommended that two people lift the unit together.
▶ Lift the box using the straps provided.
▶ Use safe lifting techniques – keep your back straight and

bend your legs at the knee.

▶ Hold the load as close as possible to your body.
▶ If the unit is being lifted by two persons, ensure your

movements are coordinated during lifting.

▶ If required, get somebody to assist you in this.

4.3.3 Transporting the box from the delivery

point to the installation site – ground floor

▶ It is recommended that two people lift the unit together.
▶ Use safe lifting techniques – keep your back straight and

bend your legs at the knee.

4.4 Dimensions

62420

720

A

B125

180

130

440

80

188

160

100100

5555

12

1

3 4 5

3

5

11

4

6

789

2

10

1 Flue pipe wall duct

2 Product bracket

3 Heating flow

4 Gas connection

5 Heating return

6 Connection for the

heating expansion relief
valve drain line

7 Condensate trap con-

nection

8 Condensate trap

9 Cylinder return

10 Cylinder primary pipe-

work

11 R1 tundish/condensate

trap connection

12 Flue pipe connection

Consult the installation template that is supplied to find the
dimension A.

4 Set-up

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The product's installation depth B can be found in the tech­nical data in the appendix.

4.5 Minimum clearances

B A

C C D

Minimum clearance

A 165 mm: Air/flue pipe, 60/100 mm diameter

275 mm: Air/flue pipe, 80/125 mm diameter

B 180 mm; optimum approx. 250 mm

C 5 mm; optimum approx. 50 mm

D 500 mm in front of the heat generator to enable

easy access for maintenance work (may be
provided by an opening door).

4.6 Using the installation template

▶ Use the installation template to ascertain the locations at

which you need to drill holes and make perforations.

4.7 Wall-mounting the product

1. Check whether the wall has sufficient load-bearing ca-

pacity to bear the operational weight of the product.

2. Check if the supplied fixing material may be used for

the wall.

Conditions: The load-bearing capacity of the wall is sufficient, The fixing
material may be used for the wall

▶ Wall-mount the product as described.

Conditions: The load-bearing capacity of the wall is not sufficient

▶ Ensure that wall-mounting apparatus on-site has a suf-

ficient load-bearing capacity. Use individual stands or
primary walling, for example.

▶ Do not wall-mount the product if you cannot provide

wall-mounting apparatus with a sufficient load-bearing
capacity.

Conditions: The fixing material may not be used for the wall

▶ Wall-mount the product as described in the illustration

using the permitted fixing material provided on-site.

Installation 5

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 11

4.8 Removing the front casing

B

A

B

▶ Remove the front casing as shown in the illustration.

4.9 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 ex­ample, and potentially result in leaks.

▶ Depressurise the product on the water

side.

▶ Always remove only one side section –

never both side sections at the same time.

▶ Remove the side section as shown in the illustration.

5 Installation

Danger!
Risk of scalding and/or risk of material

damage due to incorrect installation lead­ing to escaping water.

Stresses in supply lines can cause leaks.

▶ Install the supply lines without tension.

Caution.
Risk of material damage due to the gas

leak-tightness test.

At a test pressure of >11 kPa (110 mbar), gas
leak-tightness tests may cause damage to
the gas valve.

5 Installation

12 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

▶ If, during gas leak-tightness tests, you

also place the gas lines and the gas valve
in the product under pressure, use a max.
test pressure of 11 kPa (110 mbar).

▶ If you cannot limit the test pressure to

11 kPa (110 mbar), close any gas isolator
cocks that are installed upstream from the
product before you carry out the gas leak­tightness test.

▶ If, during gas leak-tightness tests, you

have closed the gas isolator cock that is
installed upstream of the product, relieve
the gas line pressure before you open this
gas isolator cock.

Caution.
Risk of material damage caused by corro-

sion

Due to non-diffusion-tight plastic pipes in the
heating installation, air gets into the heating
water. Air in the heating water causes corro­sion in the heat generator circuit and in the
product.

▶ If you use non-diffusion-tight plastic pipes

in the heating installation, ensure that no
air gets into the heat generator circuit.

Caution.
Risk of material damage due to heat trans-

fer during soldering.

▶ Only solder connectors if the connectors

are not yet screwed to the service valves.

If you also want to install an external heating pump without
a low loss header, install the external pump in the return and
connect it via the auxiliary relay.

5.1 Installation requirements

Caution.
Risk of material damage caused by

residues in the pipelines.

Welding remnants, sealing residues, dirt or
other residues in the pipelines may damage
the product.

▶ Flush the heating installation thoroughly

before installing the product.

Caution.
Risk of material damage caused by

changes to the pipes that have already
been connected.

▶ Only bend connection pipes if they have

not yet been connected to the product.

5.1.1 Information on liquefied petroleum gas
operation

In the as-delivered condition, the product is preset for opera­tion with the gas group indicated on the data plate.

If you have a product that is preset for operation with natural
gas, you must replace the gas family coding resistor with the
enclosed coding resistor for liquefied petroleum gas during
the installation. During start-up, the product must be con­verted for operation with liquefied petroleum gas in the in­stallation assistant. You do not require a conversion set, be­cause the product has a gas-adaptive heat cell, which is set
independently to the relevant gas type within the gas family.
The gas type can also be changed at a later point using dia­gnostics code D.087.

If you have selected the "liquid gas" gas type, after the start­up process is complete, affix the enclosed "Liquid gas" con­version sticker onto the data plate and affix the enclosed
tank sticker (propane quality) so that it is clearly visible on
the tank or the cylinder cabinet, if possible close to the filler
nozzle.

5.1.2 Purging the liquid gas tank

If the liquid gas tank is not purged properly, this may result in
ignition problems.

▶ Ensure that the liquid gas tank has been purged properly

before installing the product.

▶ If required, contact the filler or the liquid gas supplier.

5.1.3 Using the correct gas type

Using the incorrect gas type may cause fault shutdowns in
the product. Ignition and combustion noise may occur in the
product.

▶ Only use a gas type from the gas group that is defined on

the data plate.

5.1.4 Required preliminary work

1. Install a stopcock in the gas pipe.

2. Make sure that the existing gas meter is capable of

passing the rate of gas supply required.

3. Check that the volumetric capacity of the expansion

vessel is sufficient for the system volume.

Conditions: The volume of the installed expansion vessel is insufficient

▶ Install an additional expansion vessel, connected as

close to the product as possible, in the heating return.

4. Install a tundish with condensate trap for the condens-

ate discharge and the exhaust pipe on the expansion
relief valve. Route drain pipework that is as short as
possible, at a downward gradient away from the tun­dish.

5. Insulate bare pipes exposed to environmental influ-

ences to protect them from frost using suitable insula­tion material.

Installation 5

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 13

5.2 Installing the gas connection

1. Install the gas line in accordance with the recognised
rules of technology.

2. Connect the product to the gas line in accordance with
the recognised rules of technology.

3. Remove the residues from the gas line by blowing
through the gas line beforehand.

4. Purge the gas line before start-up.

5.3 Checking the gas line for leak-tightness

▶ Check the entire gas line properly for leak-tightness.

5.4 Installing the cylinder connections

1

▶ Connect the cylinder connections (1) to the domestic hot

water cylinder.
– For this purpose, you can use an optional cylinder

connection set.

5.5 Connecting the heating flow and heating

return

1

▶ Establish the heating connections (1) in accordance with

the relevant standards.

5.6 Connecting the condensate drain pipework

Danger!
Risk of death from escaping flue gases!

The condensate drain pipework of the con­densate 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.

▶ Do not connect the condensate drain

pipework tightly to the waste-water pip­ing.

A

1

2

The product is equipped with a condensate trap (2). (The
filling height is 145 mm). The condensate trap collects the
condensate that has formed in a vessel with a capacity of
approximately 200 ml, and intermittently releases the con­tents into the discharge pipe. This minimises the risk of the
discharge pipe freezing.

▶

Connect the condensate discharge (1) to a condensate
discharge pipe (3) that has a minimum internal diameter
of 19 mm (30 mm internal diameter for all externally in­stalled lines) and is made from an acid-resistant material
(e.g. plastic overflow pipe).

– The condensate discharge pipework must have

a continuous fall (45 mm per metre) and should
whenever possible terminate at a suitable discharge
point within the heated envelope of the building
that will remain frost free under long periods of low
external temperatures.

▶ During installation remove all burs from inside of cut pipe

work and avoid excessive adhesive which may trap small
pockets of water close to the pipe wall which can freeze
and build into a larger ice plug.

▶ As with other pipe work insulate the condensate dis-

charge pipe to minimise any risk of freezing and beware
when crossing cavities that the fall is maintained and the
pipe sleeved.

5 Installation

14 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

▶ Ensure that the condensate drain pipework terminates in

a suitable location. Further information can be obtained
from BS 6798 Specification for installation of gas–fired
boilers of rated input not exceeding 70 kW net.

▶ Leave an installation space of at least 300 mm beneath

the condensate trap.

5.7 Installing the discharge pipe on the
expansion relief valve

1. Install the discharge pipe for the expansion relief valve

so that it does not interfere with the removal and fitting
of the lower section of the condensate trap.

1

2. Install the discharge pipe as shown (do not shorten).

3. Make sure that the end of the pipe is visible.

4. Ensure that discharged water or steam cannot cause

injury to persons or damage to electronic components.

5. Ensure the discharge pipe work is installed, routed and

terminated correctly to minimise the risk of freezing up.

5.8 Flue installation

5.8.1 Installing and connecting the flue pipe

1. You can find out which flue pipes may be used by con-

sulting the enclosed flue pipe installation manual.

Conditions: Installation in damp rooms

▶ You must connect the product to a room-sealed air/flue

gas installation. 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 install­ation.

2. Install the flue pipe using the installation manual.

5.8.2 Replacing the connection piece for the
air/flue pipe as required

1. Replace the connection piece for the air/flue pipe as

required. The product-specific standard equipment is
listed under Technical Data in the appendix.

2. Remove the connection piece for the air/flue pipe.

(→ Page 14)

5.8.2.1 Removing the connection piece for the
air/flue pipe

A

B

C

1. Insert a screwdriver into the slot between the measuring

stub pipes.

2. Press the screwdriver carefully down.

3. Turn the connection piece anticlockwise as far as it will

go and then remove it by pulling it upwards.

5.8.2.2 Installing the connection piece for the
air/flue pipe, 80/125 mm diameter

1. Remove the connection piece for the air/flue pipe.

(→ Page 14)

2. Insert the alternative connection piece. In doing so, pay

attention to the latching lugs.

3. Turn the connection piece clockwise until it clicks into

position.

5.9 Electrical installation

Only qualified electricians may carry out the electrical install­ation.

Danger!
Risk of death from electric shock!

Mains connection terminals L and N remain
live even if the on/off switch is turned off.

▶ Switch off the power supply.
▶ Secure the power supply against being

switched on again.

Installation 5

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 15

5.9.1 Opening the electronics box

A

B

▶ Open the electronics box as shown in the illustration.

5.9.2 Carrying out the wiring

Caution.
Risk of material damage caused by incor-

rect installation.

Mains voltage at incorrect terminals and plug
terminals may destroy the electronics.

▶ Do not connect any mains voltage to the

eBUS terminals (+/-).

▶ Only connect the mains connection cable

to the terminals marked for the purpose.

1. Route the supply lines of the components to be connec­ted through the cable duct provided on the underside of
the product on the left.

2. Use strain reliefs.

3. Shorten the supply lines as necessary.

30 mm max.

4. To prevent short circuits if a strand accidentally comes
loose, only strip the outer sheathing of flexible lines to a
maximum of 30 mm.

5. Ensure the inner conductor insulation is not damaged
when stripping the outer sheathing.

6. Only strip inner conductors just enough to establish
good, sound connections.

7. To avoid short circuits resulting from loose individual
wires, fit conductor end sleeves on the stripped ends of
the conductors.

8. Screw the respective plug to the supply line.

9. Check whether all conductors are sitting mechanically
securely in the terminals of the plug. Remedy this if
necessary.

10. Plug the plug into the associated PCB slot; see the

connection diagram in the appendix.

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, elec­tronic components may be damaged.

▶ Make sure that the rated voltage of the

mains is 230 V.

1. Make sure that the nominal mains voltage is 230 V.

2. Provide one common power supply for the boiler and
for the corresponding control:

– Power supply: Single-phase, 230 V, 50 Hz
– Fuse protection: ≤ 3 A

3. Install a fused spur adjacent to the boiler.

4. Open the electronics box. (→ Page 15)

5. Connect the product using a fixed connection and an
electrical partition with a contact opening of at least 3
mm (e.g. fuses or power switches).

6. Route a three-core power supply cable that complies
with the relevant standards through the grommet and
into the product.

– Power supply cable: Flexible line

7. Carry out the wiring. (→ Page 15)

8. Remove the supplied plug from the bracket in the elec­tronics box and screw the plug onto the power supply
cable.

9. Close the electronics box.

10. Make sure that access to the power supply is always

available and is not covered or blocked.

5.9.4 Installing the product in a wet room

Danger!
Risk of death from electric shock!

If you install the product in a room with high
levels of moisture, e.g. a bathroom, observe
the nationally recognised technical standards
for electrical installations. If you use the fact­ory-installed connection cable, if installed,
with an earthed plug, there is a risk of death
from electric shock.

▶ Never use the factory-installed connection

cable with earthed plug when installing the
product in a moist environment.

▶ Connect the product using a fixed connec-

tion and an electrical partition with a con­tact opening of at least 3 mm (e.g. fuses
or power switches).

▶ Use a flexible line for the mains connec-

tion line, which is routed through the cable
duct into the product.

6 Operation

16 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

1. Open the electronics box. (→ Page 15)

2. Detach the ProE plug from the PCB slot for the mains
connection (X1).

3. Unscrew the ProE plug for the factory-installed power
supply cable, if installed.

4. Instead of the factory-installed power supply cable, if
installed, use a suitable three-core power supply cable
which complies with the relevant standards.

5. Carry out the wiring. (→ Page 15)

6. Close the electronics box.

7. Observe the flue-gas connection that is required on a
room-sealed air/flue system. (→ Page 14)

5.9.5 Connecting controls to the electronics

1. Install the control if necessary.

2. Open the electronics box. (→ Page 15)

3. Carry out the wiring. (→ Page 15)

4. Observe the wiring diagram in the appendix.

Conditions: Connecting a weather-compensated control or a room tem­perature control via eBUS

▶ Connect the control to the eBUS connection.
▶ Bridge the 24 V = RT connection (X100 or X106), if there

is not already a bridge.

Conditions: Connecting a low-voltage control (24 V)

▶ Remove the bridge and connect the control to the

24 V = RT connection (X100 or X106).

Conditions: 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).

Conditions: Connecting a limit thermostat for underfloor heating

▶ Remove the bridge and connect the limit thermostat to

the Burner off connection.

5. Close the electronics box.

6. For multi-circuit controls, change D.018 from Eco (in­termittently operating pump) to Comfort (continuously
operating pump). (→ Page 24)

5.9.6 Replacing the gas family coding resistor, if

required

1. Open the electronics box. (→ Page 15)

X31

X12

1

2. Remove the gas family coding resistor (1) (plug X24)
(factory setting: natural gas = yellow) and plug in the
coding resistor from the bag of small parts (liquefied
petroleum gas = grey).

3. Close the electronics box.

4. When starting up in the installation assistant or retro­actively via diagnostics code D.087, set the correct gas
type.

5.9.7 Connecting additional components

You can actuate an additional component with the aid of the
auxiliary relay that is installed, and you can actuate two other
components with the multi-functional module.

5.9.7.1 Using the auxiliary relay

1. Connect an additional component directly to the integ­rated auxiliary relay using the grey plug on the PCB.

2. Carry out the wiring.

3. Activate the component via D.026, see section "Adapt­ing to the heating installation".

5.9.7.2 Using the VR 40 ("2 in 7" multi-functional

module)

1. Install the components in accordance with the respect­ive instructions.

Conditions: Components connected to relay 1

▶ Activate D.027, see section "Adapting to the heating

installation".

Conditions: Components connected to relay 2

▶ Activate D.028, see section "Adapting to the heating

installation".

6 Operation

6.1 Operating concept

The operating concept and the read-off and setting facilities
of the operator level are described in the operating instruc­tions.

An overview of the reading and setting options for the in­staller level is included in the table in the appendix.

Installer level – Overview (→ Page 34)

6.2 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 .

Start-up 7

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 17

6.3 Live Monitor (status codes)

Menu → Live monitor

Status codes in the display provide information on the pro­duct's current operating mode.

Status codes – Overview (→ Page 41)

7 Start-up

7.1 Carrying out the initial start-up

Initial start-up must be carried out by a customer service
technician or an authorised competent person using the
commissioning checklist. The commissioning checklist in the
appendix (→ Page 50) of the installation instructions must be
filled in and stored carefully along with the unit's documenta­tion.

▶ Carry out the start-up procedure using the commissioning

checklist in the appendix.

▶ Fill in and sign the commissioning checklist.

7.2 Switching the product on/off

▶ Press the on/off button on the product.

◁ The basic display appears on the display.

7.3 Running the installation assistants

The installation assistant is displayed whenever the product
is switched on until it has been successfully completed.
It provides direct access to the most important check
programmes and configuration settings for starting up the
product.

To recheck and reset the most important system parameters,
call up the Appliance config..

Menu → Installer level → Appliance config.

The settings options for more complex systems can be found
in the Diagnostics menu.

Menu → Installer level → Diagnostics menu

▶

Press to confirm the start of the installation assistant.

◁ All heating and hot water requests are blocked whilst

the installation assistant is active.

Note

If you do not confirm the launch of the install­ation assistant within 10 seconds of switching
the system on, the basic display reappears.

▶

To access the next point, confirm by pressing in each
case.

7.3.1 Language

▶ Set the required language.
▶ To confirm the set language and to avoid unintentionally

changing it, press to confirm this twice.

If you have unintentionally set a language that you do not
understand, proceed as follows to change it:

▶

Press and hold and at 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 .

7.3.2 Filling mode

Filling mode (check programme P.06) is activated automatic­ally in the installation assistant for as long as the filling mode
appears on the display.

▶ Fill the heating installation. (→ Page 20)

7.3.3 Purging

1. Unlike in the Check programs menu, to purge the sys­tem, start check programme P.00 by pressing or .

2. If you need to change the circuit that is to be purged,
press .

7.3.4 Target feed temperature

1.

Press and to set the target feed temperature.

2.

Confirm by pressing .

7.3.5 Hot water temperature

Applicability: Product with hot water generation through external domestic

hot water cylinder

Danger!
Risk of death from legionella.

Legionella multiply at temperatures below
60 °C.

▶ Ensure that the end user is familiar with

all of the Anti-legionella measures in order
to comply with the applicable regulations
regarding legionella prevention.

1.

Press and to set the hot water temperature.

2.

Confirm by pressing .

3. Set the hot water temperature.

Conditions: Water hardness: > 3.57 mol/m³

– Water temperature: ≤ 50 ℃

7.3.6 Heating partial load

The heating partial load of the product is set to Auto at the
factory. The product independently determines the optimum
heating output depending on the current heat demand of
the system. You can retroactively adjust the setting in the

Diagnostics menu under D.000.

7.3.7 Green iQ

▶ Set Green iQ mode (energy-saving mode for hot water

generation with cylinder and heating mode) (default set­ting: On).

7 Start-up

18 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

Note
Green iQ mode is a special operating mode

that can be used to save energy. If this mode
is activated, the product operates in the heat­ing and cylinder charging mode in such a way
that the maximum benefits associated with
condensing technology are achieved. Un­der certain circumstances, this may result in
comfort bottlenecks because, in this operating
mode, the cylinder charging time may be ex­tended, for example.

7.3.8 Auxiliary relay and multi-functional module

1. If you have connected additional components to the
product, assign these components to the individual re­lays.

2.

In each case, confirm by pressing .

Note

This setting can be retroactively changed in
the Diagnostics menu using D.026, D.027
and D.028.

7.3.9 Gas type

1. Select the gas type that is available at the installation
site (default setting: Natural gas). If required, retroact­ively change the gas type using diagnostics code D.087
and plug the correct coding resistor (plug X24: Natural
gas = yellow, liquefied petroleum gas = grey) into the
PCB; see the wiring diagram in the appendix.

Conditions: Liquid gas set

▶ If you have selected the "liquid gas" gas type, after the

start-up process is complete, affix the enclosed "Liquid
gas" conversion sticker onto the data plate and affix
the enclosed tank sticker (propane quality) so that it is
clearly visible on the tank or the cylinder cabinet, if pos­sible close to the filler nozzle.

7.3.10 Contact data

▶ If required, store your telephone number in the Appli-

ance config. (max. 16 digits/no blank spaces). The oper-

ator can view the telephone number.

7.3.11 Ending the installation assistant

▶ Once you have run through the installation assistant suc-

cessfully, confirm by pressing .

◁ The installation assistant will close and will not launch

again when the product is next switched on.

7.4 Restarting the installation assistants

Menu → Installer level → Start inst. assistant

You can restart the installation assistant at any time by call­ing it up in the menu.

7.5 Test programmes

Menu → Installer level → Test programs

As well as the installation assistants, you can also call up
the following test programmes for start-up, service and
troubleshooting.

– Check programs
– Function menu
– Electronics self-test

7.6 Using check programmes

Menu → Installer level → Test programs → Check pro­grams

Display Meaning

P.00 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 programme is displayed by
a countdown timer. The programme then ends.

P.01 Maximum load check programme:

After successful ignition, the product is operated at
maximum heat input.

P.02 Minimum load check programme:

After successful ignition, the product is operated at
minimum heat input.

P.04 Reset eGas CH (Central Heating) check programme:

Calling up the programme deletes all of the CH cor­rection values 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 check programme:

The diverter valve is moved to the mid-position. The
burner and pump are switched off (to fill or drain the
product).

7.7 Checking and treating the heating
water/filling and supplementary water

Caution.
Risk of material damage due to poor-qual-

ity heating water

▶ Ensure that the heating water is of suffi-

cient quality.

▶ Before filling or topping up the installation, check the

quality of the heating water.

Start-up 7

0020193966_01 ecoTEC exclusive Installation and maintenance instructions 19

Checking the quality of the heating water

▶ Remove a little water from the heating circuit.
▶ Check the appearance of the heating water.
▶ If you ascertain that it contains sedimentary materials,

you must desludge the installation.

▶ Use a magnetic rod to check whether it contains mag-

netite (iron oxide).

▶ If you ascertain that it contains magnetite, clean the in-

stallation and apply suitable corrosion-protection meas­ures, or fit a magnetic filter.

▶ Check the pH value of the removed water at 25 °C.
▶ If the value is below 8.2 or above 10.0, clean the installa-

tion and treat the heating water.

▶ Ensure that oxygen cannot get into the heating water.

Checking the filling and supplementary water

▶ Before filling the installation, measure the hardness of the

filling and supplementary water.

Treating the filling and supplementary water

▶ Observe all applicable national regulations and technical

standards when treating the filling and supplementary
water.

Provided the national regulations and technical standards
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 the heating water is less than 8.2 or

more than 10.0.

Total
heating
output

Water hardness at specific system volume

1)

≤ 20 l/kW

> 20 l/kW
≤ 50 l/kW

> 50 l/kW

kW

ppm

CaCO₃

mol/m³ppm

CaCO₃

mol/m³ppm

CaCO₃

mol/

m³

< 50 < 300 < 3 200 2 2 0.02

> 50
to ≤ 200

200 2 150 1.5 2 0.02

> 200
to ≤ 600

150 1.5 2 0.02 2 0.02

> 600 2 0.02 2 0.02 2 0.02

1) Nominal capacity in litres/heating output; in the case of multi­boiler systems, the smallest single heating output is to be used.

Caution.
Risk of material damage if the heating

water is treated with unsuitable additives.

Unsuitable additives may cause changes in
the components, noises in heating mode and
possibly subsequent damage.

▶ Do not use any unsuitable frost and cor-

rosion protection agents, biocides or seal­ants.

No incompatibility with our products has been detected to
date with proper use of the following additives.

▶ When using additives, follow the manufacturer's instruc-

tions without exception.

We accept no liability 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
permanently in the installation

– Adey MC ZERO
– Fernox Antifreeze Alphi 11
– Sentinel X 500

▶ If you have used the above-mentioned additives, inform

the end user about the measures that are required.

▶ Inform the end user about the measures required for frost

protection.

7.8 Preventing low water pressure

To ensure that the heating installation operates smoothly,
the indicator on the pressure gauge must point to the upper
half of the grey area or to the middle of the bar graph display
in the display (marked by the dashed limit values) when the
heating installation is cold. This corresponds to a filling pres­sure of between 0.1 MPa and 0.2 MPa (1.0 bar and 2.0 bar).

If the heating installation extends over several storeys,
higher filling pressures may be required to avoid air entering
the heating installation.

If the filling pressure falls below 0.08 MPa (0.8 bar), the
product indicates low pressure by displaying a flashing
pressure value. If the filling pressure falls below 0.05 MPa
(0.5 bar), the product switches off. The display shows F.22.

▶ Top up the heating water to start the product up again.

The pressure value flashes in the display until a pressure of

0.11 MPa (1.1 bar) or higher has been reached.

7 Start-up

20 Installation and maintenance instructions ecoTEC exclusive 0020193966_01

7.9 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.

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
system and open the purging valves on the radiators so
that the contaminated water can completely drain.

4. Close the drain 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 valve.

7. Check the pressure in the heating system and top up

with water if necessary.

8. Close the filling valve and the cold water valve.

7.10 Filling the heating installation

1

1. Flush the heating installation through.

2. Select the check programme P.06.

◁ The diverter valve moves to the mid-position, the

pumps do not run and the product does not switch
to heating mode.

Note

The cap on the automatic air vent (1) has
already been opened at the factory.

3. Observe the information on treating heating water.

(→ Page 18)

4. Check all connections and the entire system for leaks.

5. Connect the filling and drainage tap in the heating in-

stallation to a heating water supply, if possible with the
cold water valve, in accordance with the relevant stand­ards.

6. Open the heating water supply.

7. Open all thermostatic radiator valves in the heating in­stallation.

8. If necessary, check that both service valves on the
product are open.

9. Slowly open the filling and drainage tap so that the wa­ter flows into the heating system.

10. Purge the lowest radiator until water flows out of the

purging valve without bubbles.

11. Purge all other radiators until the entire heating system

has been filled with water.

12. Close all purging valves.

13. Monitor the rising filling pressure in the heating installa-

tion.

14. Fill with water until the required filling pressure is

reached.

15. Close the filling and drainage tap and the cold water

valve.

7.11 Purging the heating installation

1. Select the check programme P.00.

◁ The product does not start up, the internal pump

operates intermittently and purges either the heating
circuit or the hot water circuit.

◁ The display shows the filling pressure of the heating

installation.

2. Make sure that the filling pressure of the heating install­ation does not fall below the minimum filling pressure.

– ≥ 0.08 MPa (≥ 0.80 bar)

◁ At the end of the filling procedure, the filling pres-

sure of the heating installation should be at least

0.02 MPa (0.2 bar) above the counter-pressure
of the expansion vessel ("Exp") (P

Installation

≥ P

Exp

+

0.02 MPa (0.2 bar)).

3. If there is still too much air in the heating installation at
the end of the check programme P.00, repeat the check
programme.

7.12 Filling the condensate trap

1

1. Remove the lower section from the condensate trap (1).

2. Fill the lower section with water up to 10 mm below the
upper edge.

3. Attach the lower section to the condensate trap.