Page 1
Installation and maintenance instructions
ecoTEC exclusive
627 (VU 256/5‑7 (H-GB))
GB, IE
Publisher/manufacturer
Vaillant GmbH
Berghauser Str. 40 D-42859 Remscheid
Tel. +49 21 91 18‑0 Fax +49 21 91 18‑2810
info@vaillant.de www.vaillant.de
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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
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0020193966_01 ecoTEC exclusive Installation and maintenance instructions 3
Index ................................................................................... 59
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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 +44 (0) 800 111999 by tele-
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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.
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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.
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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
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4 Set-up
8 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
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
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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.
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4 Set-up
10 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
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.
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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.
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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.
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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.
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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.
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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.
Page 16
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 .
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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).
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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.
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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.
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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.
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0020193966_01 ecoTEC exclusive Installation and maintenance instructions 21
7.13 Gas inspection
7.13.1 Checking the leak-tightness of the flue gas
installation and flue gas recirculation
1. Check the flue gas installation is intact in accordance
with the latest gas safe technical bulletin and information supplied in the installation instructions.
2. For extended flue gas installations check for flue gas
recirculation using the air analysis point.
3. Use a flue gas analyser.
4. If you discover CO or CO2in the supply air, search for
the leak in the flue gas installation or for signs of flue
gas recirculation.
5. Eliminate the damage properly.
6. Check again whether the supply air contains any CO or
CO2.
7. If you cannot eliminate the damage, do not start up the
product.
7.13.2 Checking the gas flow rate
The gas flow rate has been set during production and does
not require adjustment. With the front casing fitted check the
gas flow rate of the boiler as follows:
▶ Start up the product with the check programme P.01.
▶ In addition, ensure that maximum heat can be dissipated
into the heating system by turning up the room thermostat.
▶ Wait at least 5 minutes until the boiler has reached its
operating temperature.
▶ Ensure that all other gas appliances in the property are
turned off.
▶ Measure the gas flow rate at the gas meter.
▶ Compare the measured values with the corresponding
values in the table.
Qnw from the data
plate
H gas in m³/h
Nom. +5% −10%
15.3 1.62 1.70 1.46
18.4 1.95 2.05 1.76
24.7 2.61 2.74 2.35
25.7 2.72 2.86 2.45
28.6 3.03 3.18 2.73
30.6 3.24 3.40 2.92
35.7 3.78 3.97 3.40
Conditions: Gas flow rate not in the permissible range
▶ Check all of the piping and ensure that the gas flow rates
are correct.
▶ Only put the product into operation once the gas flow
rates have been corrected.
Conditions: Gas flow rate in the permissible range
▶ End the check programme P.01.
▶ Allow the boiler to cool down by allowing pump overrun to
operate for a minimum of 2 minutes.
▶ Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
7.13.3 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 isolator cock.
1
2
3. Use a screwdriver to undo the sealing screw of the
measuring nipple (1) at the gas valve.
4. Connect a pressure gauge (2) to the measuring nipple
(1).
5. Open the gas isolator cock.
6. Start up the product with the check programme P.01.
◁ S.93 is briefly displayed.
◁ If the display switches to S.04, the product is ready
for the measurement.
7. In addition, ensure that maximum heat can be dissipated into the heating system by turning up the room
thermostat.
8. With the boiler operating at full load check that the gas
inlet working pressure at the reference test point complies with the requirements.
9. Measure the gas flow pressure in comparison with the
atmospheric pressure.
– Permissible gas flow pressure for operation
with G20 natural gas: 1.3 … 2.3 kPa (13.0
… 23.0 mbar)
– Permissible gas flow pressure for operation
with G31 liquid gas: 2.3 … 4.3 kPa (23.0
… 43.0 mbar)
10. Should the pressure recorded at the reference test
point in the boiler be lower than indicated check if there
is any blockage in the pipework or if the pipework is undersized.
11. Decommission the product.
12. Close the gas isolator cock.
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22 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
13. Remove the pressure gauge.
14. Tighten the screw on the measuring nipple (1).
15. Open the gas isolator cock.
16. Check the measuring nipple for gas tightness.
Conditions: Gas flow pressure not in the permissible range
Caution.
Risk of material damage and operating
faults caused by incorrect gas connection pressure.
If the gas connection pressure lies outside
the permissible range, this can cause operating faults in and damage to the product.
▶ Do not make any adjustments to the
product.
▶ Do not start up the product.
▶ If you cannot correct the failure, notify the gas supply
company 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 isolator cock.
▶ Remove the pressure gauge and retighten the sealing
screw (1) for the measuring nipple.
▶ Open the gas isolator cock.
▶ Check the measuring nipple for gas tightness.
▶ Close the gas isolator cock.
▶ Install the front casing.
▶ Disconnect the product from the power mains.
▶ You must not start up the boiler.
Conditions: Gas flow pressure in the permissible range
▶ End the check programme P.01.
▶ Allow the boiler to cool down allowing pump overrun to
operate for a minimum of two minutes.
▶ Close the gas isolator cock.
▶ Remove the pressure gauge and retighten the sealing
screw (1) for the measuring nipple.
▶ Open the gas isolator cock.
▶ Check the measuring nipple for gas tightness.
▶ Install the front casing.
▶ Reset boiler controls for normal operation.
▶ Record the appliance gas inlet working pressure (kPa
resp. mbar) in the Benchmark gas boiler commissioning
checklist.
7.13.4 Calibrating the heat generator and
measuring the CO/CO₂ content and gas
flow in heating mode
Caution.
Risk of operating faults caused by the
corruption of the measured values during
the calibration.
Operating the product with the front casing
open or not completely installed, or with the
flue pipe open, may negatively influence the
calibration of the gas-air mixture.
▶ During the calibration and when measur-
ing the CO₂ 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 transferred to the heating installation by opening the radiator
thermostats.
Note
All radiators should be cold before you
start calibration. This ensures that the heat
volume can be transferred to the heating
installation.
Note
If there is an excessive air temperature at the
radiators, calibration may not be possible.
3. Start check programme P.01.
◁ The heat generator starts in heating mode.
◁ The heat generator first switches between status
S.01 and status S.02.
◁ The heat generator switches to status S.93 after
approximately two minutes for calibration.
◁ Do not measure the CO/CO₂ content or the gas flow
during calibration (status S.93).
Conditions: The flow temperature increases to above 80 °C in the next
five to six minutes.
▶ The heat generator does not switch to status S.04.
Note
Calibration is not complete and the CO/CO₂
content and gas flow cannot be measured.
▶
Use to end check programme P.01.
4.
Alternatives 1 / 2
▶ If required, carry out calibration and measurement
again.
4.
Alternatives 2 / 2
▶ Calibrate the heat generator and measure the
CO/CO₂ content and the gas flow in cylinder
charging mode. (→ Page 23)
Conditions: The flow temperature remains below 80 °C in the next five to
six minutes.
▶ If the heat generator switches from status S.93 to status
S.04 after approximately five to six minutes, calibration
at maximum heat input is complete.
Page 23
Start-up 7
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 23
▶ In the next few minutes, measure the CO/CO₂ content
and the gas flow at maximum load.
▶
Use to end check programme P.01.
▶ Start check programme P.02.
◁ The heat generator starts in heating mode.
◁ The heat generator switches to status S.93 after
approximately two minutes for calibration.
◁ Do not measure the CO/CO₂ content or the gas flow
during calibration (status S.93).
◁ If the heat generator permanently switches from
status S.93 to status S.04 after approximately five
to six minutes, calibration at minimum load is complete.
▶ In the next few minutes, measure the CO/CO₂ content
and the gas flow at minimum load.
▶
Use to end check programme P.02.
◁ Calibration and measurement in heating mode are
complete.
7.13.5 Calibrating the heat generator and
measuring the CO/CO₂ content and gas
flow in cylinder charging mode
1. The following steps are only required if calibration and
measurement in heating mode (→ Page 22) could not
be completed successfully.
2. Ensure that there is a heat demand at the domestic hot
water cylinder.
3. If required, open all of the draw-off point and allow the
domestic hot water cylinder to cool.
4. Set the domestic hot water temperature at the heat generator to the maximum.
◁ There is a risk of scalding at the domestic hot water
draw-off points if the water temperature is set to the
maximum.
Danger!
Risk of burns and scalding!
There is a risk of scalding at the domestic hot
water draw-off points if the water temperature
is set to the maximum.
▶ Avoid contact with the water that escapes
from the domestic hot water draw-off
point.
5. Start check programme P.01.
◁ The heat generator starts in cylinder charging mode.
◁ The heat generator first switches between status
S.21 and status S.23.
◁ The heat generator switches to status S.93 after
approximately two minutes for calibration.
◁ Do not measure the CO/CO₂ content or the gas flow
during calibration (status S.93).
Conditions: The domestic hot water temperature in the cylinder reaches
the maximum water temperature in the next five to six minutes.
▶ The heat generator does not switch to status S.24.
Note
Calibration is not complete and the CO/CO₂
content and gas flow cannot be measured.
▶
Use to end check programme P.01.
6.
Alternatives 1 / 2
▶ 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 / 2
▶ Check the installation and, if required, carry out cal-
ibration and measurement again with the correct
installation.
Conditions: The domestic hot water temperature in the cylinder does not
reach the maximum water temperature in the next five to six minutes.
▶ If the heat generator switches from status S.93 to status
S.24 after approximately five to six minutes, calibration
at maximum heat input is complete.
▶ In the next few minutes, measure the CO/CO₂ content
and the gas flow at maximum load.
▶
Use to end check programme P.01.
▶ Start check programme P.02.
◁ If the heat generator permanently switches from
status S.93 to status S.24 after five to six minutes,
calibration at minimum load is complete.
▶ In the next few minutes, measure the CO/CO₂ content
and the gas flow at minimum heat input.
▶
Use to end check programme P.02.
◁ Measurement and calibration in cylinder charging
mode are complete.
7.14 Checking leak-tightness
▶ Check the gas pipe, the heating circuit and the domestic
hot water circuit for leak-tightness.
▶ Check that the air/flue pipe has been installed correctly.
Conditions: Room-sealed operation
▶ Check whether the vacuum chamber has been closed
tightly.
7.14.1 Checking the heating mode
1. Make sure that there is a heat requirement.
2. Call up Live monitor.
◁ If the product is working correctly, the display shows
S.04.
Page 24
8 Adapting the unit to the heating installation
24 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
7.15 Thoroughly flushing the heating installation
("hot")
1. Operate the appliance until the boiler and the heating
system are up to temperature.
2. Check the heating system for leaks.
3. Connect a hose to the drain valve located at the lowest
position of the heating system.
4. Shut off the boiler, open the drain valve and all purge
valves on the radiators and allow the water to flow out
of the heating system and the boiler quickly and fully.
5. Close the drain valve.
6. Fill the heating system again with water as described in
Filling the heating installation (→ Page 20) and Purging
the heating installation (→ Page 20).
7. Re-fill the system until the system design pressure of
0,1 MPa (1,0 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 additional 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 inhibitor it
should be applied at this stage in accordance
with the manufacturer’s instructions. Further
information can be obtained from Sentinel,
Betz Dearborn Ltd., Tel: 0151 420 9595, or
Fernox, Alpha– Fry technologies. Tel: 0870
8700362.
8. Install the front casing.
8 Adapting the unit to the heating
installation
To reset the most important system parameters, use the
Appliance config. menu point.
Menu → Installer level → Appliance config.
Or manually relaunch the installation assistant.
Menu → Installer level → Start inst. assistant
You can find setting options in the Diagnostics menu.
Menu → Installer level → Diagnostics menu
Overview of diagnostics codes (→ Page 36)
8.1 Calling up diagnostics codes
The settings options for more complex systems can be found
in the Diagnostics menu.
Menu → Installer level → Diagnostics menu
Overview of diagnostics codes (→ Page 36)
You can use the parameters that are marked as adjustable
in the overview of diagnostics codes to adapt the product to
the heating installation and the needs of the customer.
8.2 Burner anti-cycling time
To prevent frequent switching on and off of the burner and
thus prevent energy losses, an electronic restart lockout
is activated for a specific period each time the burner is
switched off. The burner anti-cycling time is only active
for the heating mode. Hot water handling during a burner
anti-cycling time does not affect the time function element
(default setting: 20 mins).
8.2.1 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
.
T
Flow
(target)
[°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
40 2.0 3.5 6.5 10.0 13.0 16.5 19.5
45 2.0 3.0 6.0 8.5 11.5 14.0 17.0
50 2.0 3.0 5.0 7.5 9.5 12.0 14.0
55 2.0 2.5 4.5 6.0 8.0 10.0 11.5
60 2.0 2.0 3.5 5.0 6.0 7.5 9.0
65 2.0 1.5 2.5 3.5 4.5 5.5 6.5
70 2.0 1.5 2.0 2.5 2.5 3.0 3.5
75 2.0 1.0 1.0 1.0 1.0 1.0 1.0
T
Flow
(target)
[°C]
Set maximum burner anti-cycling time
[min]
35 40 45 50 55 60
30 29.0 33.0 37.0 41.0 45.0 49.5
35 25.5 29.5 33.0 36.5 40.5 44.0
40 22.5 26.0 29.0 32.0 35.5 38.5
45 19.5 22.5 25.0 27.5 30.5 33.0
50 16.5 18.5 21.0 23.5 25.5 28.0
55 13.5 15.0 17.0 19.0 20.5 22.5
60 10.5 11.5 13.0 14.5 15.5 17.0
65 7.0 8.0 9.0 10.0 11.0 11.5
70 4.0 4.5 5.0 5.5 6.0 6.5
75 1.0 1.0 1.0 1.0 1.0 1.0
Page 25
Adapting the unit to the heating installation 8
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 25
8.2.2 Resetting the remaining burner anti-cycling
time
1.
Alternatives 1 / 2
▶ Navigate to Menu → Reset anti-cycl. time.
◁ The current burner anti-cycling time appears in
the display.
▶
Press to reset the burner anti-cycling time.
1.
Alternatives 2 / 2
▶
Press the Fault clearance button.
8.3 Setting the maintenance interval
1. Navigate to Menu → Installer level → Diagnostics
menu → D.084 Maintenance in and confirm by press-
ing .
2. Set the maintenance interval (operating hours) until the
next maintenance work is due and confirm by pressing
.
Heat demand
Number
of persons
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
20.0 kW
3 ‑ 4 2600 h
4 ‑ 5 2700 h
25.0 kW
3 ‑ 4 2800 h
4 ‑ 6 2900 h
> 27.0 kW
3 ‑ 4 3000 h
4 ‑ 6 3000 h
8.4 Setting the pump output
1. Navigate to Menu → Installer level → Diagnostics
menu → D.014 Pump speed target value and confirm
by pressing .
2. Set the required pump output.
Conditions: Low loss header installed
▶ Switch off the speed regulation and set the pump output
to a fixed value.
8.4.1 Remaining pump head
8.4.1.1 Pump characteristic line 627 (VU 256/5-7)
350
400
300
250
200
150
100
50
0 600200 400 800 1000 1400 16001200 1800
B
A
100%
80%
70%
60%
53%
A Remaining feed head
[hPa (mbar)]
B System volume flow [l/h]
8.5 Setting the bypass valve
Caution.
Risk of material damage caused by incor-
rect setting of the high-efficiency pump
If the pressure at the bypass valve is increased (by turning it clockwise) and the
pump output is set to less than 100%, the
product may not operate correctly.
▶ In this case, set the pump output to
5 = 100% using diagnostics code D.014.
▶ Remove the front casing. (→ Page 11)
1
▶ Regulate the pressure using the adjusting screw (1).
Position of the
adjusting screw
Pressure
in MPa
(mbar)
Notes/application
Right-hand stop
(turned all the
way down)
0.035
(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
Page 26
9 Troubleshooting
26 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Position of the
adjusting screw
Pressure
in MPa
(mbar)
Notes/application
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.
8.6 Handing the product over to the operator
▶ When you have finished the installation, affix the en-
closed sticker (which requests that the user reads the
instructions) to the front of the product in the operator's
language.
▶ Explain to the operator how the safety devices work and
where they are located.
▶ Inform the operator how to handle the product.
▶ In particular, draw attention to the safety information
which the operator must follow.
▶ Inform the operator that they must have the product
maintained in accordance with the specified intervals.
▶ Pass all of the instructions and documentation for the
product to the operator for safe-keeping.
▶ Inform the operator about measures taken to ensure the
supply of combustion air and flue gas guiding, and instruct the operator that he must not make any changes.
▶ Inform the operator that they must not store or use ex-
plosive or highly flammable substances (such as petrol,
paper 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.
9 Troubleshooting
9.1 Comfort protection mode for the heat cell
Conditions: Neither nor a fault code F.xx are shown in the display
Unusual operating noises are emitted from the heat cell in
the product.
▶ Check whether S.40 is displayed in Live monitor.
If S.40 is displayed, the product is in a temporary test mode,
which it again exits automatically.
Conditions: is displayed.
The Live monitor shows S.40 and D.118 is at 0. The heat
cell is in permanent comfort protection mode. This is not
caused by the all-gas sensor.
▶ Decommission the product and check the entire air/flue
pipe.
▽ Are there any blockages or leaks?
▶ Eliminate the cause.
▽ Are any components damaged?
▶ Replace the defective components.
▶ If the air/flue pipe is OK, restart the product.
▶ Prepare the flue gas analyser for checking the recircula-
tion.
◁ The measuring probes must be rinsed and must not
be contaminated by a previous measurement.
▶ Check for recirculation at the air test point. The following
measured values are indicators of recirculation.
– Oxygen value in the intake air: < 20 vol. %
– Intake air CO value: ≥ 100 ppm
▽ Recirculation is present.
▶ Eliminate the deficiencies in the air/flue pipe.
▽ No recirculation is present.
▶ Ensure that there is a heat requirement. In the
Live Monitor, check whether the product has the
status S.4 or S.14.
▶ If the combustion values are not OK, carry out check
programmes P.4 and P.14.
Conditions: and F.55 are displayed
The Live monitor shows S.40 and D.118 ≥ 1. The heat cell
is in permanent comfort protection mode.
▶ Check and, if required, replace the all-gas sensor.
9.2 Checking service messages
▶ To obtain further information, call up the Live monitor.
(→ Page 17)
Conditions: S.40 is displayed
The product is in Comfort protection mode. The product has
detected a temporary fault and continues to run with restricted comfort. The product switches back to the normal operating mode.
▶ To establish whether or not a component is defective,
read the fault memory. (→ Page 27)
Note
If no fault message is present, the product will
automatically switch back to normal operating
mode after a certain time.
Conditions: S.86 is displayed
The product remains in comfort safety mode and does not
switch back to normal operating mode.
▶ Check the component that is mentioned and, if required,
replace it.
▶ To establish whether or not a component is defective,
read the fault memory (→ Page 27).
appears if you have set a maintenance interval, for ex-
ample, and this has passed or a service message is issued.
Page 27
Troubleshooting 9
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 27
9.3 Eliminating faults
▶ If fault messages (F.XX) appear, eliminate the fault
by referring to the table in the appendix or using the
Function menu (→ Page 30) and the Check programmes
(→ Page 18).
Overview of fault codes (→ Page 43)
If several faults occur at the same time, the display shows
the corresponding fault messages for two seconds each in
alternation.
▶
Press (max. three times) to restart the product.
▶ If you are unable to eliminate the fault and the fault re-
curs despite reset attempts, contact customer service.
9.4 Calling up/clearing the fault memory
If faults have occurred, the last ten (max.) fault messages
are available in the fault memory.
▶ Navigate to Menu → Installer level → Fault list and con-
firm by pressing .
◁ The display shows the number of faults that have
occurred, the fault numbers and the corresponding
plain text display.
▶
Press or to call up individual fault messages.
▶
Press twice to delete the fault list.
9.5 Resetting parameters to factory settings
1. Navigate to Menu → Installer level → Diagnostics
menu → D.096 Reset to factory settings? and con-
firm by pressing .
2.
Press to set the value to 1 and confirm by pressing
.
9.6 Preparing the repair work
1. Temporarily decommission (→ Page 33) the product.
2. Disconnect the product from the power mains.
3. Remove the front casing. (→ Page 11)
4. Close the service valves in the heating flow, in the heat-
ing return and in the cold water pipe.
5. Drain the product (→ Page 33) if you want to replace
any of the product's water-bearing components.
6. Make sure that water does not drip on live components
(e.g. the electronics box).
7. Use only new seals.
9.6.1 Procuring spare parts
The original components of the product were also certified
by the manufacturer as part of the declaration of conformity.
If you use other, non-certified or unauthorised parts during
maintenance or repair work, this may void the conformity 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 reverse of these instructions.
▶ If you require spare parts for maintenance or repair
work, use only the spare parts that are permitted for the
product.
9.7 Replacing defective components
9.7.1 Replacing the burner
1. Remove the compact thermal module. (→ Page 31)
2
1
2. Undo the four screws (1) on the burner.
3. Remove the burner.
4. Install a new seal (2) on the new burner.
5. Install the compact thermal module. (→ Page 32)
9.7.2 Replacing the gas valve assembly
1. Switch off heating mode and hot water generation (→
Operating instructions).
B
A
2. Remove the air intake pipe.
3. Remove the two plugs from the gas valve assembly.
4. Unscrew the union nut from the gas valve assembly.
Page 28
9 Troubleshooting
28 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
1
5. Unscrew both screws to secure the gas valve assembly
to the fan.
6. Reinstall the new gas valve assembly in the reverse
order. Use new seals for this.
7. Read the offset value (1) that is imprinted on the new
gas valve assembly.
8. After installing the new gas valve assembly, carry out a
leak-tightness test (→ Page 23).
9. Close the front casing.
10. Switch on the product.
11. Navigate to Menu → Installer level → Diagnostics
menu → D.052 Min. gas valve steps offset and confirm by pressing .
12. Enter the offset value that you read off and confirm by
pressing .
13.
9.7.3 Replacing the fan
1. Remove the air intake pipe.
2. Remove the gas valve (→ Page 27).
B
A
1
4 2 3
3. Remove the plug (1) from the fan.
4. Unscrew the three screws between the mixture pipe
and the fan flange.
5. Replace the defective fan.
6. Reinstall the new fan in the reverse order. You must
use new seals for this. Ensure that the order in which
the three screws are screwed in between the fan and
the mixture pipe corresponds to the numbering (2), (3)
and (4).
9.7.4 Replacing the heat exchanger
1. Drain the product. (→ Page 33)
2. Remove the compact thermal module. (→ Page 31)
3. Remove the left side section.
4. Detach the condensate drain hose from the heat exchanger.
Page 29
Troubleshooting 9
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 29
2 3
4
1
5. Remove the clamps (2) and (3) from the flow connection and the return connection.
6. Undo the cap nut (4) on the return connection of the
pump 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. Remove two screws (1) on each of the two retainers.
9. Remove the all-gas sensor. (→ Page 30)
1
3
2
10. Remove the lower three screws (2) on the rear section
of the retainer.
11. Support the heat exchanger and swing the retainer (3)
to the side around the top screw (1).
12. Pull the heat exchanger downwards and to the left, and
remove it from the product.
13. Push the new heat exchanger into the air/flue gas con-
nection from above.
14. Push the heat exchanger into the groove in the retainer
on the right and swing the retainer on the left back into
its original position.
◁ The heat exchanger is now held in place by the
guides in the two retainers.
15. Install the two front clamps on the retainers and then
fit the screws you removed in the retainer on the left
(always work in this order).
16. Install all the connections and the all-gas sensor in the
reverse order.
17. Replace the seals.
Note
To make the installation easier, use only
the lubricant that may be included with the
Vaillant spare part. If no lubricant is included
with the Vaillant spare part, use only water or
commercially available soft soap.
18. Ensure that the clamps on the heat exchanger's connections are seated correctly.
19. Remove the compact thermal module. (→ Page 31)
20. Install the left-hand side section.
21. Fill (→ Page 20) and purge (→ Page 20) the product
and, if required, the heating installation.
9.7.5 Replacing the expansion vessel
1. Drain the product. (→ Page 33)
2. Remove the right side section.
2
3
4
1
3. Remove the right side section.
4. Undo the screwed connection (4).
5. Remove both screws (1) on the support plate (2).
6. Remove the support plate (2).
7. Pull out the expansion vessel (3) towards the front.
8. Insert the new expansion vessel into the product.
9. Screw the new expansion vessel to the water connec-
tion. Use a new seal for this.
10. Attach the support plate using both screws (1).
11. Install the right side section.
12. Fill (→ Page 20) and purge (→ Page 20) the product
and, if required, the heating installation.
Page 30
10 Inspection and maintenance
30 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
9.7.6 Replacing the PCB or the display
Note
If you only replace one component, when the
product is switched on, the new component adopts the parameters that were previously set from
the component that was not replaced.
1. Open the electronics box. (→ Page 15)
2. Replace the PCB or display according to the assembly
and installation instructions supplied.
X31
X12
1
3. If you are replacing the PCB, remove the coding resistance (1) (plug X24) from the old PCB and plug the plug
onto the new PCB.
4. Close the electronics box.
9.7.7 Replacing the PCB and the display
1. Open the electronics box. (→ Page 15)
2. Replace the PCB and display according to the
assembly and installation instructions supplied.
X31
X12
1
3. Remove the coding resistance (1) (plug X24) from the
old PCB and plug the plug into the new PCB.
4. Close the electronics box.
5. Press the on/off button on the product. (→ Page 17)
◁ After switching on, the product switches directly to
the menu to select the language. The default language setting is English.
6. Select the required language and confirm by pressing
.
◁ You are automatically taken to D.093 to set the
device specific number.
7. Remove the correct value for the relevant product type
from the technical data in the appendix, and press to
confirm.
◁ The electronics are now set to the product type and
the parameters of all diagnostics codes are set to
default settings.
◁ The installation assistant starts. (→ Page 17)
8. Make the system-specific settings.
9.7.8 Replacing the all-gas sensor
3
2
1
1. Remove the air intake pipe; see Removing the compact
thermal module (→ Page 31).
2. Undo the screws (3) just enough so that you can pull
out the all-gas sensor (1) by the cable.
3. Remove the plug (2) by pushing in the latching lug.
4. Reinstall the new all-gas sensor in the reverse order.
9.8 Completing repair work
1. Establish the power supply.
2. Switch the product back on if this has not yet been
done. (→ Page 17)
3. Install the front casing.
4. Open all service valves and the gas isolator cock.
10 Inspection and maintenance
▶ Adhere to the minimum inspection and maintenance in-
tervals. The inspection may require maintenance to be
carried out earlier, depending on the results.
Inspection and maintenance work – Overview
(→ Page 48)
10.1 Function menu
Menu → Installer level → Test programs → Function menu
The function menu allows you to actuate and test individual
components in the heating installation.
Display
Test
programme
Action
T.01 Check internal
pump
Switch the internal pump on
and off.
T.02 Check 3-way
valve
Move the diverter valve to
the heating position or to the
hot water position.
T.03 Check fan Switch the fan on and 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.
Page 31
Inspection and maintenance 10
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 31
Display
Test
programme
Action
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.
10.2 Electronics self-test
Menu → Installer level → Test programs → Electronics
self-test
You can use the electronics self-test to check the PCB.
10.3 Working on the compact thermal module
10.3.1 Removing the compact thermal module
Note
The compact thermal module consists of four
main components:
– Speed-regulated fan,
– Gas valve,
– Burner flange,
– Premix burner.
Danger!
Risk of death and risk of material damage
caused by hot flue gas.
The seal, insulating mat and self-locking nuts
on the burner flange must not be damaged.
Otherwise, hot flue gases may escape and
cause personal injury and material damage.
▶ Replace the seal each time you open the
burner flange.
▶ Replace the self-locking nuts on the
burner flange each time you open the
burner flange.
▶ If the insulating mat on the burner flange
or on the back wall of the heat exchanger
shows signs of damage, replace the insulating mat.
1. Disconnect the product from the power supply.
2. Close the gas isolator cock.
3. Remove the front casing.
4. Tilt the electronics box forward.
1
2
3
5. Unscrew the retaining screw (2) and remove the air
intake pipe (1) from the intake stub.
6. Unscrew the cap nut from the gas valve (3).
1
3
2
4
5
7
6
7. Remove the ignition line plug (2) and the earth line plug
(3) from the ignition electrode.
8. Remove the plug (7) from the fan motor by pushing in
the latching lug.
9. Remove the two plugs from the gas valve (6).
10. Unscrew the four nuts (1).
11. Remove the entire compact thermal module (5) from
the heat exchanger (4).
12. Check the burner and the heat exchanger for damage
and dirt.
13. If necessary, clean or replace the components accord-
ing to the following sections.
14. Fit a new burner flange seal.
15. Check the insulating mat on the burner flange and on
the back wall of the heat exchanger. If you notice any
signs of damage, replace the relevant insulating mat.
Page 32
10 Inspection and maintenance
32 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
10.3.2 Cleaning the heat exchanger
1. Protect the folded down electronics box against sprayed
water.
1 2
3
4
2. Never undo the four nuts on the stud bolt (1) or tighten
them.
3. Clean the heating coil (3) of the heat exchanger (4) using 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 exchanger.
◁ The water flows out of the heat exchanger through
the condensate trap.
10.3.3 Checking the burner
2
3
1
1. Check the surface of the burner (1) for damage. If you
see any damage, replace the burner.
2. Fit a new burner flange seal (3).
3. Check the insulating mat (2) on the burner flange. If you
notice any signs of damage, replace the insulating mat.
10.3.4 Installing the compact thermal module
1
3
2
4
5
7
6
1. Connect the compact thermal module (5) to the heat
exchanger (4).
2. Tighten the four nuts (1) in a cross-wise pattern until the
burner flange fits closely and uniformly onto the mating
surfaces.
– Tightening torque: 6 Nm
3. Reconnect the plug (2) for the ignition line and the plug
(3) for the earth line.
4. Reconnect the plug (6) to the gas valve.
5. Reconnect the plug (7) to the fan motor.
6. Connect the gas line using a new seal. In the process,
secure the gas pipe against twisting.
7. Open the gas isolator cock.
8. Make sure that there are no leaks.
9. Check that the sealing ring in the air intake pipe is positioned correctly in the seal seat.
10. Reconnect the air intake pipe to the intake nozzle.
11. Secure the air intake pipe with the retaining screw.
12. Check the gas flow pressure. (→ Page 21)
10.4 Cleaning the condensate trap
1. Remove the lower section from the condensate trap.
2. Flush out the lower section with water.
3. Fill the lower section with water up to about 10 mm below the upper edge.
4. Attach the lower section to the condensate trap.
Page 33
Decommissioning 11
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 33
10.5 Draining the product
1. Close the service valves of the product.
2. Start the check programme P.06 (diverter valve midposition).
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.
10.6 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 vessel at the vessel valve.
Conditions: Pre-charge pressure < 0.075 MPa (0.75 bar)
▶ Ideally, you should top up the expansion vessel with
nitrogen. Otherwise, top it up with air. Ensure that the
drain valve is open when topping up.
3. If water escapes from the valve of the expansion
vessel, you must replace the expansion vessel
(→ Page 29).
4. Fill the heating installation. (→ Page 20)
5. Purge the heating installation. (→ Page 20)
10.7 Completing inspection and maintenance
work
▶ Check the gas flow pressure. (→ Page 21)
▶ Calibrate the heat generator and measure the CO/CO₂
content and the gas flow in heating mode. (→ Page 22)
▶ If required, reset the maintenance interval. (→ Page 30)
▶ Check that the product is leak-tight. (→ Page 23)
▶ Install the front casing.
▶ Fill out the relevant Service Record section in the Bench-
mark Checklist.
11 Decommissioning
11.1 Temporarily decommissioning the product
▶ Press the on/off button.
◁ The display goes out.
▶ Close the gas isolator cock.
▶ For products with hot water generation and products with
a connected domestic hot water cylinder, you must also
close the cold water stop valve.
11.2 Decommissioning the product
▶ Press the on/off button.
◁ The display goes out.
▶ Disconnect the product from the power mains.
▶ Close the gas isolator cock.
▶ Close the cold water stop valve.
▶ Drain the product. (→ Page 33)
12 Recycling and disposal
Disposing of the packaging
▶ Dispose of the packaging correctly.
▶ Observe all relevant regulations.
13 Customer service
To ensure regular servicing, it is strongly recommended
that arrangements are made for a Maintenance Agreement.
Please contact Vaillant Service Solutions for further details:
Telephone: 0330 100 3461
Page 34
Appendix
34 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Appendix
A Installer level – Overview
Setting level Values
Unit Increment, select, explanation
Default
setting
Min. Max.
Installer level →
Enter code 00 99 – 1 (competent person code 17) –
Installer level → Fault list →
F.XX – F.XX¹ Current value
– –
–
Installer level → Test programs → Check programs →
P.00 Purging – – – Yes, No –
P.01 Maximum load – – – Yes, No –
P.02 Minimum load – – – Yes, No –
P.04 Reset eGas CH – – – Yes, No –
P.06 Filling mode – – – Yes, No –
Installer level → Test programs → Function menu →
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 hot water generation or connected
domestic hot water cylinder
–
Green iQ
– –
– On, Off On
Auxiliary relay 1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (not active)
8 = eBUS remote control (not active)
9 = Legionella protection pump (not active)
10 = Solar valve (not active)
2
¹Fault lists are only displayed, and can only be deleted, if faults have occurred.
Page 35
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 35
Setting level Values
Unit Increment, select, explanation
Default
setting
Min. Max.
Accessory relay 1 1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (not active)
8 = eBUS remote control (not active)
9 = Legionella protection pump (not active)
10 = Solar valve (not active)
2
Accessory relay 2 1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (not active)
8 = eBUS remote control (not active)
9 = Legionella protection pump (not active)
10 = Solar valve (not active)
2
Heating partial load – – kW Partial load only, full load only, auto Auto
Contact details 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 midposition
0 2 – 0 = Normal operating mode
1 = Mid-position (parallel operation)
2 = Permanent heating mode position
–
Purge program: Select circ. using
+/-
– – – Automatic adaptive purging of the heating circuit
and hot water circuit
Not active
Active
–
Target flow temp. 30 75 ℃ 1 –
DHW temperature 35 60 ℃ 1
Product with hot water generation
–
Green iQ
– –
– On, Off On
Heating partial load – – kW Partial load only, full load only, auto Auto
Auxiliary relay 1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (not active)
8 = eBUS remote control (not active)
9 = Legionella protection pump (not active)
10 = Solar valve (not active)
2
¹Fault lists are only displayed, and can only be deleted, if faults have occurred.
Page 36
Appendix
36 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Setting level Values
Unit Increment, select, explanation
Default
setting
Min. Max.
Accessory relay 1 1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (not active)
8 = eBUS remote control (not active)
9 = Legionella protection pump (not active)
10 = Solar valve (not active)
2
Accessory relay 2 1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (not active)
8 = eBUS remote control (not active)
9 = Legionella protection pump (not active)
10 = Solar valve (not active)
2
Set the type of gas 0 2 – 0: Natural gas
1: Propane 50 mbar
2: Propane 30/37 mbar
–
Contact details Phone number – 0-9 –
End the installation assistant? – – – Yes, No –
¹Fault lists are only displayed, and can only be deleted, if faults have occurred.
B 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
Default
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 current system
demand
Auto
D.001 Pump overrun: Heating 1 60 min Overrun time of internal heating
pump for heating mode
1
5
D.002 Max. anti-cycl. time: Heat-
ing
2 60 min Max. burner anti-cycling time heat-
ing at 20 °C flow temperature
1
20
D.003 Outlet temperature actual
value
Current value °C – – Not ad-
justable
D.004 Cylinder temperature ac-
tual value
Current value °C Measured value of hot water
sensor
– Not ad-
justable
D.005 Heating target flow temper-
ature
Current value °C Flow temperature target value (or
return target value)
– Not ad-
justable
D.006 Outlet temperature target
value
Current value °C Domestic hot water temperature
target value (only products with integrated domestic hot water generation)
– Not ad-
justable
Page 37
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 37
Code Parameter
Values
Unit Increment, select, explanation
Default
setting
Own
setting
Min. Max.
D.007 Cylinder temperature tar-
get value
Comfort mode target value
Current value °C Only products with no integrated
hot water generation and with a
connected cylinder
Only products with integrated hot
water generation
– Not ad-
justable
D.008 Controller 3-4 Current value – 0: Open (Room thermostat at ter-
minal RT open = No heat requirement)
1: Closed (Room thermostat at terminal RT closed = Heat requirement)
– Not ad-
justable
D.009 eBUS controller target
value
Current value – Target value from external eBUS
controller
– Not ad-
justable
D.010 Internal pump Current value – 0: Off
1: On
– Not ad-
justable
D.011 External pump Current value – 0: Off
1: On
– Not ad-
justable
D.012 Cyl. charging pump Current value – 0: Off
1: On
– Not ad-
justable
D.013 Circulation pump Current value – 0: Off
1: 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 changeover
0: Flow
1: Return (conversion for underfloor
heating)
If you have activated the return
temperature control, the function
for automatically limiting the heating output using the volume flow
remains active. The partial heat
load that is selected under D.000
(auto = max.) continues to be the
upper limit.
0
D.018 Pump operating mode 1 3 – Setting
1 = Comfort (continuously operating pump)
The internal pump is switched on
when the heating flow temperature
is not at Heating off and the heat
requirement is enabled via an external control
3 = Eco (intermittently operating
pump)
Internal pump is switched on every
25 minutes for 5 minutes once the
overrun time has elapsed
3
Page 38
Appendix
38 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Code Parameter
Values
Unit Increment, select, explanation
Default
setting
Own
setting
Min. Max.
D.020 Max. DHW temperature
target value
50 70 °C Max. setting for cylinder target
value
1
65
D.022 DHW demand Current value – Domestic hot water requirement via
C1/C2, impeller or APC
0: Off
1: On
– Not ad-
justable
D.023 Heating mode status Current value – Summer/winter mode (heating
off/on)
0: Blocked
1: Released
– Not ad-
justable
D.024 Air pressure sensor actual
value
Current value Pa – – Not ad-
justable
D.025 Ext. eBUS signal: Cylinder
charging
Current value – Hot water generation enabled by
eBUS control
0: Off
1: On
– Not ad-
justable
D.026 Auxiliary relay 1 10 – 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 active)
9 = Anti-legionella pump (not active)
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 active)
9 = Anti-legionella pump (not active)
10 = Solar valve (not active)
2
D.028 Accessory relay 2 1 10 – Switching of relay 2 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 active)
9 = Anti-legionella pump (not active)
10 = Solar valve (not active)
2
D.029 Water circulation vol. ac-
tual value
Current value m³/h Actual value: Circulation water
volume for flow sensor
– Not ad-
justable
D.033 Fan speed target value Current value rpm – – Not ad-
justable
Page 39
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 39
Code Parameter
Values
Unit Increment, select, explanation
Default
setting
Own
setting
Min. Max.
D.034 Fan speed actual value Current value rpm – – Not ad-
justable
D.035 3-way valve position Current value – Position of the diverter valve
0. Heating mode
1: Parallel operation (mid-position)
2: DHW mode
– Not ad-
justable
D.036 DHW flow rate Current value l/min – – Not ad-
justable
D.039 Solar inlet temp. actual
value
Current value °C – – Not ad-
justable
D.040 Flow temperature actual
value
Current value °C – – Not ad-
justable
D.041 Return temperature actual
value
Current value °C – – Not ad-
justable
D.044 Ionisation value actual
value
Current value – > 800 = No flame
< 400 = Good flame
– Not ad-
justable
D.046 Pump mode 0 1 – 0 = Relay with disable facility
1 = PWM with disable facility
0
D.047 Current outside temperat-
ure
Current value °C (with Vaillant weather-compensated
control)
– Not ad-
justable
D.050 Offset min. speed 0 3000 rpm Nominal value set in factory –
D.051 Offset max. speed -990 0 rpm Nominal value set in factory –
D.052 Min. gas valve steps offset 0 99 – The offset is specified at the gas
valve assembly.
1
–
D.058 Solar post-heating 0 3 – Only products with integrated hot
water generation
0 = Solar post-heating deactivated
3 = 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. ignition time Current value s – – Not ad-
justable
D.067 Remaining anti-cycl. time
for heating
Current value min – – Not ad-
justable
D.068 Number of first start at-
tempts
Current value – Unsuccessful ignitions at 1st at-
tempt
– Not ad-
justable
D.069 Number of second start
attempts
Current value – Unsuccessful ignitions at 2nd at-
tempt
– Not ad-
justable
D.070 3-way valve operation 0 2 – 0 = Normal operating mode
1 = Mid-position (parallel operation)
2 = Permanent heating mode position
0
D.071 Max. heating target flow
temp.
40 80 °C Target value maximum heating flow
temperature
1
75
D.072 Pump overrun after cylin-
der charging
0 10 min Internal pump
1
2
D.073 Offset setting for comfort
mode
−15 5 K Only products with integrated hot
water generation
1
0
D.074 Anti-legionella funct. with
integrated cyl.
0 1 – 0: Off
1: On
1
Page 40
Appendix
40 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Code Parameter
Values
Unit Increment, select, explanation
Default
setting
Own
setting
Min. Max.
D.075 Max. cylinder charging
time
20 90 min Max. charging time for domestic
hot water cylinder without independent control system
1
45
D.076 Device Specific Number Current value – (Device specific number = DSN) – Not ad-
justable
D.077 DHW partial load Output-range-
specific
kW Adjustable cylinder charging output 100 %
D.078 DHW max. flow temperat-
ure
55 80 °C Limit on cylinder charging temper-
ature
1
Note
The chosen value must be at least
15 K above the cylinder target
value.
75
D.080 Heating operating hours Current value h – – Not ad-
justable
D.081 DHW operating hours Current value h – – Not ad-
justable
D.082 Heating burner starts Current value – – – Not ad-
justable
D.083 DHW burner starts Current value – – – Not ad-
justable
D.084 Maintenance in „– – –” 3000 h Number of hours until the next
maintenance
1
"– – –" = Deactivated
–
D.086 Maintenance 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 hot water draw-
off detection via impeller (combination products only)
0 = 1.5 l/hr (no delay)
1 = 3.7 l/hr (2 s delay)
0
D.089 Ignition gas-air ratio offset −10 15 % – 8
D.090 eBUS controller Current value – 0: Not recognised
1: Recognised
– Not ad-
justable
D.091 Status DCF77 Current value – 0: No reception
1: Reception
2: Synchronised
3: Valid
– Not ad-
justable
D.092 actoSTOR communication
status
Current value – actoSTOR module detection
0: Not connected
1: Connection error
2: Connection active
– Not ad-
justable
D.093 Adjust Device Specific
Number
0 999 – (Device specific number = DSN)
627 (VU 256/5‑7 (H-GB)) = 209
–
D.094 Clear fault history 0 1 – 0: No
1: Yes
–
Page 41
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 41
Code Parameter
Values
Unit Increment, select, explanation
Default
setting
Own
setting
Min. Max.
D.095 Software version: PeBUS
participant
Current value – 0: BMU
1: AI
2: APC
3: SMU
0
D.096 Reset to factory settings? 0 1 – 0: No
1: Yes
–
D.118 CO sensor fault number Current value – 1: Heater short circuit
2: Heater open circuit
3: Heater temperature control fault
4: Heater temperature plausibility
check not OK
5: Sensor short circuit/open circuit
6: Reference resistance measurement not OK
7: Sensor impedence too high
8: Standby reference resistance not
OK
9: EEPROM error
10: Sensor open circuit
11: Not used
12: Sensor plausibility test fault
13: Electrical power consumption
too low
14: Electrical power consumption
too high
15: Reference voltage too low
16: Reference voltage too high
– Not ad-
justable
D.132 Multi-occupancy 0 1 – 0: Off
1: On
0
D.145 Flue gas monitoring 0 1 – 0: Off
1: On
1
C Status codes – Overview
Status code Parameter Meaning
Heating mode
S.00 Heating: No heat demand Heating: No heat demand
S.01
Heating mode: Fan start-up
Heating mode: 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: Remaining anti-cycling time
S.09 Heating mode: Measuring program Heating mode: Measuring programme
DHW mode
S.10 DHW demand Domestic hot water requirement via impeller sensor
S.11 DHW mode: Fan start-up DHW mode: Fan start-up
S.13 DHW mode: Ignition DHW mode: Ignition
S.14 DHW mode: Burner on DHW mode: Burner on
S.15 DHW mode: Pump/fan overrun DHW mode: Pump/fan overrun
S.16 DHW mode: Fan overrun DHW mode: Fan overrun
S.17 DHW mode: Pump overrun DHW mode: Pump overrun
Page 42
Appendix
42 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Status code Parameter Meaning
S.19 DHW mode: Measuring program DHW mode: Measuring programme
Cylinder charging mode
S.20 DHW demand Domestic hot water requirement
S.21
DHW mode: Fan start-up
DHW mode: Fan start-up
S.22 DHW mode: Pump pre-run DHW mode: Pump prerun
S.23 DHW mode: Ignition DHW mode: Ignition
S.24 DHW mode: Burner on DHW mode: Burner on
S.25 DHW mode: Pump/fan overrun DHW mode: Pump/fan overrun
S.26 DHW mode: Fan overrun DHW mode: Fan overrun
S.27 DHW mode: Pump overrun DHW mode: Pump overrun
S.28 DHW anti-cycling time Domestic hot water burner anti-cycling time
S.29 DHW mode: Measuring program DHW mode: Measuring programme
Others
S.30 No heat demand: Controller Room thermostat (RT) is blocking heating mode
S.31 No heat demand: Summer mode
Summer mode active or no heat requirement from eBUS
control
S.32 Waiting time deviation: Fan speed Waiting period because of fan speed deviation
S.33 Waiting time: Air monitor
Waiting period: Air pressure sensor/switch reports that
the pressure signal is too low
S.34 Heating mode: Frost protection Frost protection mode active
S.36 Target value for ext. controller lower than 20 °C
Reference setting for continuous controller 7-8-9 or
eBUS controller is < 20°C and blocks the heating mode
S.37 Waiting time: Deviation in fan speed Waiting period: Fan failure in operation
S.39 Contact thermostat triggered
"Burner off contact" has responded (e.g. surface-mounted thermostat or condensate pump)
S.40 Comfort protection active
Comfort protection mode is active: Product running with
limited heating comfort
S.41 Water pressure too high Water pressure > 2.8 bar
S.42 Flue non-return flap closed
Flue non-return flap response blocks burner operation
(only in conjunction 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 deficiency (flow/return spread too large)
S.54 Waiting time: Water shortage
Product is within the waiting period of the operating
blocking function as a result of water deficiency
(temperature gradient)
S.55 Waiting time: CO sensor Waiting period: CO sensor
S.56 Waiting time: CO limit value exceedance Waiting period: CO limit value exceedance
S.57 Waiting time: Measuring program
Calibration unsuccessful. Waiting period, comfort protection mode
S.58 Burner modulation limitation Modulation limitation due to noise/wind
S.59 Waiting time: Water circulation vol. Minimum circulation water volume
S.76 Service message: Check water pressure System pressure too low. Top up water.
S.86 Service message: Check vortex sensor Service message: Check vortex sensor
S.88 Purging programme is running Purging programme is running
S.92 Water circulation volume self-test Water circulation volume self-test
S.93 Flue gas measurement not possible
Flue gas analysis not possible because not all measuring programmes have yet run
S.96 Return temperature sensor self-test
Return sensor test running, heating demands are
blocked.
S.97 Water pressure sensor self-test
Water pressure sensor test running, heating demands
are blocked.
Page 43
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 43
Status code Parameter Meaning
S.98 Flow/return temperature sensor self-test
Flow/return sensor test running, heating demands are
blocked.
S.99 Vaillant self-test Self-test
D Overview of fault codes
Note
Since the code table is used for various products, some codes may not be visible for the product in question.
Code Parameter Possible causes
F.00 Interruption: Flow sensor NTC plug not plugged in or has come loose, multiple plug on the PCB
not plugged in correctly, interruption in cable harness, NTC defective
F.01 Interruption: Return sensor NTC plug not plugged in or has come loose, multiple plug on the PCB
not plugged in correctly, interruption in cable harness, NTC defective
F.02 Interruption: DHW outlet sensor Only in conjunction with F.91
NTC defective, NTC cable defective, defective plug connection on NTC,
defective plug connection on the actoSTOR electronics
F.03 Interruption: Cylinder sensor Only in conjunction with F.91
NTC defective, NTC cable defective, defective plug connection on NTC,
defective plug connection on the actoSTOR electronics
F.10 Short circuit: Flow sensor NTC defective, short circuit in cable harness, cable/housing
F.11 Short circuit: Return sensor NTC defective, short circuit in cable harness, cable/housing
F.12 Short circuit: DHW outlet sensor Only in conjunction with F.91
NTC defective, short circuit in cable harness, cable/housing
F.13 Short circuit: Cylinder sensor Combination product: Warm start sensor/cylinder sensor short circuit
Combination product with actoSTOR: Short circuit cylinder sensor (NTC)
only in combination with F.91
NTC defective, short circuit in cable harness, cable/housing
F.20 Safety switch-off: Temperature limiter Incorrect earth connection between cable harness and product, flow or
return NTC defective (loose connection), stray spark via ignition cable,
ignition plug or ignition electrode
F.22 Safety switch-off: Low water pressure No or insufficient 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-return valve blocked/incorrectly installed
F.25 Safety switch-off: Flue temp. too high Break in plug connection for optional flue gas safety cut-out (SCO),
break in cable harness
F.26 Fault: Fuel valve not working Gas valve assembly stepper motor not connected, multiple plug on the
PCB not plugged in correctly, interruption in cable harness, gas valve
assembly stepper motor defective, electronics defective
F.27 Safety switch-off: Flame simulation Moisture on the electronics, electronics (flame monitor) defective, gas
solenoid valve leaking
F.28 Start-up failure: Ignit. unsuccessful Gas meter defective or gas flow monitor has triggered, air in gas, gas
flow pressure too low, thermal isolator device (TAE) has triggered, condensate route blocked, incorrect gas injector, incorrect spare part gas
valve assembly, value in D.052 does not correspond to the printed value
on the current gas valve assembly, fault on the gas valve assembly, multiple plug on PCB incorrectly plugged in, break in cable harness, ignition
system (ignition transformer, ignition cable, ignition plug, ignition electrode) defective, ionisation flow interrupted (cable, electrode), incorrect
earthing of product, electronics defective
F.29 Start-up failure: Ignit. unsuccessful Gas supply temporarily stopped, flue gas recirculation, condensate route
blocked, defective earthing of product, ignition transformer has spark
failure
F.32 Fault: Fan Plug on fan not correctly plugged in, multiple plug on PCB not correctly
plugged in, break in cable harness, fan blocked, Hall sensor defective,
electronics defective
Page 44
Appendix
44 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
Code Parameter Possible causes
F.33 Pressure switch Check: Cable harness, vacuum hose (blockage), supply air/flue gas
route (blockage), panel (correct type), flue pipe (length), air pressure
sensor, settings (if necessary, switch D.132 to multiple-flue configuration), pressure switch, fan.
F.35 Fault: Air/flue gas duct Check the entire air/flue pipe for:
– Permitted design
– Restriction or blockage in the air/flue pipe caused by obstructions
– Damage
The air/flue pipe must be installed in accordance with the recognised
rules
If the supply of combustion air (air pipe) or discharge of flue gas (flue
pipe) occurs with no problems, clear any faults in the product with
and start it up
If F.35 occurs again after start-up and the air/flue pipe is present and
correct, the function for checking the air/flue pipe can be deactivated via
D.145
If the function is deactivated via D.145, any faults can be cleared in the
product and it can be started up
Note
D.145 can be used to permanently activate or deactivate the function
After the function is deactivated, the product no longer automatically
checks whether there are restrictions for the air/flue pipe.
F.42 Fault: Coding resistor Gas family coding resistor short circuit/interruption (on the PCB)
– Gas family coding resistor missing
– The coding resistor does not match the gas type selection under
D.087
Incorrect coding resistor or incorrect gas type selected
F.49 Fault: eBUS Short circuit on eBUS, eBUS overload or two power supplies with differ-
ent polarities on the eBUS
F.55 Fault: CO sensor Checking the cable harness
All-gas sensor defective, replace the all-gas sensor
Electronics defective, replace the PCB
F.56 Safety switch-off: CO limit exceeded Safety shutdown: CO limit 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 connection))
– 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 highly corroded
F.61 Fault: Fuel valve actuation The gas valve assembly cannot be actuated
– Cable harness supply line to the gas valve assembly is defective
(short to earth, short circuit)
– Gas valve assembly defective
– PCB defective
F.62 Fault: Fuel valve switch-off delay Delayed switch-off sequence of gas valve assembly detected
– Flame indicator light (ignition and monitoring electrode indicates
delayed extinguishing of the flame signal)
– Gas valve assembly defective
– PCB defective
F.63 Fault: EEPROM Electronics defective
F.64 Fault: Electronics/sensor Flow or return NTC short circuited, electronics defective
F.65 Fault: Electronics temp. Electronics overheating due to external influences, electronics defective
F.67 Fault: Electronics/flame Implausible flame signal, electronics defective
F.68 Fault: Flame signal unstable Air in gas, gas flow pressure too low, incorrect air ratio, condensate
route blocked, ionisation flow interruption (cable, electrode), flue gas
recirculation, condensate route
Page 45
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 45
Code Parameter Possible causes
F.70 Fault: Invalid Device Specific Number If spare parts fitted: Display and PCB replaced at same time and DSN
not reset, incorrect or missing output range coding resistance
F.71 Fault: Flow sensor Flow temperature sensor signalling constant value:
– Flow temperature sensor incorrectly positioned at flow pipe
– Flow temperature sensor defective
F.72 Fault: Flow/return sensor Flow/return NTC temperature difference too great → flow and/or return
temperature sensor defective
F.73 Fault: Water press. sensor Interruption/short circuit of water pressure sensor, interruption/short
circuit to GND in supply line to water pressure sensor or water pressure
sensor defective
F.74 Fault: Water press. sensor The line to the water pressure sensor has a short circuit to 5 V/24 V or
internal fault in the water pressure sensor
F.75 Fault: Pump/ water shortage Water pressure sensor and/or pump defective, air in the heating installa-
tion, insufficient water in the product; connect external expansion vessel
to the return
F.77 Fault: Flue non-ret. valve/condens. pump No response from flue non-return flap or condensate pump defective
F.78 Interrupt.: DHW outlet sensor on ext. contr. UK link box is connected but the domestic hot water NTC is not bridged
F.80 Fault: actoSTOR inlet sensor Only in conjunction with F.91
NTC defective, NTC cable defective, defective plug connection on NTC,
defective plug connection on the actoSTOR electronics
Sensor plug has short to earth to the housing, short circuit in cable harness, sensor defective
F.81 Fault: cylinder charging pump Only in conjunction with F.91
Cylinder is not fully charged after specified time.
– Check cylinder charging sensor and cylinder 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 anode was interrupted
– Cable between PCB and external current anode defective
– External current anode defective
F.83 Fault: NTC temp. gradient When the burner starts, the temperature change registered at the flow
and/or return temperature sensor is non-existent or too small.
– Insufficient water in product
– Flow or return temperature sensor not in correct position at pipe
F.84 Fault: NTC temp. diff. implausible Flow and return temperature sensors returning implausible values.
– Flow and return temperature sensors have been inverted
– Flow and return temperature sensors have not been correctly in-
stalled
F.85 Fault: NTCs fitted incorrectly The flow and/or return temperature sensors have been installed on the
same pipe/incorrect pipe
F.90 Fault: Communication
Check the cable harness from the product to the actoSTOR module
(PEBus).
If the product is to be operated without an actoSTOR module, set
D.092 = 0.
F.94 Fault: Vortex and differential pressure Check: Cable harness, plug, sensors.
LED
actoSTOR
module
actoSTOR electronics status LED on: Communication OK
LED flashing: Communication not OK
LED off: No power supply
Communication
fault
Communication fault Communication fault between display and PCB in the electronics box
Page 46
Appendix
46 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
E Wiring diagram
Page 47
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 47
X18
X51
X20
X101
X13
24V
230V~
24V
230V~
X41
X25
6
5
4
3
2
1
X21
6
5
4
3
16
1
12
4
X2
13
11
14
3
1
4
10
15
13
2
1
3
6
3
2
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 BUSRT 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
22
19
X24
17
3
Page 48
Appendix
48 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
1 Main PCB
2 Operator control panel PCB
3 All-gas sensor
4 Gas valve assembly
5 Outdoor temperature sensor, flow temperature
sensor (optional, external), DCF receiver
6 Circulation pump remote 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 relay (select via D.026)
21 Circulation pump
22 Ignition electrode
F Inspection and maintenance work – Overview
Note
The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If national regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed in the table.
No. Work
Inspection
(annual)
Mainten-
ance
(must be
carried out
at regular
intervals)
1
Check the air/flue pipe for leak-tightness and to ensure that it is fastened correctly. Make sure
that it is not blocked or damaged and has been installed in accordance with the relevant set-up
instructions.
X X
2
Check the general condition of the product. Remove any dirt from the product and the vacuum
chamber.
X X
3
Visually inspect the general condition of the product. In doing so, pay particular attention to signs
of corrosion, soot and other defects.
X X
4
Check the gas flow pressure at maximum heat input. If the gas flow pressure is not within the
correct range, carry out maintenance work.
X X
5
Check the product's CO₂ content (air ratio) and adjust this, if required. Keep a record of this.
X X
6
Disconnect the product from the power grid. Check that the electrical plug connections and other
connections are seated correctly and correct these if necessary.
X X
7
Close the gas stopcock and the service valves.
X
8
Drain the product on the water side (observe the manometer). Check the pre-charge pressure
of the expansion vessel and top the vessel up, if necessary (approx. 0.3 bar below the system
filling pressure).
X
9
Remove the compact thermal module.
X
10
Check the insulating mats in the combustion area. If you notice any damage, replace the insulating mats. Replace the burner flange seal each time it is opened and accordingly each time
maintenance work is carried out.
X
11
Clean the heat exchanger.
X
12
Check the burner for damage and replace it if necessary.
X
13
Check the condensate trap in the product, clean and fill this, if required.
X X
14
Install the compact thermal module. Caution: Replace the seals.
X
15
Open the gas stopcock, reconnect the product to the mains and switch it on.
X X
16
Open the service valves, fill up the product/heating installation to 1.0-2.0 bar (depending on the
static height of the heating installation) and start the purging programme P.00.
X
17
Run a function test for the product and the heating installation – especially the domestic hot
water generation. Then purge the installation again, if required.
X X
18
Check the gas type.
X
19
Visually inspect the ignition and burner behaviour.
X X
20 Check the CO₂ content (the air ratio) of the product again.
X
Page 49
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 49
No. Work
Inspection
(annual)
Mainten-
ance
(must be
carried out
at regular
intervals)
21
Ensure that no gas, flue gas, domestic hot water or condensate is leaking from the product.
Restore leak-tightness if necessary.
X X
22
Record the inspection/maintenance work carried out.
X X
Page 50
Appendix
50 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
G Commissioning Checklist
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Benchmark Commissioning and
Servicing Section
It is a requirement that the boiler is installed and commissioned to the
completed in full.
Page 51
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 51
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
CONTROLS
Optimum start control
Fitted
Fitted
Fitted
Fitted
ALL SYSTEMS
Yes
Yes
CENTRAL HEATING MODE
OR
mbar OR mbar
COMBINATION BOILERS ONLY
Yes
Yes
DOMESTIC HOT WATER MODE
OR
mbar OR mbar
Yes Temperature
CONDENSING BOILERS ONLY
Yes
ALL INSTALLATIONS
AND
²
Ratio
AND
²
Ratio
Yes
Yes
Yes
Yes
Page 52
Appendix
52 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
SERVICE RECORD
SERVICE 01
AND
²
%
AND
²
%
SERVICE 02
AND
²
%
AND
²
%
SERVICE 03
AND
²
%
AND
²
%
SERVICE 04
AND
²
%
AND
²
%
SERVICE 05
AND
²
%
AND
²
%
SERVICE 06
AND
²
%
AND
²
%
SERVICE 07
AND
²
%
AND
²
%
SERVICE 08
AND
²
%
AND
²
%
SERVICE 09
AND
²
%
AND
²
%
SERVICE 10
AND
²
%
AND
²
%
Page 53
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 53
PRIOR TO CO AND COMBUSTION RATIO CHECK
The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas
supply pressure/rate checked as required prior to commissioning.
As part of the installation process, especially where a flue has been fitted by persons other than the
boiler installer, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that manufacturer’s max. flue lengths have not been
exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
The flue gas analyser should be of the correct type, as specified by BS 7967
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the
manufacturer. The installer must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.
NOTE
THE AIR GAS RATIO VALVE IS FACTORY
SET AND MUST NOT BE ADJUSTED
DURING COMMISSIONING UNLESS THIS
ACTION IS RECOMMENDED FOLLOWING
CONTACT WITH THE MANUFACTURER.
If any such adjustment is recommended and
further checking of the boiler is required the
installer/service engineer must be competent
to carry out this work and to use the flue gas
analyser accordingly.
If the boiler requires conversion to operate with
a different gas family (e.g. conversion from
natural gas to LPG) separate guidance will be
provided by the boiler manufacturer
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER
Insert analyser probe into air inlet test point and allow readings to stabilise.
NOTE - where no air inlet test point is provided then a flue integrity check
with the analyser is not possible. The installer should verify that flue
integrity has been visually checked in accordance with the “Prior to
CO and combustion ratio check” box above before proceeding to the
“Check CO and combustion ratio at maximum rate” stage below.
SET BOILER TO MINIMUM RATE
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
NOTE - If manufacturer’s instructions do not 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 guidance.
CHECK CO AND COMBUSTION RATIO AT MAX. RATE
With boiler still set at maximum 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 guidance.
SET BOILER TO MAXIMUM RATE
In accordance with boiler instructions, set boiler to operate at max. rate
(full load condition). Allow sufficient time for combustion to stabilise.
NOTE - Do not insert analyser probe during this period to avoid
possible “flooding” of sensor.
Is
CO less than
350ppm and
CO/CO
2
ratio
less than 0.004
Is
O
2
20.6%
and
CO
2
< 0.2%
Is
CO less than
350ppm and
CO/CO
2
ratio
less than 0.004
BOILER IS OPERATING SATISFACTORILY
no further actions required.
Ensure test points are capped, boiler case is correctly replaced and
all other commissioning procedures are completed.
Complete Benchmark Checklist, recording CO and combustion ratio
readings as required.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
FOR ADVICE.
THE APPLIANCE MUST NOT BE
COMMISSIONED UNTIL PROBLEMS ARE
IDENTIFIED AND RESOLVED.
VERIFY FLUE INTEGRITY
Analyser readings indicate that combustion products
and inlet air must be mixing. Further investigation of
the flue is therefore required.
Check that flue components are assembled, fixed
and supported as per boiler/flue manufacturer’s
instructions.
Check that flue and flue terminal are not obstructed.
Is
CO
less than
335ppm
and
CO/CO
2
ratio less
than 0.004
Is
O
2
20.6%
and
CO
2
< 0.2%
Check all seals around the appliance burner,
internal flue seals, door and case seals.
Rectify where necessary.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
FOR ADVICE.
THE APPLIANCE MUST NOT BE
COMMISSIONED UNTIL PROBLEMS ARE
IDENTIFIED AND RESOLVED. IF
COMMISSIONING CANNOT BE FULLY
COMPLETED, THE APPLIANCE MUST BE
DISCONNECTED FROM THE GAS SUPPLY IN
ACCORDANCE WITH THE GSIUR.
NOTE: Check and record CO and combustion ratio
at both max. and min. rate before contacting the
manufacturer.
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
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Appendix
54 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
H Opening of the flue pipe
G
N
N
MM
A
I
I
O
H
H
C
B
L
J
Q
Q
Q
Q
Q
K
P
D, E
F
I
S
R
T
H.1 Positioning of the opening of a fan-supported flue gas pipe
Installation site
Minimum dimensions
A
Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm
B Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm
C Horizontally to an opening, air bricks, opening windows, etc., that can be opened. 300 mm
D
Below temperature-sensitive building components, e.g. plastic gutters, down pipes or wastewater
pipes
75 mm
E Below eaves 200 mm
F Below balconies or car port roofs 200 mm
G From vertical wastewater pipes or down pipes 150 mm
H From external or internal corners 200 mm
I Above floors, roofs or balconies 300 mm
J From a surface facing a terminal 600 mm
K From a terminal facing a terminal 1200 mm
L From an opening in the car port (e.g. door, window) which leads into the dwelling 1200 mm
M Vertical from a terminal on the same wall 1500 mm
N Horizontal from a terminal on the same wall 300 mm
O From the wall on which the terminal has been installed 0 mm
P From a vertical structure on the roof N/A
Q Above the roof area 300 mm
R Horizontal from adjacent windows on pitched or flat roofs 600 mm
S Above adjacent windows on pitched or flat roofs 600 mm
T Below adjacent windows on pitched or flat roofs 2000 mm
Page 55
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 55
I Horizontal terminal positioning
BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows:
a) at least 2 m from an opening in the building directly opposite, and
b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely to
cause a nuisance to a neighbour or discharge over a walkway or patio.
For IE see current issue of IS 813.
For boilers covered within this manual.
1) Dimensions D, E, F and G:
These clearances may be reduced to 25 mm without affecting the performance of the boiler. In order to ensure that the condensate plume does not affect adjacent surfaces the terminal should be extended as shown below.
Balcony/eaves
Gutter
Adequately secured
air/flue gas pipe
The flue pipe must
protrude beyond any overhang
2) Dimension H:
This clearance may be reduced to 25 mm without affecting the performance of the boiler. However, in order to ensure that
the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred.
For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed away
from the building fabric.
J Technical data
Technical data – General
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Designated country (designation in accordance
with ISO 3166)
GB (United
Kingdom)
Approved unit categories
II
2H3P
Gas connection, boiler
side
15 x 1.0 mm
Flow/return heating connections, boiler side
22 x 1.5 mm
Expansion relief valve
connector (min.)
15 mm
Air/flue gas connection
60/100 mm
Condensate drain pipework (min.)
19 mm
Gas connection pressure,
G20 natural gas
2.0 kPa
(20.0 mbar)
Gas connection pressure,
G31 propane
3.7 kPa
(37.0 mbar)
Gas flow rate at 15 °C
and 1013 mbar (based on
hot water generation, if
applicable), G20
3.2 m³/h
Page 56
Appendix
56 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Gas flow rate at 15 °C
and 1013 mbar (based on
hot water generation, if
applicable), G31
2.35 kg/h
Min. flue gas mass rate
(G20)
1.47 g/s
Min. flue gas mass rate
(G31)
1.81 g/s
Max. flue gas mass rate
13.60 g/s
Min. flue gas temperature
40 ℃
Max. flue gas temperature
65 ℃
Approved gas-fired units
C13, C33,
C53
30% efficiency
108.3 %
NOx class
6
Device Specific Number
(DSN)
209
SEDBUK (2005)
A
SEDBUK (2009)
(G20/G31)
89.3 %
Boiler dimension, width
440 mm
Boiler dimension, height
720 mm
Boiler dimension, depth
338 mm
Mounting weight
37.5 kg
Operating weight (with
water)
39.0 kg
Technical data – G20 power/loading G20
* The lowest 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.
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Nominal heat output
range P at 50/30 °C *
3.4
… 26.7 kW
Nominal heat output
range P at 80/60 °C *
3.0
… 24.7 kW
Maximum heat output for
hot water generation
30.0 kW
Maximum heat input for
hot water generation
30.3 kW
Maximum heat input,
heating side
25.3 kW
Minimum heat input
3.3 kW
Heating adjustment range
3 … 26 kW
Technical data – Power/loading G31
* The lowest 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.
Page 57
Appendix
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 57
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Nominal heat output
range P at 50/30 °C *
4.2
… 26.7 kW
Nominal heat output
range P at 80/60 °C *
3.7
… 24.7 kW
Maximum heat output for
hot water generation
30.0 kW
Maximum heat input for
hot water generation
30.3 kW
Maximum heat input,
heating side
25.3 kW
Minimum heat input
4.0 kW
Technical data – Heating
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Maximum flow temperature
85 ℃
Max. flow temperature
adjustment range (default
setting: 75 °C)
30 … 80 ℃
Permissible total overpressure
0.25 MPa
(2.50 bar)
Minimum pressure for
full operation
0.08 MPa
(0.80 bar)
Expansion vessel capacity
10 l
Circulation water volume
(with reference to
ΔT= 20 K)
1,064 l/h
Approx. condensate rate
(pH value 3.5 to 4.0) in
50/30 °C heating mode
2.52 l/h
Remaining feed head of
pump (at nominal circulation water volume)
0.020 MPa
(0.200 bar)
Technical data – Electrics
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Electric connection
230 V/50 Hz
Permissible connected
voltage
190 … 253 V
Built-in fuse (slow-blow)
2 A
Min. electrical power consumption
28 W
Max. electrical power
consumption for heating mode (nominal heat
loading)
62 W
Max. electrical power
consumption for cylinder
charging
80 W
Page 58
Appendix
58 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
627
(VU 256/5‑7
(H-GB))
ecoTEC
exclusive
Standby electrical power
consumption
< 1.9 W
Level of protection
IP X4 D
Test symbol/registration
no.
CE‑
0085CM0320
Page 59
Index
0020193966_01 ecoTEC exclusive Installation and maintenance instructions 59
Index
A
Air ratio setting .............................................................. 22–23
Air/flue pipe, connecting ...................................................... 14
Air/flue pipe, installed ............................................................ 5
Air/flue pipe, installing ......................................................... 14
Air/flue pipe, installing and connecting ................................ 14
All-gas sensor, replacing ..................................................... 30
Appliance config. ................................................................. 24
Automatic air vent................................................................ 20
Auxiliary relay ...................................................................... 18
B
Burner anti-cycling time....................................................... 24
Burner anti-cycling time, resetting ....................................... 25
Burner anti-cycling time, setting .......................................... 24
Burner, checking ................................................................. 32
Burner, replacing ................................................................. 27
Bypass valve, setting........................................................... 25
C
Calling up, diagnostics codes.............................................. 24
Calling up, diagnostics codes .............................................24
Calling up, fault memory...................................................... 27
Calling up, installer level...................................................... 16
CE label.................................................................................8
Check programmes ............................................................. 18
Checking, burner ................................................................. 32
Checking, pre-charge pressure for the internal expansion
vessel ..................................................................................33
Cleaning, heat exchanger ................................................... 32
Clearing, fault memory ........................................................27
Closing, electronics box ...................................................... 15
CO₂ content, checking................................................... 22–23
CO₂ content, setting ...................................................... 22–23
Combustion air supply........................................................... 5
Comfort protection mode..................................................... 26
Compact thermal module ......................................................6
Compact thermal module, installing .................................... 32
Compact thermal module, removing ................................... 31
Competent person ................................................................. 4
Completing, inspection work ............................................... 33
Completing, maintenance work ........................................... 33
Completing, repair work ...................................................... 30
Component test ................................................................... 30
Condensate drain pipework.................................................13
Condensate siphon ............................................................... 5
Condensate trap ............................................................ 20, 32
Connecting, control ............................................................. 16
Connection dimensions ......................................................... 9
Contact details..................................................................... 18
Control, connecting ............................................................. 16
Corrosion............................................................................... 6
Corrugated gas pipe.............................................................. 6
D
Decommissioning................................................................ 33
Decommissioning, temporarily ............................................ 33
Diagnostics codes, calling up .............................................. 24
Disposal, packaging ............................................................33
Disposing of the packaging ................................................. 33
Documents ............................................................................7
Draining, product ................................................................. 33
E
Electricity ............................................................................... 5
Electronics box, closing....................................................... 15
Electronics box, opening .....................................................15
Electronics self-test .............................................................31
Ending, installation assistant ............................................... 18
Expansion vessel, replacing................................................ 29
F
Fan, replacing...................................................................... 28
Fault codes....................................................................27, 43
Fault memory, calling up ..................................................... 27
Fault memory, deleting........................................................ 27
Fault messages ................................................................... 27
Filling ................................................................................... 20
Filling mode ......................................................................... 17
Flue gas route .......................................................................5
Flue pipe equipment connection piece................................ 14
From the delivery point to the installation site ....................... 9
Front casing, closed .............................................................. 5
Front casing, installing......................................................... 11
Front casing, removing........................................................ 11
Frost ......................................................................................6
Function menu.....................................................................30
G
G230, setting ....................................................................... 18
Gas family coding resistor, replacing .................................. 16
Gas flow rate ....................................................................... 21
Gas flow, measuring...................................................... 22–23
Gas type .............................................................................. 12
Gas type, setting .................................................................18
Gas valve assembly, replacing............................................ 27
H
Handing over to the operator............................................... 26
Handling ................................................................................9
Heat cell ..............................................................................26
Heat exchanger, cleaning....................................................32
Heat exchanger, replacing .................................................. 28
Heating flow......................................................................... 13
Heating partial load ............................................................. 17
Heating return...................................................................... 13
Hot water temperature......................................................... 17
I
Identification plate ................................................................. 8
If you smell flue gas............................................................... 5
If you smell gas .....................................................................4
Inspection work ............................................................. 30, 48
Inspection work, completing ................................................ 33
Installation assistant, ending ...............................................18
Installation assistants, restarting ......................................... 18
Installation site................................................................... 5–6
Installer level, calling up ...................................................... 16
Installing, compact thermal module..................................... 32
Installing, front casing.......................................................... 11
Installing, side section ......................................................... 11
Intended use..........................................................................4
Isolator devices ................................................................... 33
L
Language ............................................................................ 17
Leak-tightness ..................................................................... 23
Liquid gas ........................................................................ 5, 12
Liquid gas, setting ............................................................... 18
Page 60
Index
60 Installation and maintenance instructions ecoTEC exclusive 0020193966_01
M
Maintenance interval, setting...............................................25
Maintenance work .........................................................30, 48
Maintenance work, completing............................................ 33
M-gas, setting......................................................................18
Minimum clearance .............................................................10
Multi-functional module ....................................................... 18
O
Open-flued operation.............................................................5
Opening, electronics box..................................................... 15
Operating concept ............................................................... 16
P
PCB and display, replacing ................................................. 30
PCB or display, replacing .................................................... 30
Power supply.......................................................................15
Pre-charge pressure for the internal expansion vessel,
checking ..............................................................................33
Preparing, repair work ......................................................... 27
Product dimensions............................................................... 9
Product, draining .................................................................33
Product, switching off .......................................................... 33
Propane...............................................................................12
Pump output, setting ........................................................... 25
Pump, remaining feed head ................................................ 25
Purging ................................................................................ 20
Q
Qualification...........................................................................4
R
Regulations ........................................................................... 6
Remaining feed head, pump ............................................... 25
Removing, compact thermal module................................... 31
Removing, front casing........................................................11
Removing, side section .......................................................11
Repair work, completing...................................................... 30
Repair work, preparing ........................................................ 27
Replacing the burner ........................................................... 27
Replacing, all-gas sensor .................................................... 30
Replacing, expansion vessel ............................................... 29
Replacing, fan ..................................................................... 28
Replacing, gas family coding resistor.................................. 16
Replacing, gas valve assembly ........................................... 27
Replacing, heat exchanger..................................................28
Replacing, PCB and display................................................ 30
Replacing, PCB or display................................................... 30
Replacing, unit connection piece for the air/flue pipe.......... 14
Resetting, burner anti-cycling time ...................................... 25
S
Safety device.........................................................................5
Schematic drawing ................................................................ 5
Scope of delivery...................................................................8
Self-test ...............................................................................30
Serial number ........................................................................ 8
Service message................................................................. 26
Setting, burner anti-cycling time .......................................... 24
Setting, bypass valve .......................................................... 25
Setting, G230 ...................................................................... 18
Setting, gas type.................................................................. 18
Setting, liquid gas ................................................................ 18
Setting, maintenance interval .............................................. 25
Setting, M-gas .....................................................................18
Setting, pump output ........................................................... 25
Side section, installing......................................................... 11
Side section, removing ........................................................ 11
Spare parts..........................................................................27
Starting, installation assistants ............................................ 18
Status codes.................................................................. 17, 41
Switching off, product .......................................................... 33
Switching on/off ................................................................... 17
T
Target feed temperature...................................................... 17
Telephone number, competent person ............................... 18
Test programmes ................................................................18
Tool ....................................................................................... 6
Transport ............................................................................... 6
Treating the heating water................................................... 18
U
Unit connection piece for the air/flue pipe, 80/125 mm
diameter .............................................................................. 14
Unit connection piece for the air/flue pipe, replacing .......... 14
Unloading the box ................................................................. 9
V
Voltage ..................................................................................5
W
Weight .................................................................................10
Page 61
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Page 63
Page 64
0020193966_01 14.08.2017
Supplier
Vaillant Ltd.
Nottingham Road Belper Derbyshire DE56 1JT
Telephone 0330 100 3461
info@vaillant.co.uk www.vaillant.co.uk
© These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with
the manufacturer's written consent.
We reserve the right to make technical changes.
0020193966_01
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