For heating engineer/user Operating and Installation Manual VRC 630/2 Weather compensated cascade control VRC 630 GB
Contents Contents Overview 1 - Operation... 3 Overview 2 - Displays...4 Notes on the documentation...5 Other applicable documents...5 Attachment and storage of the documents...5 Symbols used...5 Operating manual...5 1 Description of the device...5 1.1 Structure and function...5 1.2 System overview...6 2 Operation...6 2.1 Display types...6 2.2 Dial...7 2.3 Operator guidance...7 2.3.1 Menu selection...7 2.3.3 Special functions...7 3 Error messages... 12 4 Frost protection... 12 5 Vaillant warranty... 12 6 Data transmission... 12 Installation instructions...13 1 General information...13 2 Safety instructions and regulations...13 2.1 Safety instructions...13 2.2 Regulations...13 3 Installation... 14 3.1 Scope of delivery... 14 3.2 Accessories... 14 VR 30 bus coupler for ecomax boilers... 14 3.3 Installing the VRC 630/2 heating control... 15 3.3.1 Installing the wall box... 15 3.3.2 Installing the control as a remote control device... 15 3.3.3 Installing the outdoor sensor... 16 4 Electrical installation...17 4.1 Connecting the boiler...17 4.2 Wiring... 18 4.2.1 Connecting a mixer circuit as a cylinder charging circuit... 18 4.2.2 Special features of the circulation pump connection... 18 4.2.3 Inputs for special functions... 18 4.2.4 Connector assignment... 19 4.2.5 Specifics if a hot water cylinder is connected... 20 4.3 Connecting the outdoor sensor...32 4.4 Connecting accessories...32 4.4.1 Connecting the remote control device...32 4.4.2 Connecting further mixer circuits...32 4.5 Connecting several boilers (cascade)...33 4.5.1 Modulating heating appliances...33 4.5.2 One and two stage heating appliances...33 5 Start-up...33 5.1 Setting system parameters... 34 5.2 Handing over the device to the owner... 34 6 Error codes...35 Appendix...36 Settings on the code level... 36 Chimney sweeper function... 38 (maximum output function)... 38 Manual operation... 39 List of error codes... 39 Overview of functions...40 Technical data...44 Vaillant Service... 45 2
Overview 1 - Operation Overview 1 - Operation 1 2 Basic data 1 Language Date Day of week Time >Select language > GB english 09.05.03 Fr 16:55 3 5 Fig. 0.1 Operating overview 4 Key 1 Menu name 2 Cursor indicating the selected parameter 3 Menu number 4 Dial, Set parameter (turn), Select parameter (press) 5 Dial, Select menu (turn), Activate special function (press) Operation procedure User level Turn the dial Press the dial Turn the dial to select the menu to select the parameter to be changed to change the selected parameter Special functions Only possible on the basic display (Saving, Party, one-time cylinder charging) To three times press the dial up to select the special function Press the dial to select the changed parameter and to accept the selected parameter value (after changing by turning) Turn the dial to set the desired value (only necessary for Saving) Press the dial to end the special function Service functions (heating engineer specific selection) Selection possible from the basic display Press the dials and once simultaneously for chimney sweeper function Press the dials and twice simultaneously for manual operation 3
Overview 2 - Displays Overview 2 - Displays Fr 17.05.02 heat zone 1 FLOOR 1 FLOOR 2 Cylinder >select operation mode 15:37 > heating Eco Auto Auto - 15 C 22 C 20 C 15 C Basic display The display shows the current operating mode and the target room temperature for each heating circuit and allows the operating mode of each heating circuit to be changed quickly. If more than two heating circuits are connected, they are displayed one after another (by turning the dial ). Basic data Language Date Day of week Time >Select language > GB english 09.05.03 Fr 16:55 1 Display example on the menu level User-specific settings. heat zone 1 Parameter Type direct circuit Night set back temp. Heating curve Max limit outs. temp >Select room temperature C2 > 15 C 0,90 20 C Display example on the code level System-specific settings to be made only by the heating engineer. Fr 17.05.02 15:37-15 C Chimney sweeper function (maximum output function) enabled Heating appliance > 1 Service function display example Functions which the heating engineer can activate. >Select heating appliance Fr 17.05.02 15:37-15 C Energy saving enabled to >18:30 Special function display example Functions which temporarily change the operating mode of the heating circuit and are ended automatically. They can only be set in the basic display. >Select stop time 4
Notes on the documentation Description of the device 1 Notes on the documentation The following instructions are intended to help you throughout the entire documentation. Further documents apply in combination with this operating and installation manual. We accept no liability for any damage caused by non-observance of these instructions. Other applicable documents For the owner of the system: Always follow the respective instruction manuals for the various system components when operating the system. For the heating engineer: The respective installation manuals for the various system components must be observed during the assembly and start-up. Attachment and storage of the documents Please pass on this operating and installation manual as well as the auxiliary equipment to the operator of the system, whose responsibility it is to ensure the manuals and auxiliary equipment are available whenever required. Symbols used Please observe the safety instructions in this installation manual when installing the device. d Danger! Immediate risk of serious injury or death! e Danger! Danger of death by electrocution! H Danger! Danger of burning and scalding! a Caution! Potentially dangerous situation for the product and environment! h Note! Useful information and instructions Symbol for a necessary task Operating manual 1 Description of the device 1.1 Structure and function The VRC 630/2 control set contains devices and sensors for the set-up of a weather-dependent flow temperature control with timer programme for a hot water central heating system with hot water supply. The control can control the following system circuits: A direct heating circuit, Two mixer circuits, e.g. for floor heating, An indirectly heated hot water cylinder, A hot water secondary re-cirulation pump. To extend the system, up to six further mixer circuit modules (accessory) with two mixer circuits each can be connected, i.e. the control can control a maximum of 15 heating circuits. The mixer circuits are programmed via the central control. To operate the circuits separately, a separate remote control device is required for each mixer circuit. To operate them more conveniently, remote control devices can be connected for the first eight heating circuits. Each mixer circuit can be assigned for a different system type. The options available are: - Heating circuit (radiator circuit, floor circuit, etc.) - Fixed value controlling, - Increase in return flow, Hot water circuit (in addition to integrated hot water circuit). Information concerning the changeover of the mixer circuits can be found in Section 5. Up to six modulating Vaillant boilers or six one and twostage heating appliances can be connected with the modulating bus coupler (accessory). With the remote telephone contact connection (floating contact input), the operating mode of the control can be changed from any location by telephone via the teleswitch telephone remote control switch. 5
1 Description of the device 2 Operation 1.2 System overview The control system, in its basic version, consists of the contoller set including connection base. Electrical connection is via the Pro-E Terminal on the base unit. Connections for 230V are found on the bottom of the unit, low voltage connections are on the top. In the basic version - A hot water cylinder, - A maximum of two modulating boilers or alternatively one two-stage boiler, - Two controlled circuits, - 1 uncontrolled circuit can be actuated. Additional modules, which can be found in the system overview (Fig. 1.1, page 6), can be integrated in the system for further system components such as further heating circuits etc. 2 Operation You can make all settings required in the system on the main control. The main control is equipped with a graphic display for this purpose. For ease of operation plain text is used. You can change the display language, if necessary. 2.1 Display types The control display varies, depending on the selection (basic display, menu displays, displays on the code level). The current operating statuses and the target room temperatures of the individual heating circuits are displayed on the basic display. You can also change the operating statuses and target room temperatures of the individual heating circuits on the basic display. The possible displays are shown as examples in the list (Overview 2) on Page 4. The display switches to the basic display, on which the current operating statuses and target room temperatures of the individual heating circuits can be displayed and changed, if you turn the dial on the left. You can go to the menu displays, where settings relevant to the user, such as heating times, set-back temperatures and heating curves, can be accessed, by turning the dial further. These menus are indicated by a number at the top right of the display (see Overview 1, front foldout page). The numbers make it easier to find individual menus during programming. VR 90 VRC 639 VR 60 Fig. 1.1 System Overview 6
Operation 2 Turn the dial further to reach the code level. The code level should only be accessed by the heating engineer because of the types of parameters which are displayed. A password is required to access the code level to protect the system from accidental changes to the settings. The following parameters can be displayed in the individual menus, but cannot be changed if no password is entered, i. e. access to the code level is disabled. This level is indicated by numbers with a prefix C (C1, C2, C3,...). Furthermore it is possible to display and select special functions, such as the saving function and heating engineer- specific service functions. The required operation procedure is described in Overview 1 (front fold-out page). 2.2 Dial The control system is programmed only with two dials ( and, Overview 1, front fold-out page). The dial is used to select (by pressing) and set (by turning) the parameters. The dial is used to select the menu (by turning) and to activate special functions (by pressing). 2.3 Operator guidance The operating principle is based on the Vaillant click and turn operating concept as well as a plain text display for the unambiguous identification of the programming performed. Overview 1 (front fold-out page) shows the basic structure of the display and the operating procedure for the user or heating engineer. 2.3.2 Tables for the menu level Please proceed in accordance with the description under Section 2.3.1 to change the parameters. The editable parameters are displayed in Table 2.2 on a grey background for clarity. You can find explanations on the parameters next to the individual displays and in the appendix in the chapter Overview of functions. 2.3.3 Special functions Special functions can be selected only from the basic display. To do so, press the dial. To change the parameter, you must press the dial to select it and turn the dial to change its value. Press the dial again to confirm. The special functions can be selected: - Saving function Press dial once - Party function Press dial twice - One-time cylinder charging Press dial thrice You can find a list of special functions in Table 2.3 "Special Functions" on Page 10. To activate one of the functions, it is simply selected. In the saving function it is necessary to enter the time until the saving function (regulation to set-back temperature) is to apply. The basic display appears either after the function expires (the time has arrived) or if you press the dial again. The functions are explained in the appendix of this manual. The required operating steps are described in the following. In tables 2.1 and 2.2 you can see which menu you have to select to display or change the desired parameter. 2.3.1 Menu selection The first menu you see is the basic display on which the current operating modes and the target room temperatures of each heating circuit are displayed. You can move the cursor to the desired parameter by turning the dial. The cursor only goes to parameters which can be changed on this menu display. At the same time the changes which can be made by turning the dial, e.g "Select operating mode", appear in the line. Select change in the parameter by pressing the dial. The parameter is changed immediately when you turn the dial and the changed value appears immediately on the display of the control and confirmed by pressing the dial. 7
2 Operation Displayed menu Fr 17.05.02 heat zone 1 FLOOR 1 FLOOR 2 Cylinder >select operation mode 15:37 > heating Eco Auto Auto - 15 C 22 C 20 C 15 C Explanation and setting options The following information can be taken from the basic display: - the current date, - the time, - the outdoor temperature - the current room temperature, if the unit is used as remote control and if the room setback is activated - the current operation mode - the target room temperature allocated to the specific heating circuit Each heating circuit or hot water circuit is controlled separately in accordance with the operating mode selected. The heating, energy saving, auto, eco and off operating modes are available to the heating circuits: Auto The selected circuit is operated automatically between the desired set point and set back temperatures according to the on and off time programmes. Eco The selected circuit is operated automatically between the desired set point and fully off according to the on and off timer programmes. The frost protection function will still activate if enabled. Heating The selected circuit operates continuously on at the desired on temperature set point, regardless of the programmed times. Energy The selected circuit operates continuously on at the desired off/setback saving temperature set point, regardless of the programme times. Off The selected circuit is continually off except for when frost protection is activated. The auto, on, and off operating modes are available to the connected hot water cylinders as well as the secondary re-circulation circuit: Auto The Hot Water will operate automatically as the set programme times (or the secondary re-circulation pump). On The hot water is permanently on in hot water priority mode. Off The Hot Water is permanently off and will only operate to the frost protection minimum set point of 15 C (after the cylinder reaches 10 C) Flow temperature in C 90 80 70 60 50 40 30 Heating curves 4.0 5.5 3.0 2.5 2.0 1.5 1.2 1.0 0.6 0.2 A further adjustable parameter is the target room temperature, which can also be set separately for each heating circuit. The target room temperature is taken into account for the calculation of the heating curve. Increasing the required room temperature moves the heating curve parallel on a 45 axis and the flow temperature is accordingly adjusted by the control. The diagram on the left shows the relationship between the target room temperature and the heating curve. 20 20 15 10 5 0-5 -10-15 -20 Outside temperature in C Table 2.1 Parameter 8
Operation 2 Displayed menu Explanation and setting options Basic data Language Date Day of week Time >Select language > GB english 09.05.03 Fr 16:55 1 In the "basic data" display you can set the language, the current date, the day of the week and the current time of day can be set. These settings apply to all connected system components. heat zone 1 3 Time programme >Mo-Fr 1 08:00-2 16:00-3 - 14:00 22:00 >Select day of week Holiday programming 4 for cpl. System Periods: 1 > 18.07.03 2 16.09.03 - - Target temperature >Set starting day 31.07.03 05.10.03 15 C You can set the heating times for each heating circuit in the Time programme display. First select the heating circuit by turning the dial. Up to three heating times can be programmed per day or block of days. The control operates according to the heating curve and the target room temperature. The heating circuits have a default programme: Mon Fri Sat Sun 6:00 22:00 7:30 23:30 7:30 22:00 You can also programme the cylinder charging circuit and the circulation pump circuit. It is possible to program two holiday periods by specifying the dates in the control and all system components connected to it. Furthermore you can set the desired setback temperature, i.e. the target room temperature during the holiday period. After the holiday time has elapsed, the control automatically reverts to the previous operating mode. The holiday programme can be activated only in auto and eco mode. Connected cylinder charging circuits or circulation pump circuits are automatically switched off during the holiday programme. Table 2.2 Parameter that can be set on the menu display 9
2 Operation Displayed menu heat zone 1 5 Parameter Night set back temp. Heating curve > 15 C 0,90 Explanation and setting options The set-back temperature and heating curve parameters can be set on the heating circuit parameter display. The set back temperature is the reduced target temperature during the OFF periods of the control. It is possible to set individual temperatures for each circuit installed. >Select room temperature Flow temperature in C 90 80 70 60 50 40 30 Heating curves 4.0 5.5 3.0 2.5 2.0 1.5 1.2 1.0 0.6 0.2 The heating curve represents the relation between the outside temperature and target flow temperature. A separate heating curve can be set for each heating circuit. For the control to deliver the desired room temperature it is important that the correct heating curve is selected. The curve is set depending on the design outside temperature of your heating system and its design maximum flow temperature. If the selected heating curve is too high, the temperatures in the system will also be too high, resulting in higher energy consumption. If the selected heating curve is too low, the desired temperature level may only be reached after a while or not reached at all. 20 20 15 10 5 0-5 -10-15 -20 Outside temperature in C DHW 5 Parameter The desired cylinder temperature can be set here. Target Cyl. temp. > 60 C >Select flow temperature Names 6 change heat zone 1 : heat zone 2 : heat zone 3 heat zone 4 : : >select > FLOOR 1 FLOOR 2 FLOOR 3 TENANT Code layer 7 enabled Code number: > 0 0 0 0 Standard code: 1 0 0 0 >Adjust numeric character You can give each heating circuit of your system its own name. A maximum of ten letters are available per heating circuit for this purpose. The selected names are saved automatically and displayed on the corresponding displays. The last display of the user level is the code entry for the installer level. This level is protected against accidental changes by an access code, since the settings there should be made only by the engineer. To view setting parameters without entering the code, you must press the dial once. You can then view all parameters of the code level by turning the dial but not change them. Table 2.2 Parameter that can be set on the menu level (continued) 10
Operation 2 Displayed menu Fr 17.05.02 15:37-15 C Explanation and setting options Energy saving function: This function allows you to adjust the heating ON times for an adjustable period of time. Enter the end time of the energy saving function: hours: minutes Energy saving enabled to >18:30 >Select stop time Fr 17.05.02 Room temperature Party function enabled 15:37-15 C 21 C Party function (over-ride function): This function allows you to continue the heating and hot water times beyond the next off time up to the next heating start. The party function only applies to those heating or hot water circuits which are set to Auto or ECO mode. Fr 17.05.02 Room temperature 15:37-15 C 21 C One-time charging: This function allows you to charge the hot water cylinder once, regardless of the current timer programme. one-time Cylinder charging enabled Table 2.3 Special functions 11
3 Error messages, 4 Frost protection 5 Vaillant warranty, 6 Data transmission 3 Error messages Error messages are displayed on the central control in the event of malfunctions to the system. They are displayed in plain text. Please call your heating engineer for troubleshooting. The telephone number will be displayed if the engineer has programmed it. 4 Frost protection The control has a frost protection function. This function ensures your heating system is protected against frost in the Off" and Eco-Off mode. If the outside temperature falls below a temperature of +3 C automatically the (night) set-back temperature is set for each heating circuit. 5 Vaillant warranty We only grant a Vaillant manufacturers warranty if a suitably qualified engineer has installed the system in accordance with Vaillant instructions. The system user will be granted a warranty in accordance with the Vaillant terms and conditions. All requests for work during the guarantee period must be made to Vaillant Service Solutions (0870 6060 777). 6 Data transmission Depending on the conditions on site, it can take up to 15 minutes until all data (outside temperature, appliance status etc.) is updated. a Caution! Risk of the system freezing - The frost protection function is only effective if the boiler is not disconnected from the mains supply. 12
General information 1 Safety instructions and regulations 2 Installation instructions 1 General information The assembly, electrical connection and the settings in the control as well as the commissioning must be carried out only by a suitably qualified heating engineer. As an overview: How to install the VRC 630/2 control. 1. Preparation: Read the installation instructions Check the scope of delivery 2. Installation of the control: Install the wall box and the central controller Install the outdoor temperature sensor Carry out the electrical installation 3. Preparation for operation: Make the basic settings on the central controller Make the system-specific settings Here are a few explanations: The VRC 630/2 control allows heating systems with different components to be controlled. To adapt the control system to the conditions on site, the electrical installation must be according to the components in the system. Further information on the electrical installation can be found in Chapter 4. CE label The CE label shows that, in combination with Vaillant boilers, the VCR 630/2 control meets the basic requirements of the Directive on electromagnetic compatibility (89/336/EEC directive of the council). Intended use The VRC 630/2 control is a state-of-the-art appliance which has been manufactured in accordance with recognised safety regulations. Nevertheless, there is a risk of death or serious injury to the user or others, or of damage to the device and other property in the event of improper use or use for which it is not intended. The central control VRC 630/2 is a bus-modular control system to control the hot water central heating systems with integrated hot water preparation. Any other use or any expansion of the use is considered to be improper use. The manufacturer/supplier is not liable for any resulting damage. The owner alone bears the risk. Intended use includes the observance of the operating and installation manual. 2 Safety instructions and regulations The control must be installed by a qualified engineer, who is responsible for adhering to the prevailing standards and regulations. We accept no liability for any damage caused by failure to observe these instructions. 2.1 Safety instructions a Danger! Risk of fatal electric shock from touching live connections. Before carrying out work on the control, switch off the power supply and secure it against being switched on again. Only remove the control from the wall box or from the plinth when it is potential free. 2.2 Regulations The regulations of VDE and EVU must be observed during the electrical installation. Use standard wires for wiring. Minimum cross-section of the wires: 230 V connection cable (pump or mixer connection cable) 1.5 mm 2 - Low-voltage lines (sensor or bus lines) 0.75 mm 2 The following maximum wire lengths may not be exceeded: - Sensor lines 50 m - Bus lines 300 m Where lengths are greater than 10m, route the connection cables carrying 230V separately from the sensor or bus cables. 230 V connection cables must be provided in 1.5 mm 2 and fastened to the wall box using the cable clamps supplied. Do not use free terminals of the appliances as support terminals for other wiring. The control must be installed in a dry room. A minimum distance of 25cm between 230V and sensor or ebus cables must be maintained. All wiring must be in accordance with Building Regulations Part P and BS 7671 (IEE Wiring Regulations), and must be carried out by a suitably qualified person. h Note! Where low voltage cables pass through areas close to or in contact with mains voltage cables it may be necessary to use shielded cable to avoid interference. The shielding earth should only be connected to one central earth terminal. 13
3 Installation 3 Installation The central control can be mounted directly to the wall in the wall box or as a remote control device with the VR 55 mounting box (accessory). 3.1 Scope of delivery Use Table 3.1 to check that all the components have been delivered with the control set. Pos. Number Component 1 1 VRC 630/2 control with wall box 2 4 VR 10 standard sensor 3 1 Mains cable 230 V, 3 m long 4 1 7/8/9 connection cable, 3 m long 5 1 Outdoor sensor Table 3.1 Scope of delivery for the VRC 630 3.2 Accessories You can use the following accessories to extend the bus modular control system: VR 55 mounting box The range of accessories includes a mounting box, with which the operating unit can be used as a remote control device with the ProE terminal strips, which means regardless of where the central wall box is installed. Communication takes place via the ebus. The accessories include a screen, which can be inserted in the central wall box instead of the operating unit. VR 60 mixer module The heating system can be extended by two mixer circuits using the mixer module. A maximum of six mixer modules can be connected. A unique bus address is set on the VR 60 using the rotary switch. The heating programme and all of the required parameters are set by means of the central control via ebus. All heating circuit connections (sensors and pumps) are made directly on the mixer module using a ProE plug. VR 30 bus coupler for ecomax boilers The bus coupler allows the VRC 630 control to communicate with several Vaillant boilers. If more than two boilers are to be connected in cascade, a bus coupler is required for each boiler to connect it to the ebus (Western socket). Up to six VR 30 bus couplers can be connected. The bus coupler is integrated directly in the switch box of the boiler, communication to the control takes place via the ebus. A unique bus address is set on the VR 30 using the rotary switch. All further settings are made on the central control VRC 630. VR 31 switching bus coupler The VR 31 bus coupler allows the VRC 630/2 central control to communicate with a switching heating appliance. In this combination, communication between the control and boiler always takes place via ebus. If a cascade is set up, a separate bus coupler is required for each heating appliance. Up to six bus couplers can be connected. Bus coupler VR 32 for ecotec Where more than two boilers are connected in a cascade, a separate bus coupler is required for each boiler to connect it to the ebus (X30 Western socket). You can connect up to six VR 32 bus couplers to the VRC 630/2 controller. Each boiler is assigned a separate address using the rotary switch. Where VR 32 is installed, you can also install vrnetdialog for monitoring and remote parameterisation. VR 90 remote control device A separate remote control device can be connected for the first eight heating circuits (heat zone 1 heat zone 8). It allows the operating mode and target room temperature to be set, and takes into account the actual room temperature measured by the built-in room sensor, if necessary. It is also possible to adjust the parameters for the associated heating circuit (time programme, heating curve etc.) and to select the special functions (party etc.). It is also possible to query the heating circuit, and show maintenance and fault messages for the boiler. Communication with the heating control unit is via the ebus. VR 80 remote control device The VR 80 is a remote control device used to control a heating circuit which is controlled centrally with the VRC 630. All settings for the heating circuit can also be made at the VRC 630 central control, regardless of whether a remote control device is used. A maximum of eight remote control devices can be connected. The VR 80 remote control communicates with the VRC 630 central control via ebus. It can be connected to any interface in the system. Ensure that the bus interfaces are connected to the central control. VR 10 standard sensor Additional sensors are required such as flow, return, or cylinder sensors, depending on the configuration of the system. A standard sensor is available in the Vaillant accessory range. The VR 10 standard sensor is designed to be used as an immersion sensor, e.g. as a cylinder sensor in a cylinder sensor pocket, or as a flow sensor in a low loss header. It can also be attached to the flow or return heating pipe with the supplied strap and used as a strap-on sensor. To ensure good heat transfer, the sensor is flat on one side. 14
Installation 3 We also recommend that the pipe with the sensor is insulated to ensure optimum temperature measurements. Fig. 3.1 VR 10 standard sensor 3.3 Installing the VRC 630/2 heating control 3.3.1 Installing the wall box The control is delivered with a wall boxing box with electrical terminal strips. The terminal strips are designed as ProE system equipment. All electrical connections are to be made to these strips. Fig. 3.2 Opening the wall box The cover comprises a single part. 1 2 Fig. 3.3 Installation of the wall box h Please observe that - the low-voltage lines (e. g. sensor lines) have to be laid behind the wall box through the top cable opening (4). - the mains lines (230 V) have to be laid through the bottom cable opening. a Caution! A maximum of 30 mm of the sheathing may be removed from the ends of lines carrying 230 V in order to connect the ProE plug. If more insulation is removed there will be a risk of short circuits on the circuit board if the cables are accidentally connected improperly to the plug. Mark all three fixing holes (3) and drill holes. Select the wall plugs according to the condition of the wall, and screw the wall box tight. Wire the control according to the wiring diagram (see Page 20). Fix all cables with the accompanying cable clamps (5). Install the housing cover back again. 3.3.2 Installing the control as a remote control device A mounting box (VR 55 accessory) is available. A cover for the wall box is supplied together with this mounting box accessory. Loosen screw (1) on the upper side of the housing. Flap the housing cover (2) downwards. Take the housing cover off its hinge and remove it. The following should be observed for wall boxing if a control is used as remote control device with room temperature modulation: 15
3 Installation The best place for installation is usually on an inside wall of the main living room at an approximate height of 1.5 m. There, the control should be able to record the circulating air, unhindered by furniture, curtains or other objects. Choose a location where the room thermostat is not affected by draughts from doors or windows, or by heat sources such as radiators, chimney walls, television sets or direct sunlight. All radiator valves must be fully open in the room in which the control is installed if room temperature modulation is activated. It is advised that you complete all electrical wiring before installing the main controller in the housing. 1 3.3.3 Installing the outdoor sensor This equipment may only be opened by a suitably qualified heating engineer and installed as shown in the diagram. The current safety regulations must be observed as well as the installation instructions for the boiler and the heating control. Place of installation The outdoor sensors should ideally be mounted on the coldest side of the building. North or north-west aspects are preferred. Do not mount above bird roosts. In buildings with up to three floors install at 2/3 of the facade height, if there are more than three floors, install between 2nd and 3rd floor. The location should not be protected from nor particularly exposed to wind and should not be exposed to direct sunlight. The sensor must be at least 1 m away from any openings in the outer wall, from which warm air can either continuously or occasionally escape. It can be installed either in or on the wall, depending on the accessibility of the location. 2 3 Fig. 3.4 Installation as a remote control device 4 > 1 m 1/3 Make sure the cable to the control is not live. Open the wall box with a screwdriver and remove the housing cover. Remove the control. Make two fixing holes (3) for the VR 55 mounting box with a diameter of 6 mm as shown in Fig. 3.4 and insert the supplied wall plugs. Guide the connection cable through the duct (4). Attach the wall plinth to the wall with the two screws provided. Connect the connection cable as shown in Fig. 4.17 on Page 32. Place the control on the mounting box so that the pins on the back of the top part fit into the recesses (2). Push the control onto the mounting box until it engages. Insert the supplied cover in the wall box. Install the housing cover back again. 2/3 N W O S ð N, NW (optional) Fig. 3.5 Mounting location outdoor sensor VRC 693 a Caution! Danger from moisture to wall and equipment! By careful work and by appropriate cable routing, ensure that the outdoor sensor and the building are both watertight. The device must be fixed to the wall as shown in Fig. 3.6! The cable entry (3, Fig. 3.6) must point downwards. 16
Installation 3 Electrical installation 4 4 Electrical installation 5 1 6 2 7 8 3 3 Fig. 3.6 Mounting location outdoor sensor VRC 693 4 Remove the cover (1) of the housing and fix the housing with two screws above the fixing holes (8) on the wall. Lay the connection cable (4) (at minimum 2 x 0,75 mm 2 ) on site and pull it through the cable entry point from below. By careful work and by appropriate cable routing, ensure that the outdoor sensor and the building are both watertight. Wire the connectors as shown in Fig. 4.1. Make sure that the sealing of the housing is fixed correctly to the upper part of the housing (1) and press the upper part onto the housing. Fix the upper part (1) to the lower part with the screws supplied. 8 9 4 The electrical connection may only be carried out by a suitably qualified heating engineer. e Danger! Risk of fatal electric shock through contact with live connections. Before carrying out work on the control, switch off the power supply and secure it against being switched on again. Using the mains switch is not sufficient to isolate all terminals of the system. a Caution! For safety reasons, a maximum of 30 mm of the sheathing may be removed from the ends of lines carrying 230 V in order to connect the ProE plug. If more sheathing is removed there will be a risk of short circuits on the circuit board if the cables are accidentally connected improperly to the plug. 4.1 Connecting the boiler Open the switch box of the boiler as described in its installation instructions. Wire up the boiler with the supplied connection line as illustrated in Fig. 4.1. 7/8/9 connection cable (included) 230 V~ connection 230 V mains cable (provided by the customer) (included) Fig. 4.1 Connecting the boiler Use the supplied mains cable to connect the boiler to the mains supply in the mounting box. h Note! The VRC 630/2 has a mains switch which can be used to switch off the internal electronics and all connected actuators (pumps, mixers) for testing or maintenance purposes. 17
4 Electrical installation If the maximum total current of 6.3 A or the maximum contact load of 2 A is exceeded within the system, the consumer(s) must be wired via a contactor. 4.2 Wiring The VRC 630/2 control has an automatic sensor recognition function. The connected heating appliances are configured automatically. You must configure the connected heating circuits in accordance with the system combination. Possible hydraulics are illustrated on pages 20 to 31. Wire the components according to the corresponding wiring diagram. a Caution! In order to work perfectly, it is generally necessary that the VF1 sensor is connected to determine the common flow temperature. 4.2.1 Connecting a mixer circuit as a cylinder charging circuit Each mixer circuit in the system can be used alternatively as a cylinder charging circuit. Wire the mixer circuits as shown in Fig. 4.2. 4.2.2 Special features of the circulation pump connection The control has a separate connection for a secondary re-circulation pump. This pump connection can be timed independently of the Hot Water programme. The control has only one dedicated and independent secondary re-circulation pump connection. If another secondary re-circulation pump is required, a spare reconfigured mixer circuit can be used (the text will read cylinder loading pump ). Alternatively the re-circulation pump can be wired in parallel with the primary loading pump providing the maximum load is not exceeded. 4.2.3 Inputs for special functions The control has special inputs which can be used for special functions if necessary. Circulating pump input A floating contact (push to make or pull switch or IR switch) can be connected to this input. The circulation pump is started for 5 minutes after briefly pressing the button, regardless of the set timer programme. TEL input A floating contact (switch) can be connected to this input. The operating mode of the connected heating circuits, hot water circuits and circulation pump is changed on actuating the switch, depending on the setting in the C9 menu. Fig. 4.2 Connecting a mixer circuit as a cylinder charging circuit Key for Fig. 4.2 1 Cylinder primary loading pump 2 DHW secondary re-circulation pump 3 Cylinder sensor 18
Electrical installation 4 4.2.4 Connector assignment Mains connection 230 V~ Output Flow sensor, low loss header Mains connection 230 V~ Input Flow sensor heating circuit 2 Flow sensor heating circuit 3 Cylinder charging pump/ Motorised valve Only for cascade control of boilers with VR 31 couplers and with manual thermostat (non themister) Circulation pump Cylinder sensor Direct heating circuit pump 1 Mixer, heating circuit 2 Pump, heating circuit 2 DHW re-circulation switch Mixer heating circuit 3 ebus connection Pump heating circuit 3 Outdoor sensor VRC ecocraft / atmocraft boiler connection Stage 1 low ecocraft / atmocraft boiler connection Stage 2 high Cylinder thermostat connection (optional) ecomax boiler 1 connection Switching valve (not required) ecomax boiler 2 connection Fig. 4.3 Connector Assignment 19
4 Electrical installation 4.2.5 Specifics if a hot water cylinder is connected Example 1 - direct connection If a hot water cylinder is connected directly to the boiler, always set the isolation switch parameter in the C10 menu to yes to ensure the boiler works perfectly. Additional reconfigured hot water circuits which are integrated downstream of the low loss header are not affected by this setting. The heating system consists of: - 1 heating appliance (e.g. wall boxed gas boiler, connection via 7/8/9) - 1 hot water cylinder - 1 uncontrolled heating circuit (burner circuit, control via remote control device) - 2 controlled heating circuits (2 floor circuits, control via remote control devices) Fig. 4.4 Wall-mounted boiler with VRC 630 20
Electrical installation 4 white natural blue yellow yellow-green natural turquoise white white yellow red natural grey beige white natural yellow yellow beige beige natural natural red turquoise VR 90 (Option) Cylinder sensor Flow sensor 3 Flow sensor 2 Flow sensor 1 Heating pump 3 Feed thermostat Mixer 2 Stage 2 Stage 1 Heating pump 2 Mixer 1 Feed thermostat Heating pump 1 Circulation pump VR 90 (Option) VR 90 (Option) Charging pump Mains VC E box grey green purple white blue turquoise Pump 2 Pump Feed thermostat Ext. controller 230 V contact Mains input Ext. controller 7-8-9 (constant) Fig. 4.5 Wiring of VRC 630, 1...VC, 3 heat zones, VIH 21
4 Electrical installation Example 2 The Isolation switch parameter in the C10 menu should be set to No if the hot water cylinder is installed downstream of the hydraulic switch. For boilers with built-in preference switching valve for the hot water supply, the plug for the preference switching valve is pulled off so that the connection to the hydraulic switch is not blocked for the heating water supply. The heating system consists of: - 2 heating appliances (e.g. 2 wall boxed gas boilers, connection via 7/8/9) - 1 hot water cylinder (connected downstream of the hydraulic switch) - 1 uncontrolled heating circuit (burner circuit, control via remote control device) - 2 controlled heating circuits (2 floor circuits, control via remote control devices) Fig. 4.6 Wall-mounted boilers with VRC 630 VIH downstream of switch 22
Electrical installation 4 white Stage 2 Stage 1 natural blue yellow yellow-green natural turquoise white white yellow red natural grey beige white natural yellow yellow beige beige natural orange red turquoise VR 90 (Option) Mains Mains VRC 693 DCF- 0 -AF Cylinder sensor Flow sensor 3 Flow sensor 2 Flow sensor 1 Heating pump 3 Feed thermostat Mixer 2 Heating pump 2 Mixer 1 Feed thermostat Heating pump 1 VR 90 (Option) VR 90 (Option) VC E box 2 Circulation pump Charging pump Mains grey green purple white blue turquoise Pump 2 Pump Ext. controller 230 V contact Mains input Ext. controller 7-8-9 (constant) Feed thermostat VC E box 1 grey green purple white blue turquoise Pump 2 Pump Ext. controller 230 V contact Mains input Ext. controller 7-8-9 (constant) Feed thermostat Fig. 4.7 Wiring of VRC 630, 2...VC, 3 heat zones, VIH 23
4 Electrical installation Example 3 For systems with two or more boilers, the isolation switch should also be set to Yes if a hot water circuit is directly connected to a boiler. The heating system consists of: - 4 heating appliances (e.g. 4 VC 466 wall boxed gas boilers, connection via VR 30-1 hot water cylinder (connected downstream of the hydraulic switch) - 1 uncontrolled heating circuit (burner circuit, control via remote control device) - 4 controlled heating circuits (4 radiator circuits, control via remote control devices) Fig. 4.8 VRC 630/2 with 5 heating circuits and 4 VC 466 24
Internal pump Mains Mixer Mixer Mains Mains Flow sen. VRC 693 DCF- 0 -AF Flow sen. Heating p. FBG VR 90 Mixer FBG VR 90 Charging pump Internal pump Ext. controller 230 V contact Mains input Ext. controller 7-8-8 (constant) Feed thermostat Circ. p. remote contr. Outdoor sensor Flow/Return sensor DCF connection Earth plug Cont. accessory earth Co. electr. accessories Co. digit. interface Bus coupler module Bus Bus addr. 1 Mains FBG VR 90 FBG VR 90 FBG VR 90 Charging pump Internal pump Charging pump Internal pump Charging pump Ext. controller 230 V contact Ext. controller 230 V contact Ext. controller 230 V contact Mains input Mains input VR 30 Mains Mains Heating pump Mixer Cylinder s. Flow sen. Flow sen. Flow sen. Heating p. Mixer 2 Heating p. Mixer 1 Heating p. Circulation p. Charging p. Mains + _ 1 + _ 1 + _ 1 + _ Mains input Ext. controller 7-8-8 (constant) Feed thermostat Ext. controller 7-8-8 (constant) Feed thermostat Ext. controller 7-8-8 (constant) Feed thermostat Circ. p. remote contr. Outdoor sensor Flow/Return sensor DCF connection Earth plug Cont. accessory earth Circ. p. remote contr. Outdoor sensor Flow/Return sensor DCF connection Earth plug Cont. accessory earth Circ. p. remote contr. Outdoor sensor Flow/Return sensor DCF connection Earth plug Cont. accessory earth Co. electr. accessories Co. electr. accessories Co. electr. accessories Co. digit. interface Co. digit. interface Co. digit. interface VR 30 VR 30 Bus coupler module Bus coupler module 1 Electrical installation 4 Bus coupler module Stage 2 Stage 1 blue yellow yellow-green natural natural turquoise red natural natural yellow turquoise white white white white yellow yellow gray beige beige beige natural orange red Auf gray green purple turquoise white blue gray gray gray green purple turquoise green purple turquoise green purple turquoise white blue white blue white blue Bus addr. 3 Bus Bus addr. 2 Bus + + Bus addr. 4 Bus red brownyellow yellow yellow beige beige beige turquoise turquoise Fig. 4.9 Wiring of VRC 630, 4 VC466, 5 heat zones 25
4 Electrical installation Example 4 The heating system consists of: - 1 heating appliances (e.g. 2 irovit floor mounted boilers, connection via 7/8/9) - 1 hot water cylinder - 1 uncontrolled heating circuit (burner circuit, control via remote control device) - 2 controlled heating circuits (2 radiator circuits, control via remote control devices) Fig. 4.10 VRC 630/2 floor mounted appliance 1 26
Electrical installation 4 natural blue yellow yellow-green white white white yellow red natural grey beige Stage 2 Stage 1 natural white natural yellow yellow beige beige turquoise natural orange red turquoise VR 90 (Option) VRC 693 DCF- 0 -AF Cylinder sensor VR 90 (Option) VR 90 (Optional) X1 VK E box Flow sensor 3 Flow sensor 2 Flow sensor 1 Heating pump 3 Mixer 2 Heating pump 2 Mixer 1 Heating pump 1 Circulation pump Charging pump 230 V~ Ext. controller 230 V contact grey green purple white blue turquoise Mains input Charging pump Ext. controller 7-8-9 (constant) Feed thermostat Fig. 4.11 Wiring of VRC 630 floor mounted appliance 27
4 Electrical installation Example 5 The heating system consists of: - 1 heating appliances (e.g. 1 GP 210 floor mounted boiler) with increase in return flow - 1 hot water cylinder - 1 uncontrolled heating circuit (burner circuit, control via remote control device) - 1 controlled heating circuit (1 radiator circuit, control via remote control device) Boiler Fig. 4.12 VRC 630, increase in return flow 28
Electrical installation 4 Error message Plug 1 and 2 For accessory operating hours counter Either plug on VRC-K or cut the central wire jumper see below Boiler 1 Connection VIH - Switch panel Ext. 1st stage Ext. 2nd stage Exhaust Water deficiency Sol.V.extLP/UV Network Cylinder sensor Return stroke sensing element Program start routine sensing element Program start routine sensing element Boiler pump RL-Mixer 2 Mixer Heating pump Anl. Thermostat Heating pump Circulation pump Charging pump Network Fig. 4.13 Wiring of VRC 630, GP210, increase in return flow 29
4 Electrical installation Example 6 The heating system consists of: - 2 heating appliances (e.g. GP 210 floor mounted boiler) with increase in return flow and cylinder isolation switch - 1 VR 60 mixer circuit module - 1 hot water cylinder - 1 uncontrolled heating circuit (burner circuit, control via remote control device) - 2 regulated heating circuits (1 floor circuit, 1 radiator circuit, control via remote control device) Boiler 2 Boiler 1 Fig. 4.14 GP 210 cascade with increase in return flow, cylinder isolation switch 30
Electrical installation 4 Heating zones for increasing return flow configured 230 V Network Network turqois turqois beige beige Yellow Yellow red beigeyellow braun Mixer Mixer Stage 2 Stage 1 Treapta 2 Treapta 1 Return flow Return flow Boiler pump Reţea Bus Address Boiler pump Network VR 31 Bus Address Error message Error message Either plug on VRC-K or cut the central wire jumper see below Connection VIH Switch panel Ext. 1st stage Ext. 2nd stage GDW Exhaust Water deficiency Either plug on VRC-K or cut the central wire jumper see below Connection VIH Switch panel Ext. 1st stage Ext. 2nd stage GDW Exhaust Water deficiency Sol.V.extLP/UV Sol.V.extLP/UV Plug 1 and 2 For accessory operating hours counter Boiler 2 Network LP/UV HP-B Network Charging pump Circulation pump Heating pump Mixer Heating pump RL-Mixer 2 Termostat maximal Heating pump Plug 1 and 2 For accessory operating hours counter Boiler 1 LP/UV HP-B Network Program start routine sensing element Boiler pump Cylinder sensor FBG VR 90 FBG VR 90 AF DCF- 0 -AF turqois Red nature turqois orange Beige Beige Yellow Yellow nature White nature Beige Gray Yellow green Yellow blau nature Red White White nature Yellow White Treapta 2 Treapta 1 LP/UV Fig. 4.15 Wiring of VRC 630, GP210, 3 heat zones, VIH 31
4 Electrical installation 4.3 Connecting the outdoor sensor Wire the outdoor sensor as shown in Fig. 4.16. Fig. 4.16 Connecting the outdoor sensor 4.4 Connecting accessories The following accessories can be connected: - Up to eight remote control devices to control the first eight heating circuits. - Up to six mixer modules to extend the system by 12 system circuits (pre-set as mixer circuits). 4.4.1 Connecting the remote control device The remote control devices communicate with the heating control via ebus. They can be connected to any interface in the system. It merely has to be ensured that the bus interfaces are eventually connected to the central control. The structure of the Vaillant system allows you to lay the ebus from component to component (see Fig. 4.8). This means that the wires can be swapped without impairing communication. Fig. 4.17 Connecting the remote control devices All ebus connector plugs are designed to allow you to wire at least 2 x 0.75 mm 2 per pigtail. We therefore recommend using 2 x 0.75 mm 2 ebus lines. 4.4.2 Connecting further mixer circuits The mixer modules also only communicate via ebus. The same procedure is used for the installation as for the connection of remote control devices. The system structure is shown in Fig. 4.9. Fig. 4.18 Connecting further mixer circuits 32