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  5. Instructions For Installation And Servicing

Vaillant ecoTEC plus 937 Instructions For Installation And Servicing

Summary of ecoTEC plus 937

  • Page 1

    For the heating engineer instructions for installation and servicing ecotec plus 937 wall hung room sealed fan assisted condensing boiler with 15 litre shift load power store vui gb.

  • Page 2

    Contents 2 contents 1 introduction .....................................................4 1.1 notes on the documentation ................................4 1.1.1 documents also having validity ...........................4 1.1.2 storage of the documents ....................................4 1.1.3 safe...

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    Contents 3 ecotec plus 937 installation and maintenance manual 6 functional checks (commissioning, part ii) .............................. 40 6.1 functional checks ................................................. 40 6.1.1 method of procedure ........................................... 40 6.1.2 heat...

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    Ecotec plus 937 installation and maintenance manual 4 1 introduction 1.1 notes on the documentation the following information is intended to help you throughout the entire documentation. Further documents apply in combination with this installation and maintenance manual. We accept no liability for ...

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    5 ecotec plus 937 installation and maintenance manual d danger! Danger to persons and/or material damage! Any improper use is forbidden. The appliances must be installed by a competent person, who is responsible for adhering to the existing regulations, rules and guidelines. 1.5 ce label ce labellin...

  • Page 6

    Ecotec plus 937 installation and maintenance manual 6 2 unit description, data and dimensions 2.1 technical data name ecotec plus 937 combination unit unit nominal heat output range of central heating 80 °c feed/60 °c return 60 °c feed/40 °c return 50 °c feed/30 °c return 40 °c feed/30 °c return 12....

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    7 ecotec plus 937 installation and maintenance manual unit description, data and dimensions 2 2.2 dimensions 24 1 20 64 2 72 0 883 323 100 100 440 35 35 13 0 180 17 5 273 24 3 566 59 8 8 6 4 3 2 1 5 7 9 1 2 3 4 5 10 11 12 fig. 2.1 dimensions ecotec plus 937 key 1 heating return pipe, Ø 22 mm 2 cold ...

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    Ecotec plus 937 installation and maintenance manual 8 24 1 20 64 2 72 0 88 3 100 100 440 35 35 17 5 6 4 3 2 1 5 130 180 198 1 2 3 4 5 7 8 fig. 2.2 dimensions shift load storage tank key 1 heating return pipe, Ø 22 mm 2 cold water connection, Ø 15 mm 3 gas connection Ø 22 mm 4 hot water connection, Ø...

  • Page 9

    9 ecotec plus 937 installation and maintenance manual 2.3 structure and functional elements the ecotec plus 937 consists of – a modified combination boiler and – a 15 litre shift load storage tank. Mains cold water heated by the combi unit is fed to the heat insulated storage tank by means of a modu...

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    Ecotec plus 937 installation and maintenance manual 10 2.5 functional description 1 2 3 4 14 13 12 6 7 8 9 11 10 16 17 15 20 19 18 5 c b a fig. 2.5 sequence diagram key 1 exhaust gas 2 heat exchanger 3 combustion chamber 4 water condensate siphon 5 expansion vessel 6 operating display 7 secondary he...

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    11 ecotec plus 937 installation and maintenance manual the ecotec plus 937 is a fully-automatic wall-mounted unit with condensing technology for central heating and hot water preparation and with a shift load storage tank for the storage of hot water. Mains cold water heated by the combi boiler is f...

  • Page 12

    Ecotec plus 937 installation and maintenance manual 12 3.3 scope of supply and accessories 1 1 10 9 8 7 6 5 4 3 2 1 fig. 3.1 scope of supply and accessories pos. Quantity name 1 1 combi boiler ecotec plus 2 1 bottom cover ecotec plus 3 1 installation template 4 4 isolating valves and filling loop 5 ...

  • Page 13

    13 ecotec plus 937 installation and maintenance manual e danger! Danger of death by electric shock! If a room-sealed combi boiler is installed in a room with a bath or a shower, the electrical switches and the boiler controller, which operate at mains voltage, must be mounted in locations where any ...

  • Page 14

    Ecotec plus 937 installation and maintenance manual 14 a 100 mm standard flue duct (item no. 303 933) is available. Further information can be obtained from the installation instructions for the flue duct. Extensions are available to increase this length to a maximum of 5.5 m. 87° elbows and 45° ben...

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    15 ecotec plus 937 installation and maintenance manual location of the junction mm a directly under or above an opening or the horizontal to an opening, a hollow ventilation tile, an opening window etc. 300 b under gutters, soil pipes or drainpipes 75 c unter eaves 200 d under balconies 200 e from v...

  • Page 16

    Ecotec plus 937 installation and maintenance manual 16 3.10 system requirements 3.10.1 water circulation system detailed recommendations concerning the water circulation system can be taken from bs 6798 and bs 5449, part 1 (for "small bore” and "micro bore” central heating systems). Pipework which d...

  • Page 17

    17 ecotec plus 937 installation and maintenance manual 3.10.7 shift load storage tank expansion vessel the shift load storage tank is fitted with a 1 litre expansion vessel. 3.11 details for the pumps 3.11.1 circulation pump the circulation pump is integrated in the combi boiler. The remaining head ...

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    Ecotec plus 937 installation and maintenance manual 18 4 sequence of operations during installation 4.1 transporting the appliance a important: with regards to the manual handling operations, 1992 regulations, the following lift operation exceeds the recommended weight for a one man lift. General re...

  • Page 19

    19 ecotec plus 937 installation and maintenance manual recommend straps and open carton flaps, then remove items from the top including the polystyrene packing and remove carton by sliding up over the boiler. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load a...

  • Page 20

    Ecotec plus 937 installation and maintenance manual 20 4.2 required minimum gaps/assembly clearances min min 5 min 5 min 500 min 180 16 5/ 24 6 fig. 4.1 distances during installation (dimensions in mm) the combination of units must be installed on a flat vertical wall which is large enough for the s...

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    21 ecotec plus 937 installation and maintenance manual 00 2 0 0 3 997 5_00 10 2 006 180 60/100 140 195 ( ) 40 60/100 17 3 2 7 6 ( ) 80/125 80/125 (art.-nr. 303210) (art.-nr. 303910) 5 5 223 25 6 a a 25 a a a 117 6 450 fig. 4.2 assembly template 4.5 flue exit • if using rear flue mark the position of...

  • Page 22

    Ecotec plus 937 installation and maintenance manual 22 4.8 mounting the combination boiler 2 1 fig. 4.4 mounting the combi boiler on the shift load storage tank • lift the combi boiler out of the packaging (see section 3.4). • lift the combi boiler (2) onto the shift load storage tank so that it is ...

  • Page 23

    23 ecotec plus 937 installation and maintenance manual 4.11 gas connection d danger! Danger of death by gas escapes if the installation is not properly carried out! The gas connection must only be made by a competent person (e.G. Corgi registered). The legal directives and local regulations for the ...

  • Page 24

    Ecotec plus 937 installation and maintenance manual 24 4.12 cold water supply and hot water outlet a caution! Ensure stress-free assembly of the connection pipework to avoid leakages! Caution! Danger of damage to the isolation valves by heat transfer! If the final connections to the combi boiler are...

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    25 ecotec plus 937 installation and maintenance manual 10 11 12 13 9 8 7 6 1 2 3 4 5 fig. 4.9 flow and return heating connections • remove the isolation valves with union nuts, olives and fibre washers from the box of accessories for the combi boiler. • insert the fibre washer (1) and screw the isol...

  • Page 26

    Ecotec plus 937 installation and maintenance manual 26 • connect the condensate drain (1) of the boiler to a condensate drain pipe (2) which has a minimum internal diameter of 19 mm (22 mm outside diameter for all external pipes) and which is made from an acid- resistant material (e.G. Plastic overf...

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    27 ecotec plus 937 installation and maintenance manual 4.16 installing the pressure relief discharge pipework 4 3 2 1 fig. 4.13 installing the discharge pipe the pressure relief for the heating system is integrated into the boiler. • remove the discharge pipe with union nut and rubber washer from th...

  • Page 28

    Ecotec plus 937 installation and maintenance manual 28 4.19 electrical connection 4.19.1 general requirements e danger! Risk of fatal electric shock from touching live connections! Before working on the appliance, turn off the power supply and secure against restart! All work on the electrical syste...

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    29 ecotec plus 937 installation and maintenance manual 1 2 3 fig. 4.16 cable run on the underside of the unit • feed the wiring harness (2) of the shift load storage tank with the grommets (3) through the cable entries provided on the shift load storage tank and on the combi boiler. On the combi boi...

  • Page 30

    Ecotec plus 937 installation and maintenance manual 30 4.19.4 wiring diagrams burner cable harness wiring harness hydraulics connection for external ebus controller room thermostat 24 v: connection 7, 8 und 9 no bi-directional interface (only analogue) room thermostat 230 v/50 hz (remove bridge when...

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    31 ecotec plus 937 installation and maintenance manual x 2 bus — + 24v 7 8 9 230v l n 3 4 5 x 20 x40 x3 1 x12 x41 electronics box hot water outlet (ntc) fan ignition electrode flow temperature sensor (ntc) diverter valve gas valve water pressure sensor return temperature sensor (ntc) x 20/5 red x 20...

  • Page 32

    Ecotec plus 937 installation and maintenance manual 32 bus — + 24v 7 8 9 230v l n 3 4 5 x3 1 x12 boiler electronics box storage tank charging sensor (ntc) x 1/3 violet x 1/1 black pump x 1/7 green x 1/1 black x 1/8 red storage tank sensor (ntc) x 1/4 orange x 1/1 black plug connection aqua-sensor sh...

  • Page 33

    33 ecotec plus 937 installation and maintenance manual 4.20 control units 4.20.1 vaillant control units and accessories controller item no. Connection vrc 400 (1-circuit controller, weather-controlled) 00 2001 0843 installation in electronics box (plug-and-play) vrt 360 (room temperature controller)...

  • Page 34

    Ecotec plus 937 installation and maintenance manual 34 4 on the combi boiler, in parallel to all the other external heating controllers. H note! External frost protection devices cannot be used if plug-in timers are used. 4.23 heating pump the combi boiler is fitted with a heating pump which is full...

  • Page 35

    35 ecotec plus 937 installation and maintenance manual 5 commissioning, part i 5.1 preparatory checks of the electrical system • check the electrical installation for short circuits, proper earthing and earth resistance and for correct polarity. 5.2 gas supply the entire gas installation including t...

  • Page 36

    Ecotec plus 937 installation and maintenance manual 36 5.4.2 filling device for ecotec plus 937 the ecotec plus 937 is fitted with a filling loop. 3 1 4 2 fig. 5.2 filling device • push the double check (1) of the filling loop into the cold water isolation valve (2) and secure the double check valve...

  • Page 37

    37 ecotec plus 937 installation and maintenance manual 5.5 initial flushing of the system ("cold“) h note! The entire heating system must be flushed through completely at least twice: once cold and once hot, in accordance with the following instructions. • check if all radiator thermostat valves and...

  • Page 38

    Ecotec plus 937 installation and maintenance manual 38 5.9 checking the gas supply 5.9.1 factory settings a caution! Before operating the boiler check the type-plate (data badge) underneath the appliance and ensure that the correct gas type appliance has been installed. The combi boiler is supplied ...

  • Page 39

    39 ecotec plus 937 installation and maintenance manual appliance maximum heat supply in kw gas rate natural gas in m 3 /h propane in kg/h nominal + 5 % - 10 % nominal + 5 % - 10 % ecotec plus 937 37.8 4.00 4.20 3.60 2.94 3.09 2.65 table 5.1 gas rate 5.10 fitting the front casing 1 2 fig. 5.7 fitting...

  • Page 40

    Ecotec plus 937 installation and maintenance manual 40 6 functional checks (commissioning, part ii) 6.1 functional checks 6.1.1 method of procedure after installing and setting the gas, perform a function check before commissioning the appliance and handing over to the user. • commission the applian...

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    41 ecotec plus 937 installation and maintenance manual 6.1.4 storage tank charging h note! The storage tank charging is delivered de- activated and must be activated during commissioning. The storage tank charging of the shift load storage tank is only active if the warm start function is switched o...

  • Page 42

    Ecotec plus 937 installation and maintenance manual 42 • shut off the appliance, open the drain valve and all vent valves on the radiators and allow the water to flow out of the heating system and the combi boiler quickly and fully. • close the drain valve. • re-fill the heating system with water as...

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    43 ecotec plus 937 installation and maintenance manual 7 inspection and maintenance 7.1 first inspection regular maintenance and service is recommended to ensure continued safe and efficient operation of the appliance. The frequency of maintenance and service depends upon the individual installation...

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    Ecotec plus 937 installation and maintenance manual 44 7.1.2 maintenance carry out a first inspection of the system before starting maintenance or repair work as follows: • check the flue system, the pipework and the electrical connections for signs of damage or wear. • check the air supply and vent...

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    45 ecotec plus 937 installation and maintenance manual 7.1.4 function check of the combination boiler • carry out a function check of the combi boiler as described earlier. • remove the front panel in accordance with the instructions and switch the combi boiler on. • check the function of the burner...

  • Page 46

    Ecotec plus 937 installation and maintenance manual 46 10 11 9 8 4 5 6 7 fig. 7.2 removal of the thermo-compact module • pull the ignition cable (5) and the earth wire (6) off the ignition electrode. • unscrew the four nuts (4) from the burner door. • pull the two electrical connections (7 and 8) of...

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    47 ecotec plus 937 installation and maintenance manual 7.2.3 checking the burner 1 fig. 7.4 checking the burner the burner (1) is maintenance-free and needs no cleaning. • check the surface of the burner for damage. If necessary, replace the burner. • after checking or replacing the burner re-fit th...

  • Page 48

    Ecotec plus 937 installation and maintenance manual 48 • re-connect the gas supply (3) to the gas valve. Use a new sealing washer and ensure it is correctly located. Use the flats of the spanner on the flexible gas pipe to hold the gas fittings in position. 11 fig. 7.8 checking the gas supply for le...

  • Page 49

    49 ecotec plus 937 installation and maintenance manual 7.5 checking filling pressure of the expansion vessel of the combination boiler 1 fig. 7.11 checking filling pressure of the expansion vessel of the combination boiler h note! This check need not be performed every year - a check every three yea...

  • Page 50

    Ecotec plus 937 installation and maintenance manual 50 7.7 re-commissioning the combination boiler • carry out the electrical safety tests. • switch on the electrical supply. • turn the isolation valves of the central heating on. • carry out a function check of the combi boiler as described earlier....

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    51 ecotec plus 937 installation and maintenance manual 8 troubleshooting 8.1 logical fault finding procedure carry out the following checks before the actual troubleshooting: • carry out the tests to check electrical safety (see section "preparatory checks on the electrical system"). • check that th...

  • Page 52

    Ecotec plus 937 installation and maintenance manual 52 display meaning hot water mode: s.10 hot water request s.11 fan running s.13 ignition s.14 burner ignited s.15 fan and pump running s.16 fan over run s.17 pump overrun warm start mode/hot water storage tank charging: s.20 warm start function dem...

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    53 ecotec plus 937 installation and maintenance manual display meaning displayed value/settable value d.0 heating partial load adjustable heating partial load in kw (factory setting: max. Output) d.1 water pump over run time for heating mode 2 - 60 minutes (factory setting: 5 minutes) d.2 max. Anti ...

  • Page 54

    Ecotec plus 937 installation and maintenance manual 54 second diagnostic level • as described above in the first diagnostic level, scroll through to the diagnosis number d.97. • change the displayed value to 17 (password) and push the button "i". You are now in the second diagnostic level where all ...

  • Page 55

    55 ecotec plus 937 installation and maintenance manual display meaning displayed value/settable value d.72 pump overrun time after warm start or shift load storage tank charging setting range in seconds: 0, 10, 20 to 600 factory setting: 80 d.73 offset for warm start target temperature setting range...

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    Ecotec plus 937 installation and maintenance manual 56 code meaning cause f.0 flow ntc open circuit ntc faulty, ntc cable faulty, faulty plug connection on ntc, faulty plug connection on the electronics f.02 shift load storage tank charging (ntc) open circuit, only in combination with f.91 ntc fault...

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    57 ecotec plus 937 installation and maintenance manual code meaning cause f.71 flow ntc reports constant value flow ntc is defective f.72 flow and/or return ntc fault feed and/or return ntc is faulty (tolerance too great) f.73 signal water pressure sensor in the wrong range (too low) line to water p...

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    Ecotec plus 937 installation and maintenance manual 58 9 replacing components the tasks listed below may only be undertaken by a qualified competent heating engineer. • only use genuine spare parts for repairs. • check that the parts are correctly fitted and that the original location and alignment ...

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    59 ecotec plus 937 installation and maintenance manual • pull the plug (4) out of the gas valve. • pull the plug (3) out of the fan. • unscrew the three screws (2) out of the thermo- compact module (1). • remove the complete component group "gas valve/ fan". 5 fig. 9.3 gas valve/fan screwed joint • ...

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    Ecotec plus 937 installation and maintenance manual 60 9.5 replacing the primary heat exchanger d danger! Before replacing components ensure that the safety instructions from section 9.1 are observed. • disconnect the appliance from the mains as described in chapter 9.1, and close the gas isolation ...

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    61 ecotec plus 937 installation and maintenance manual 9.6 replacing the expansion vessel of the shift load storage tank 1 2 fig. 9.7 replacing the expansion vessel of the shift load storage tank d danger! Before replacing components ensure that the safety instructions from section 9.1 are observed....

  • Page 62

    Ecotec plus 937 installation and maintenance manual 62 • release the spring clamp (5) on the storage tank charging pump casing (4). Support the storage tank charging pump with your other hand to prevent it from falling out of the chassis. • pull the storage tank charging pump out of the chassis down...

  • Page 63

    63 ecotec plus 937 installation and maintenance manual • isolate the unit from the mains as described in section 9.1. • close the gas isolation valve in the gas supply pipe. • comply with the assembly and installation manuals provided with the spare parts. • remove the screw on the top cover of the ...

  • Page 64

    Ecotec plus 937 installation and maintenance manual 64 h note! Only for natural gas: carry out the setting only in steps of 1/8 turn. After each setting wait for approx. 1 minute until the value has stabilised. Only for liquid gas: carry out the setting only in very small steps (approx. 1/16 turn.) ...

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    65 ecotec plus 937 installation and maintenance manual ec declaration of conformity appendix ec declaration of conformity.

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