Vaillant ecoTEC plus 937 Instructions And Maintenance Instructions
Gas fired wall hung high efficiency boiler with layered storage tank
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Also See for ecoTEC plus 937:
- Operating manual (16 pages) ,
- Instructions for installation and servicing (68 pages) ,
- Operating manual (16 pages)
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Summary of Contents for Vaillant ecoTEC plus 937
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Page 1: Ecotec Plus
For the heating engineer Instructions and maintenance instructions ecoTEC plus 937 Gas fired wall hung high efficiency boiler with layered storage tank... -
Page 2: Table Of Contents
3.10.6 Shift load storage tank expansion vessel ..16 heating system ............32 3.11 Details for the pumps........... 16 5.4.2 Filling device for ecoTEC plus 937 ....32 3.11.1 Circulation pump ........... 16 5.4.3 Initial filling of the heating system ....32 3.11.2 Shift load storage tank circulation pump ..16 Initial flushing of the system ("cold“) ....33... - Page 3 Handing over the boiler to the owner .... 38 10.2 Packaging ............... 58 Vaillant warranty..........38 6.3.1 Two years warranty ..........38 Vaillant service ..........58 6.3.2 Registering with us ..........38 6.3.3 First aid ..............38 EC declaration of conformity .........59 Inspection and maintenance .......39 First inspection .............
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Page 4: Introduction
No. 0020040000 Guarantee card with return envelope No. 802922 General notes The ecoTEC plus 937 is designed for use in a closed cen- For the heating engineer: tral heating system and is comprehensively tested in the Installation manual for flue factory. -
Page 5: Ce Label
Note Vaillant Ltd. supports the Benchmark Initiative. CE label You will find the Benchmark Logbook on the CE labelling shows that the appliances comply with the last page of this instruction manual. -
Page 6: Unit Description, Data And Dimensions
Main PCB fuse (slow-blow) for main power supply Electr. Power consumption Standby power consumption Layered storage tank capacity Installation weight, just storage tank Installation weight, just combi unit Operating weight (with water) Table 2.1 Technical Data ecoTEC plus 937 Installation and maintenance instructions ecoTEC plus 0020031552_03... -
Page 7: Dimensions
Unit description, data and dimensions 2 Dimensions Fig. 2.1 Dimensions ecoTEC plus 937 Heating return pipe, Ø 22 mm 2 Cold water connection, Ø 15 mm 3 Gas connection Ø 22 mm 4 Hot water connection, Ø 15 mm 5 Heating flow pipe, Ø 22 mm... - Page 8 2 Unit description, data and dimensions Fig. 2.2 Dimensions shift load storage tank Heating return pipe, Ø 22 mm 2 Cold water connection, Ø 15 mm 3 Gas connection Ø 22 mm 4 Hot water connection, Ø 15 mm 5 Heating flow pipe, Ø 22 mm 6 Hanging bracket 7 Shift load storage tank pressure relief connection (flexible hose supplied) 8 Cover...
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Page 9: Structure And Functional Elements
4 NTC temperature sensor - hot water outlet 5 Storage tank pressure relief valve Identification plates The identification plate of the ecoTEC plus 937 is locat- ed on the underside of the unit. Fig. 2.3 Function elements combi unit Expansion vessel combi boiler... -
Page 10: Functional Description
2 Unit description, data and dimensions Functional description Fig. 2.5 Sequence diagram Exhaust gas 14 Compact thermal module 2 Heat exchanger 15 Shift load storage tank electronics 3 Combustion chamber 16 storage charging pump 4 Water condensate siphon 17 Aqua-Sensor 5 Expansion vessel 18 Stainless steel storage tank 6 Operating display... -
Page 11: General Requirements 3
Part 3 Installation, commissioning and maintenance. The ecoTEC plus 937 is be supplied for natural gas and BS 4814: Specification for: Expansion vessels using an can be converted for propane gas with a conversion kit. -
Page 12: Scope Of Supply And Accessories
BS 5546 and in BS 6798. damage. The ecoTEC plus 937 must be mounted on a flat, vertical wall which is sufficiently strong to hold the weight of the shift load storage tank and the combi boiler. -
Page 13: Gas Supply
Danger! tions in timber framed and light steel framed Vaillant appliances are only system-certified if buildings“ genuine Vaillant flue pipes are used. Only use genuine Vaillant flue pipes. Malfunctions can Note occur if you use other accessories. These may If the boiler is to be installed in an airing result in damage and injury. -
Page 14: Optional 125 Mm Flue Pipe
3 General requirements 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° bends are also available to increase the flexibility during installation. -
Page 15: Air Supply
General requirements 3 b) so that products of combustion are not directed to Danger! discharge across a boundary. Danger of death by electric shock! 1) Dimensions B, C and D: The unit must be earthed. These dimensions can be reduced to 25 mm without having a negative effect on the performance of the 3.10 System requirements... -
Page 16: Pressure Relief Valve
3 General requirements 3.10.3 Pressure relief valve 3.10.6 Shift load storage tank expansion vessel The boiler is equipped with a pressure relief valve. This The shift load storage tank is fitted with a 1 litre expan- safety device is required for all sealed central heating sion vessel. -
Page 17: Sequence Of Operations During Installation 4
Sequence of operations during installation 4 Sequence of operations during • Take care to avoid trip hazards, slippery or wet surfaces and climbing steps and stairs. installation • Always use assistance if required. Transporting the appliance Carriage of carton from point of delivery to point of installation –... - Page 18 4 Sequence of operations during installation • Ensure safe lifting techniques are used – keep back Positioning of Appliance for Final Installation – straight – bend using legs. withincompartment etc. restricting installation. • Keep load as close to body as possible. •...
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Page 19: Required Minimum Gaps/Assembly Clearances
Sequence of operations during installation 4 Required minimum gaps/assembly clearances Further information concerning the installation location of the combi boiler can be found in the Section "Installa- tion Location". Unpacking the equipment First cut through the two plastic straps when unpacking min 500 min 5 min 5... -
Page 20: Flue Exit
4 Sequence of operations during installation Use the template provided for the installation (see • Fix the hanging bracket (1) to the wall using the plugs Fig. 4.2). and screws (2) provided with the appliance. The template shows the following: •... -
Page 21: Removing The Front Case
Sequence of operations during installation 4 Removing the front case Caution! Danger of leaks by improper installation! Ensure a stress-relief assembly of the gas pipes. Caution! Danger of damage to units and system! The electronic gas valve may be tested for leakage only with a maximum pressure of 150 mbar! At higher testing pressures there is a danger... -
Page 22: Cold Water Supply And Hot Water Outlet
4 Sequence of operations during installation • Pull the union nut (6) with the olive (5) towards the • Insert the fibre seal (1) and screw the cold water iso- gas isolator valve. Tighten the union nut hand tight. lating valve (2) to the cold water connection of the •... -
Page 23: Condensate Drain
Sequence of operations during installation 4 Note Before connecting the heating circuit to the combi boiler all pipework and radiators must be thoroughly flushed out to remove all con- taminants. Ø max. 22 mm Fig. 4.10 Diameter of the connection lines when using a low loss header 4.15 Condensate drain... -
Page 24: Installing The Pressure Relief Discharge Pipework
4 Sequence of operations during installation Note Danger! The drain pipe connected to the condensate Danger of poisoning! drain of the combi boiler must have a constant In order to prevent exhaust gases from escap- gradient (45 mm per metre) and should be ing from the combi boiler via the siphon, the installed and terminate within the building to siphon must be filled with water before the unit... -
Page 25: Storage Tank Pressure Relief Discharge Pipework
Sequence of operations during installation 4 4.17 Storage tank pressure relief discharge pipe- ration at all poles is at least 3 mm and which supplies work only the appliance and controls). The connection must permit complete isolation of the appliance and its con- nected controller from the mains supply. -
Page 26: Connection The Power Supply
4 Sequence of operations during installation • Pull the electronics box forward and lower. • Run the sensor cable (1) with plug X31 to the printed • Unclip the back cover of the electronics box and lift circuit board. the cover upwards to reveal the connections. •... -
Page 27: Wiring Diagrams
Sequence of operations during installation 4 4.19.4 Wiring diagrams Shift load storage tank connection Shift load storage tank pump connection Burner cable harness Accessory module connection Diagnosis via eBUS, vrnetDIALOG External sensor external feed or return line sensor Wiring harness hydraulics Connection for external eBUS controller Attention:... - Page 28 4 Sequence of operations during installation Return temperature Flow temperature Ignition electrode sensor (NTC) sensor (NTC) X 20/5 red X 20/7 black X 20/8 blue X 20/7 black X 20/13 black Thermal fuse X 20/12 black Gas valve Plug connection X 20/16 blue (Earth) X 20/4 grey (PWM) X 20/3 black (Hall-Signal)
- Page 29 Sequence of operations during installation 4 Shift load storage tank electronics X 1/3 Violet Storage tank charging sensor (NTC) X 1/1 Black X 1/4 orange Storage tank sensor (NTC) X 1/1 Black X 1/6 Blue Inlet sensor SWT (NTC) X 1/1 Black Aqua-Sensor X 1/7 Green X 1/1 Black...
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Page 30: Control Units
810/2 00 2002 3370 Diagnostic software Table 4.1 Vaillant control units and accessories 4.20.2 External electrical controllers tion of the timer and terminal 4 on the combi boiler The boiler terminals 3, 4 and 5 on the combi boiler are... -
Page 31: Heating Pump
Sequence of operations during installation 4 Commissioning, Part I 5 Commissioning, Part I Note External frost protection devices cannot be used if plug-in timers are used. Preparatory checks of the electrical system • Check the electrical installation for short circuits, 4.23 Heating pump proper earthing and earth resistance and for correct... -
Page 32: Checking The Filling Pressure Of The Heating System
Fig. 5.3 Double check valve separated from the system during 5.4.2 Filling device for ecoTEC plus 937 the heating process The ecoTEC plus 937 is fitted with a filling loop. • Push the double check (1) of the filling loop into the 5.4.3 Initial filling of the heating system cold water stop valve (2) and secure the double check valve (1) with the spring clip (4). -
Page 33: Initial Flushing Of The System ("Cold")
Commissioning, Part I 5 • Check that both stop valves on the combi boiler are • Remove the lower section (1) of the condensate open. siphon by turning the bayonet connection in a coun- • Connect the filling loop as described in Section 5.4.2. terclockwise direction a quarter of a turn. -
Page 34: Checking The Gas Supply
Fig. 5.6 Checking the gas inlet working pressure tolerance limits specified in Table 5.1, do not Check the gas inlet working pressure as follows: operate the appliance and inform the Vaillant Remove the front cover from the combi boiler. Customer Service. -
Page 35: Fitting The Front Casing
Gas conversion Note To convert the appliance from natural gas to liquid gas you will need the Vaillant modification kit Part No. 00 2001 0641. To convert the appliance from liquid gas to natural gas you will need the Vaillant modification kit Part No. -
Page 36: Commissioning Part Ii: Functional Checks
6 Commissioning, Part II: Functional checks Commissioning Part II: Functional checks 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 appliance in accordance with the in- Fig. -
Page 37: Subsequent Flushing Through Of The Heating System ("Hot")
Commissioning, Part II: Functional checks 6 Fig. 6.5 Display during storage tank charging De-activating the storage tank charging • De-activate the storage tank charging by turning the hot water temperature control knob fully anti-clockwise. The symbol " “ disappears. • Then set the desired hot water temperature. The unit now operates in the through-flow principle, the stor- age tank is not held at temperature. -
Page 38: Handing Over The Boiler To The Owner
6.3.3 First aid • Set the controller for the maximum radiator tempera- In the event of a fault on your Vaillant boiler firstly con- ture to the required temperature. sult your installer since his services must be obtained as • Set the controller for the maximum hot water temper- a condition of the guarantee. -
Page 39: Inspection And Maintenance 7
Note In order to ensure all the functions of the Vaillant appli- The appliance is fitted with a combustion anal- ance over a long period, only genuine Vaillant spare ysis test point. A suitable flue gas analyser can... -
Page 40: Overview Of Inspection And Maintenance Tasks
7 Inspection and maintenance 7.1.3 Overview of inspection and maintenance tasks Column 1 Column 2 An inspection Maintenance No. Step must be perfor- med once a year. Check flue system and make sure that it is not blocked, not damaged and fixed correctly. Measure the gas rate in operation (see Table 5.1 in Section Commissioning, Part l). -
Page 41: Function Check Of The Combination Boiler
Inspection and maintenance 7 7.1.4 Function check of the combination boiler • Release the screw and the spring clips on the front • Carry out a function check of the combi boiler as de- panel located under the front of the unit. scribed earlier. -
Page 42: Cleaning The Integral Condensation Heat-Exchanger
7 Inspection and maintenance 7 7.2.2 Cleaning the integral condensation heat- exchanger Caution! Protect the electronics box from water splashes. Fig. 7.4 Checking the burner 7.2.4 Fitting the thermo-compact module Fig. 7.5 Replacing the burner door gasket • Insert a new gasket (1) in the burner door. Caution! Fig. -
Page 43: Cleaning The Condensate Siphon
Inspection and maintenance 7 • Insert the compact thermo module (9) in the integral Cleaning the condensate siphon condensation heat exchanger (10). • Tighten the four nuts (4) alternately on the left and right until the burner door closes securely and evenly over the surface of the heat exchanger. -
Page 44: Checking Filling Pressure Of The Expansion Vessel Of The Combination Boiler
7 Inspection and maintenance • Isolate the unit from the electric mains in the appart- If the pressure is less than this, the vessel must be ment as described in 8.2. pumped up again using an air pump. • Close the cold water stop valve on the inlet combina- •... -
Page 45: Test Mode
Inspection and maintenance 7 Test mode Always perform the following steps after performing any maintenance work: • Commission the appliance in accordance with the in- structions in the relevant operating manual. • Check the appliance for gas and water leaks. •... -
Page 46: Troubleshooting
8 Troubleshooting Display Meaning Troubleshooting Heating mode: Logical fault finding procedure No heat demand Carry out the following checks before the actual trou- Fan running bleshooting: Pump running • Carry out the tests to check electrical safety (see Sec- Ignition tion "Preparatory Checks on the Electrical System"). -
Page 47: Diagnostic Codes
Display range 0 to 102, >80 no flame, <40 good flame display d.47 External temperature (only on weather-compensated actual value in °C Vaillant controllers) d.67 Remaining burner anti-cycling time in minutes d.76 Unit variants (device specific number) 00 to 99 d.90... - Page 48 8 Troubleshooting Second diagnostic level Scroll and change values and exit diagnosis mode as de- • As described above in the first diagnostic level, scroll scribed in the first diagnosis level. through to the diagnosis number d.97. • Change the displayed value to 17 (Password) and push Note the button "i".
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Page 49: Error Codes
Troubleshooting 8 Display Meaning Displayed value/settable value d.72 Pump overrun time after warm start or shift load storage Setting range in seconds: 0, 10, 20 to 600 tank charging Factory setting: 80 d.73 Offset for warm start target temperature Setting range: -15 K to +5 K (Factory setting: 0K) d.74 Legionella protection shift load storage tank Setting range:... -
Page 50: Error Codes
8 Troubleshooting Code Meaning Cause NTC faulty, NTC cable faulty, faulty plug connection on NTC, Flow NTC open circuit faulty plug connection on the electronics NTC faulty, NTC cable faulty, faulty plug connection on NTC, F.01 Return NTC open circuit faulty plug connection on the electronics Shift load storage tank charging (NTC) open circuit, NTC faulty, NTC cable faulty, faulty plug connection on NTC,... -
Page 51: Test Programmes
Troubleshooting 8 Code Meaning Cause Storage tank is not fully charged after a specific period of time. -Check storage tank charge sensor and storage tank sensor -Air in the APC pump F.81 APC loadpump fault connected to F.91 -Check pump wiring harness -Secondary heat exchanger blocked -Priority changeover valve defective -Pump defective... -
Page 52: Replacing Components
9 Replacing components Replacing components • Dismantle the compact thermo module as described under 7.2.1. The tasks listed below may only be undertaken by a • Release the 4 screws (1) on burner, and remove the qualified competent heating engineer. burner. -
Page 53: Replacing The Expansion Vessel
Replacing components 9 Fig. 9.3 Gas valve/fan screwed joint • Release both fixing screws (5) on the gas valve and remove the fan from the gas valve. • Replace the faulty component. Caution! Danger of damage to the equipment! Fit the gas valve and fan in the same position as before. -
Page 54: Replacing The Expansion Vessel Of The Shift Load Storage Tank
9 Replacing components Note A new burner door seal kit must be fitted every time the burner door is removed. Caution! Danger of damage to the primary heat-ex- changer! Do not release or tighten the four screws (Fig. 9.5, Item 4). Caution! Insert the „O“-rings for the flow and return hoses on the primary heat-exchanger using a... -
Page 55: Replacing The Storage Tank Pump Of The Shift Load Storage Tank
Replacing components 9 • Remove the screw on the cover of the shift load stor- • Remove the discharge pipe (1) of the heating pressure age tank. relief. • Remove the cover. • Lower the electronics box as described in Sec- •... -
Page 56: Replacing The Electronics On The Shift Load Storage Tank
• Exit the diagnostic mode. • Mount the new Aqua-Sensor in reverse order and re- place the seals. The combi boiler ecoTEC plus 937 is ready for operation. • Connect the line plug of the Aqua-Sensors with the wiring harness. -
Page 57: Checking And Setting The Co Content, If Required (Air Ratio Adjustment)
Replacing components 9 9.11 Checking and setting the CO content, if re- Note quired (air ratio adjustment) Only for natural gas: Carry out the setting only in steps of 1/8 turn. Note After each setting wait for approx. 1 Minute Checking/adjusting this value is only required until the value has stabilised. -
Page 58: Recycling And Disposal
10.1 Unit The Vaillant ecoTEC consists to a large extent (up to 92 %) of metallic components designed for recycling by melting down in the steelworks. This gives these parts almost indefinite reusability. All plastic materials are... -
Page 59: Ec Declaration Of Conformity
EC declaration of conformity EC declaration of conformity Installation and maintenance instructions ecoTEC plus 0020031552_03...