Vailant ecoTEC plus 937, Installation And Maintenance Instructions Manual

Page 1: ...For the heating engineer Installation and maintenance instructions GB IE ecoTEC plus 937 VUI...

Page 2: ...ing the location for the shift load storage tank and combination boiler 23 5 3 Unpacking the equipment 23 5 4 Using the installation template 24 5 5 Flue exit 24 5 6 Installation of the flue gas syste...

Page 3: ...8 2 Maintaining the compact thermal module 53 8 2 1 Removing the compact thermal module 53 8 2 2 Cleaning the integral condensation heat exchanger 54 8 2 3 Checking the burner 54 8 2 4 Installing the...

Page 4: ...he environment i Symbol denoting additional useful tips and information Symbol for a required task 1 4 Validity of the manual This installation manual applies exclusively to the unit with the followin...

Page 5: ...p an expansion vessel a diverter valve and a 15 l layered storage tank The shift load storage tank and combination boiler can be easily mounted on an internal wall and installed with a vertical or hor...

Page 6: ...pressure central heating 3 0 bar Volume of water circulating 20 K 1204 l h Approximating condensation water volume at 50 C Feed 30 C Return 2 9 l hr Pump head 250 mbar Minimum water flow 0 1 l min Sp...

Page 7: ...return pipe 22 mm 2 Cold water connection 15 mm 3 Gas connection 22 mm 4 Hot water connection 15 mm 5 Heating flow pipe 22 mm 6 Hanging bracket 7 Flue hole flue system 60 100 8 Flue hole flue system...

Page 8: ...2 3 4 5 7 8 Fig 2 2 Dimensions shift load storage tank Legend 1 Heating return pipe 22 mm 2 Cold water connection 15 mm 3 Gas connection 22 mm 4 Hot water connection 15 mm 5 Heating flow pipe 22 mm 6...

Page 9: ...k charging pump 1 2 3 4 6 5 7 8 13 12 10 9 11 Fig 2 3 Function elements combi unit Legend 1 Expansion vessel combi boiler 2 Air intake pipe 3 Compact thermal module 4 Ignition electrode 5 Fan 6 Divert...

Page 10: ...condary heat exchanger 8 Automatic air vent 9 Pump 10 Pressure relief valve 11 Diverter valve 12 Gas valve 13 Fan 14 Compact thermal module 15 Shift load storage tank electronics 16 storage charging p...

Page 11: ...g system can be filled using the filling devices fitted to the ecoTEC plus combination boilers The ecoTEC plus 937 is be supplied for natural gas and can be converted for propane gas with a conversion...

Page 12: ...s If possible open doors and windows fully and ensure air is circulating Avoid the use of naked flames e g lighters matches Do not smoke Do not use any electrical switches plugs doorbells telephones o...

Page 13: ...ing British Standards BS 6700 Services supplying water for domestic use within buildings and their curtilages BS 6798 Specification for installation of gas fired boil ers not exceeding 60 kW input BS...

Page 14: ...ecommendations for combi boilers The installation location for the combi boiler and shift load storage tank must permit proper connection of the flue gas system to the combi boiler In addition there m...

Page 15: ...in substances of this type which can cause corrosion in the flue gas system in the worst case even if the unit is operated as an open vent appliance Particularly in hairdressing salons lacquering and...

Page 16: ...terminal position must be located in such a position that any flammable gases can be freely dissipated b A plume of water vapour will sometimes be visi ble from the flue terminal Positions where this...

Page 17: ...inal should be extended as shown in Fig 3 7 2 Dimension F These dimensions can be reduced to 25 mm without having a negative effect on the output of the combi boiler However in order to ensure that th...

Page 18: ...for use of system cleaning agents can be obtained from Sentinel Betz Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 420 9595 or Fernox Alpha Fry Technolo gies Tandem House Marlow Way Croydon CR0 4XS Te...

Page 19: ...ments 2 of the specific system volume nominal capacity in litres heat ing output in case of multiple boiler systems the lowest indi vidual heating output should be used These data only apply up to 3x...

Page 20: ...me by the adjacent factors 0 109 0 156 Table 4 5 Size of an additional expansion vessel 4 8 6 Shift load storage tank expansion vessel The shift load storage tank is fitted with a 1 litre expan sion v...

Page 21: ...s slippery or wet surfaces and climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation first or higher floor cellar Recommend 2 p...

Page 22: ...ut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compartment etc restricting instal...

Page 23: ...st be visible i If the boiler is to be installed in a timber framed building it should be fitted in accord ance with IG UP 7 Edition 2 Gas installations in timber framed and light steel framed build i...

Page 24: ...inadequate installation The combi heater may come loose from the wall and fall if the wall or fixing material is unsuitable Only install the appliance on a firm sealed wall surface that has a sufficie...

Page 25: ...ket i If the appliance is to be fitted in a timber framed building ensure that the hanging bracket is secured to a substantial part of the timber frame capable of taking the full weight of the applian...

Page 26: ...an additional expansion vessel see Sec tion 4 8 6 5 11 Gas connection a Danger Risk of death caused by improper gas installation An improper gas installation may impair the operational safety of the a...

Page 27: ...combi boiler Tighten all connections Purge the gas pipe before commissioning Check the gas connection for leaks using leak detect ing spray 5 12 Connecting the hot and cold water a Danger Risk of scal...

Page 28: ...pump we recom mend using the accessory set Item no 0020057235 i Using a circulation pump negatively affects hot water comfort as it causes turbulence and disrupts the stratification in the tank Limit...

Page 29: ...urn heating connections Remove the stop valves with union nuts olives and fibre seals from the box of accessories for the combi boiler Insert the fibre seal 1 and screw the stop valve 2 onto the retur...

Page 30: ...e in a suitable location e g a preferably the drain line should run and termi nate internally to the house soil and vent stack at least 450 mm above the invert of the stack A trap giving a water seal...

Page 31: ...and no cable or other electrical components can be damaged if water or steam is discharged Please note that the end of the discharge pipe must be visible i We recommend that the discharge pipe for the...

Page 32: ...mains supply at terminals 7 8 9 and BUS Only connect the mains supply cable to the terminals marked for the purpose The appliance is designed for connection to 230 V 50 Hz supply with a 3 A rating Co...

Page 33: ...connector X31 onto the plug socket X31 2 left hand side of the printed circuit board Fix the cable 4 in the electronics box via the cable clamps 5 19 3 Establishing the power supply b Caution Risk of...

Page 34: ...when connecting Heating pump 2 speed pump plug with 5 pins Mains connection 230 V 50 Hz Fuse 2 A slow acting Igniter Attention Do not connect mains voltage Danger of destroying the electronics Diagno...

Page 35: ...ck X 20 7 black X 20 8 blue X 2 12 green X 2 11 red X 2 9 black Pump X 20 18 red 24 VDC X 20 9 blue Erde X 20 16 blue Earth X 20 13 black X 20 12 black X 20 4 grey PWM X 20 3 black Hall Signal X 20 17...

Page 36: ...lack 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 Shift load storage tank electronics X 1 2 brown X 1 1 Black X 1 2 Brown X 1 1 B...

Page 37: ...Accessories Item no Connection VR 65 control centre for UK cylinder installation eBUS 307215 System solution for UK cylinder connection vrDIALOG 810 2 0020023370 Diagnostic software Table 5 1 Vaillant...

Page 38: ...thermostat This frost protection ther mostat should be connected to the terminals 3 and 4 on the combi boiler in parallel to all the other external heating controllers i External frost protection dev...

Page 39: ...ck all hot and cold water pipes for leaks 6 4 Filling and bleeding the heating system i Use the following test programmes for filling and venting the heating system Filling the heating system Use the...

Page 40: ...system for the first time i If the water pressure in the heating system is too low the display switches between error message F 22 and the display of the actual pressure when the unit is switched on...

Page 41: ...er stop valve 6 6 Filling the condensate drain trap a Danger Risk of poisoning from escaping exhaust gas If the appliance is operated with an empty condensate trap exhaust gas may escape and cause poi...

Page 42: ...instructions enclosed with this boiler and as described below a visual check is carried out on the boiler combus tion circuit and the relevant seals that any defects have been corrected at this stage...

Page 43: ...operation by Pressing the and i buttons simultaneously and turn down both thermostat control knobs Allow the boiler to cool down by turning off water taps and allow pump overrun to operate for a mini...

Page 44: ...ove the pressure gauge and re tighten the seal ing screw 1 Open the gas isolation valve of the boiler Make sure that there is no leakage at the sealing screw Put the front casing back on Reset boiler...

Page 45: ...before commissioning the appliance and handing over to the user Commission the appliance in accordance with the instructions in the relevant operating manual Check the gas supply pipework the flue sy...

Page 46: ...can set the following temperatures using the knob for hot water draw off temperature Knob setting c 35 C Knob setting a 65 C a a b c c 1 1 1 Fig 7 4 Setting range for the storage tank temperature If t...

Page 47: ...is to be protected by an inhibitor it should be added at this stage in accordance with the manufacturer s instructions Further information can be obtained from Sentinel Betz Dearborn Ltd Tel 0151 420...

Page 48: ...rop erty due to neglected inspection and main tenance Neglected inspection and maintenance works or not observing the stated inspection and maintenance intervals can interfere with the operational saf...

Page 49: ...gas duct 8 1 1 General inspection and maintenance instructions To ensure the faultless operation long term availability of all functions and long working life of your Vaillant boiler and to prevent mo...

Page 50: ...and water leaks If necessary refill and re bleed the heating installa tion Replace the front casing to the boiler Carry out a functional check of the boiler see section 7 Always check earth continuit...

Page 51: ...e value stabilises Liquid gas Only perform the adjustment in very small increments approximately 1 16 turns and wait approximately 1 minute after each adjustment until the value stabilises After perfo...

Page 52: ...as isolation valve and the service valves x 9 Dump the pressure in the boiler on the water side observe pressure gauge and check the charge pressure of the expansion vessel of the boiler Top up if nec...

Page 53: ...1 Fig 8 2 Removing the air inlet pipe Remove the front of the of the unit by pulling the bottom edge forwards and lifting slightly Lower the electronic box Unscrew the screw 2 and remove the air inlet...

Page 54: ...condensate siphon Avoid pointing the water jet directly at the insulating sur face 2 on the back of the heat exchanger If necessary the heat exchanger can be cleaned using ordinary vinegar 8 2 3 Chec...

Page 55: ...ctly located Use the flats of the spanner on the flexible gas pipe to hold the gas fittings in position 11 Fig 8 9 Checking the gas supply for leaks Turn on the gas supply and check for leaks Pay par...

Page 56: ...11 Remove the connector 2 from the chassis Flush the connector out under flowing water in the opposite direction to normal flow Re fit the connector with the cleaned strainer Fit the pipe elbows of th...

Page 57: ...ves sel Re fit the cover Re pressurise the combi boiler and the hot water sys tem 8 7 Re commissioning the combination boiler Carry out the electrical safety tests Switch on the electrical supply Tur...

Page 58: ...eating System Check that the stop valves in the flow and return lines of the combi boiler are open Check that the mains switch is set to ON Set the temperature of the central heating to Maxi mum Set t...

Page 59: ...eriod of the opera tion block function due to water shortage tempera ture gradient S 96 Return flow sensor test heat demands hot water or heating are blocked S 97 Water pressure sensor test heat deman...

Page 60: ...hot water circulation pump via accessory mod ule 1 to 100 on 0 off d 22 Hot water demand 1 on 0 off d 23 Summer winter function 1 Winter 0 Summer d 25 Hot water activation via eBUS controller 1 yes 0...

Page 61: ...ctor hood 5 External gas valve 6 External error message d 28 Switching relay 2 on the accessories module 1 Circulation pump 2 Ext pump factory setting 3 External cylinder charging pump 4 Flue gas flap...

Page 62: ...W 0 1 5 l min and no delay 1 3 7 l min and 2s delay d 92 Module recognition shift load storage tank Setting range 0 not recognised 1 no communication via PE BUS Module recognised earlier 2 Communicati...

Page 63: ...e wiring harness open circuit Wiring harness thermo compact module faulty F 27 Incorrect sensing of flame Flame monitor faulty F 28 Unit will not start Attempts to ignite during start failed Faults in...

Page 64: ...er F 80 Interruption or short circuit of SWT inlet sensor only in conjunction with F 91 NTC defective NTC cable defective defective plug connection at NTC defective plug connection at APC electronics...

Page 65: ...n Tables 9 2 and 9 3 you can also reset all parameters simultane ously In the second diagnostic level under the diagnostic point d 96 change the value to 1 see Section 9 1 2 The parameters of all adju...

Page 66: ...k check the system for gas leaks and carry out a function test see Sec tion 8 8 i A new burner door seal kit must be fitted every time the burner door is removed 10 3 Replacing the fan or the gas valv...

Page 67: ...cing the component comply with the safety instructions in Chapter 10 1 Disconnect the appliance from the mains as described in Chapter 10 1 and close the gas isolator valve in the gas supply pipe Clos...

Page 68: ...ate pipe which runs from the pri mary heat exchanger to the siphon 1 2 4 3 Fig 10 5 Replacing the primary heat exchanger Remove the clamps 1 and 2 and pull off the flow and return hoses from the prima...

Page 69: ...nd close the gas isolator valve in the gas supply pipe Close the cold water inlet stop valve Open a hot water tap in order to release the pressure on the water circuit Then close the tap again Remove...

Page 70: ...rging pump in reverse order and use new gaskets Connect the electrical wires of the pump in reverse sequence Check for correct routing of the lines Re fit the discharge pipe 1 and use new gaskets Fill...

Page 71: ...der Start up the appliance Check the correct setting of the unit variants DSN as follows Enter the 2nd diagnostic level of the combi boiler Set the equipment specific DSN value parameter d 93 in accor...

Page 72: ...usehold waste Ensure that old appliances and any existing accessories are disposed of properly Packaging The specialist company that installed the appliance is responsible for disposing of the transpo...

Page 73: ...Installation and maintenance instructions ecoTEC plus 937 0020031552_06 73 EC declaration of conformity EC declaration of conformity...

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Page 75: ...Installation and maintenance instructions ecoTEC plus 937 0020031552_06 75 Installation Commissioning and Service Record...

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