Vailant ecoTEC plus 937 Manual de usuario
For the heating engineer
Installation and maintenance instructions
GB; IE
ecoTEC plus 937
VUI
Contents
2Installation and maintenance instructions ecoTEC plus 937 0020031552_06
Contents
1 Notes on the documentation................................4
1.1 Documents also having validity..............................4
1.2 Storing documents.....................................................4
1.3 Symbols used...............................................................4
1.4 Validity of the manual...............................................4
1.5 Identification plates ...................................................4
1.6 CE label .........................................................................4
1.7 Benchmark ...................................................................5
1.8 Gas Council Number ..................................................5
2 Unit description, data and dimensions .............5
2.1 General notes ..............................................................5
2.2 Technical data .............................................................6
2.3 Dimensions...................................................................7
2.4 Structure and functional elements........................9
2.5 Functional description............................................. 10
3 Safety ...........................................................................11
3.1 Safety and warning information.............................11
3.1.1 Classification of warnings ........................................11
3.1.2 Structure of warnings ...............................................11
3.2 Intended use ................................................................11
3.3 General safety instructions.....................................12
3.4 General requirements...............................................13
3.4.1 Preliminary remarks .................................................13
3.4.2 Related documents ...................................................13
4 General requirements.............................................14
4.1 Scope of supply and accessories...........................14
4.2 Installation location...................................................14
4.3 Gas supply ...................................................................15
4.4 Flue pipe.......................................................................15
4.4.1 100 mm standard flue duct.....................................15
4.4.2 Optional 125 mm flue pipe.......................................16
4.5 Flue termination ........................................................16
4.6 Air supply.....................................................................17
4.7 Electrical connection ................................................17
4.8 System requirements ...............................................18
4.8.1 Water circulation system.........................................18
4.8.2 Filling and preparation of the heating system...18
4.8.3 Pressure relief valve.................................................19
4.8.4 Pressure gauge ..........................................................19
4.8.5 Heating circuit expansion vessel...........................19
4.8.6 Shift load storage tank expansion vessel.......... 20
4.9 Details for the pumps............................................. 20
4.9.1 Circulation pump ..................................................... 20
4.9.2 Shift load storage tank circulation pump.......... 20
4.10 System-Bypass......................................................... 20
4.11 Venting....................................................................... 20
4.12 Condensate siphon.................................................. 20
5 Sequence of operations during installation....21
5.1 Transporting the appliance.....................................21
5.2 Required minimum gaps/assembly clearances 23
5.2.1 Selecting 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 system...................... 24
5.7 Fitting the appliance hanging bracket ................25
5.8 Mounting the combination boiler .........................25
5.9 Removing the front case........................................26
5.10 General instructions concerning the heating
system .........................................................................26
5.11 Gas connection..........................................................26
5.12 Connecting the hot and cold water .....................27
5.13 Connecting piping between the stratified
storage tank and the combi-heater.................... 28
5.14 Connecting the heating supply and return
lines..............................................................................29
5.15 Installing the condensate drain line.................... 30
5.16 Connecting the drain pipe to the pressure
relief valve...................................................................31
5.17 Connecting the drain hose to the pressure
relief valve of the stratified storage tank...........31
5.18 Connecting the exhaust gas system to the
combi-heater...............................................................31
5.19 Electrical connection ...............................................32
5.19.1 General requirements..............................................32
5.19.2 Establishing the electrical connection for the
stratified storage tank ............................................32
5.19.3 Establishing the power supply ..............................33
5.19.4 Connection diagrams................................................................34
5.20 Control units ..............................................................37
5.20.1 Vaillant control units and accessories................37
5.20.2 External electrical controllers...............................37
5.20.3 Details for the connection of an external
timer to the terminal strip .....................................37
5.20.4 Optional plug-in timers by Vaillant ..................... 38
5.21 Thermostatic radiator valves ............................... 38
5.22 Frost prevention ...................................................... 38
5.23 Heating pump ........................................................... 38
5.24 Anti-cyclic "Economiser" control system.......... 38
5.25 Automatic pump spin control............................... 38
6 Commissioning, Part I...........................................39
6.1 Preparatory checks of the electrical system ....39
6.2 Gas supply ..................................................................39
6.3 Cold water supply.....................................................39
6.4 Filling and bleeding the heating system.............39
6.4.1 Checking the fill pressure in the heating
system .........................................................................39
6.4.2 Filling device for ecoTEC plus 937......................40
6.4.3 Filling the heating system for the first time..... 40
Contents
3Installation and maintenance instructions ecoTEC plus 937 0020031552_06
6.5 Flushing the system for the first time ("cold")..41
6.6 Filling the condensate drain trap ..........................41
6.7 Setting the pump output .........................................41
6.8 Adjusting the bypass ................................................41
6.9 Checking the gas setting ....................................... 42
6.9.1 Checking for tightness of the flue gas
installation and flue gas recirculation................ 42
6.9.2 Checking the gas flow rate ....................................43
6.9.3 Checking the gas inlet working pressure ...........43
6.10 Assembling the front panel................................... 44
6.11 Adjusting the central heating system (range
rating)......................................................................... 44
6.12 Converting the gas type ........................................ 45
7 Commissioning Part II: Functional checks... 45
7.1 Functional checks.................................................... 45
7.1.1 Method of procedure.............................................. 45
7.1.2 Heating....................................................................... 45
7.1.3 Hot water operation ............................................... 46
7.1.4 Storage tank charging............................................ 46
7.1.5 Conclusive flushing of the heating system
("hot")..........................................................................47
7.2 Briefing users ............................................................47
7.3 Factory guarantee................................................... 48
8 Inspection and maintenance.............................. 48
8.1 Inspection and maintenance intervals............... 48
8.1.1 General inspection and maintenance
instructions ............................................................... 49
8.1.2 Safety instructions.................................................. 49
8.1.3 Checking the CO2concentration.......................... 50
8.1.4 Adjusting the CO2 concentration
(or the air ratio).........................................................51
8.1.5 Inspection and maintenance work steps............52
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 compact thermal module............. 54
8.3 Cleaning the condensate trap.............................. 55
8.4 Cleaning strainer in cold water supply .............. 56
8.5 Checking filling pressure of the expansion
vessel of the combination boiler ......................... 56
8.6 Checking filling pressure of the expansion
vessel of the shift load storage tank...................57
8.7 Re-commissioning the combination boiler.........57
8.8 Test mode...................................................................57
9.1 Logical fault finding procedure............................ 58
9.1.1 Status codes ............................................................. 58
9.1.2 Diagnostic codes...................................................... 59
9.1.3 Error codes.................................................................62
9.1.4 Fault memory ............................................................62
9.2 Test programmes .................................................... 65
9.3 Resetting the parameters to factory settings . 65
10 Replacing components......................................... 65
10.1 Safety instructions.................................................. 65
10.2 Replacing the burner.............................................. 66
10.3 Replacing the fan or the gas valve.................... 66
10.4 Replacing the expansion vessel............................67
10.5 Replacing the primary heat exchanger ............. 68
10.6 Replacing the expansion vessel of the shift
load storage tank..................................................... 69
10.7 Replacing the storage tank pump of the shift
load storage tank..................................................... 69
10.8 Replacing the aqua sensor.................................... 70
10.9 Replacing the electronics on the shift load
storage tank................................................................71
10.10 Replacing the electronics and display on the
combi-heater...............................................................71
11 Recycling and disposal .........................................72
12 Vaillant service........................................................72
EC declaration of conformity ............................................73
4Installation and maintenance instructions ecoTEC plus 937 0020031552_06
1 Notes on the documentation
The following information is intended to help you
throughout the entire documentation.
Further documents apply in combination with this instal-
lation and maintenance manual.
We accept no liability for any damage caused by failure
to observe these instructions.
1.1 Documents also having validity
Always observe all installation instructions for struc-
tural parts and components of the system when
installing the ecoTEC plus 937. These installation
instructions are enclosed with the various system
components as well as additional components.
Also observe all the operating instructions included
with the system components.
1.2 Storing documents
Pass these installation instructions and all other
applicable documents and, if necessary, any required
aids to the system operator.
He will be responsible for storing them so that the
instructions and aids are available when required.
1.3 Symbols used
The symbols used in the manual are explained below:
aSymbol denoting danger
imminent danger to life
Risk of severe personal injury
Risk of slight personal injury
–
–
–
eSymbol denoting danger
Risk of death from electric shock–
bSymbol denoting danger
Risk of material damage
Risk of damage to the environment
–
–
iSymbol 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 following part number:
0010003809
The part number of the unit can be obtained from the
identification plate. The 7th to 16th digits of the serial
number form the article number.
1.5 Identification plates
The identification plate of the ecoTEC plus 937 is
located on the underside of the unit.
1.6 CE label
CE labelling shows that the appliances comply with the
basic requirements of the following directives:
Directive 2009/142/EEC of the Commission with
revisions
"Directive for Harmonisation of Legal Regulations of
the Member States for Gas Consumer UNits"
(Gas equipment directive)
Directive 92/42/EEC of the Commission with revi-
sions
"Directive Concerning the Efficiency of New Hot
Water Heating Boilers Fired by Liquid or Gaseous
Fuels“ (Efficiency directive)
Directive 2006/95/EEC of the Commission with
revisions
"Directive Concerning Electrical Operating Equipment
for Use Within Specific Voltage Limits“
(Low voltage directive)
Directive 2004/108/EEC of the Commission with
revisions
"Directive Concerning Electromagnetic Compatibility"
The units comply with the prototype described in the EU
Prototype Test Approval:
PIN-No. CE-0085BP0464
The units comply with the following standards:
EN 483
EN 625
EN 677
EN 50165
EN 55014
EN 60335-1
EN 60529
EN 61000-3-2
EN 61000-3-3
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1 Notes on the documentation
Installation and maintenance instructions ecoTEC plus 937 0020031552_06 5
1.7 Benchmark
iVaillant Ltd. supports the Benchmark Initia-
tive. You will find the Benchmark Logbook on
the last page of this instruction manual. It is
very important that this document be filled
out properly when installing, commissioning
and handing-over to the owner of the installa-
tion.
1.8 Gas Council Number
Appliance Gas council Number
ecoTEC plus 937 47-044-39
Table 1.1 Gas Council Number
2 Unit description, data and
dimensions
2.1 General notes
The ecoTEC plus 937 is designed for use in a closed cen-
tral heating system and is comprehensively tested in the
factory. The ecoTEC plus 937 is supplied fitted with a
circulation pump, 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 horizon-
tal RSF (room sealed fan assisted flue).
The combination boilers operate with a standard flue
gas system (outside diameter 100 or 125 mm). To
increase the flexibility of the system, extensions and
additional right-angle and leg extensions are available. If
required, an inhibitor can be used in the system. Instruc-
tions for the use of these inhibitors can be found in
their instructions.
All combination boilers are equipped with an internal
diagnostic system which provides information concern-
ing the operating status of the combination boiler. This
diagnostic system provides important information to
support commissioning and troubleshooting.
Notes on the documentation 1
Unit description, data and dimensions 2
6Installation and maintenance instructions ecoTEC plus 937 0020031552_06
2.2 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
12.0 - 28.0
12.3 - 28.9
12.7 - 29.7
12.9 - 30.3
kW
kW
kW
kW
Maximum output DHW 37 kW
Maximum heating output 28 kW
Minimum output 12 kW
Category II2H3P
SEDBUK Band A
SAP Seasonal Efficiency 91.5 %
Required gas flow pressure (G20, Natural Gas) 20 mbar
Required gas flow pressure (G31, Propane) 37 mbar
Connection value (if necessary referred to storage tank charging/hot water preparation)
at 15 °C and 1013 mbar G20: 4.0
G31: 2.94 G20: m3/h
G31: kg/h
Exhaust mass flow
at minimum thermal load (40 °C Feed/30 °C Return)
at maximum thermal load (80 °C Feed/60 °C Return) 5.7
17.1 g/s
g/s
Exhaust temperature
at minimum thermal load (40 °C Feed/30 °C Return)
at maximum thermal load (80 °C Feed/60 °C Return) 40
70 °C
°C
NOx class 5
Protection class IP X4D
Max. flow temperature 85 °C
Adjustable flow temperature (default setting: max. 75 °C) 30 - 85 °C
Permissible total excess 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
Specific throughflow in 10 min (T = 30 K) 204 l/10min
Permissible excess pressure water side 10 bar
Required connection pressure for max. throughflow quantity 1.3 bar
Required connection pressure for min. throughflow quantity 0.1 bar
Hot water temperature discharge 35 - 65 °C
Flue size (concentric) 60/100 mm
Flue approval category C13, C33, C43, C53, C83, B23, B33
Pre-pressure 10 l expansion vessel 0.75 bar
Connections for heating flow and return 22 mm
Gas connection 22 mm
Diameter of the drain line for the safety valve heating (min.) 15 mm
Diameter of the drain line for the safety valve hot water (min.) 15 mm
Condensate drain pipe (min. internal diameter drain) 19 mm
Dimensions (H x W x D) 720 x 440 x 597 mm
Primary water quantity 2.5 l
Supply voltage 230/50 V ~/Hz
Main PCB fuse (slow-blow) for main power supply 2 A
Electr. Power consumption 175 W
Standby power consumption 6.5 W
Layered storage tank capacity 15 l
Installation weight, just storage tank 17 kg
Installation weight, just combi unit 38 kg
Operating weight (with water) 62 kg
Table 2.1 Technical Data ecoTEC plus 937
2 Unit description, data and dimensions
Installation and maintenance instructions ecoTEC plus 937 0020031552_06 7
2.3 Dimensions
241
20
642
720
883
323
100100
440
35 35
130
180
175
273
243
566
598
8
6
4
3
2
1
5
7
9
12345
10
11
12
Fig. 2.1 Dimensions ecoTEC plus 937
Legend:
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 15 mm
5 Heating flow pipe, Ø 22 mm
6 Hanging bracket
7 Flue hole - flue system 60/100
8 Flue hole - flue system 80/125
9 Flue duct connection
10 Connection for condensate drain pipe, Ø 19 mm
11 Heating system pressure relief valve connection, 15 mm
12 Layered storage tank pressure relief connection (flexible hose
supplied)
Unit description, data and dimensions 2
8Installation and maintenance instructions ecoTEC plus 937 0020031552_06
241
20
642
720
883
100100
440
35 35
175
6
4
3
2
1
5
130 180 198
12345
7
8
Fig. 2.2 Dimensions shift load storage tank
Legend:
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 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
2 Unit description, data and dimensions
Installation and maintenance instructions ecoTEC plus 937 0020031552_06 9
2.4 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 modulating
storage tank charging pump.
The combi unit supplies the shift load storage tank with
electrical energy for the storage tank 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 Diverter valve with built in automatic adjustable bypass
7 pump
8 Electronics box
9 Hot water heat exchanger
10 Gas valve
11 Pressure sensor
12 Heat exchanger
13 Connection flue duct
–
–
1
2
3
4
5
Fig. 2.4 Function elements shift load storage tank
Legend:
1 Shift load storage tank expansion vessel
2 Aqua-Sensor
3 Storage charging pump
4 NTC temperature sensor - hot water outlet
5 Storage tank pressure relief valve
Unit description, data and dimensions 2
10 Installation and maintenance instructions ecoTEC plus 937 0020031552_06
2.5 Functional description
1
2
3
4
14
13
12
6
7
8
9
11
10
16
17
15
20
19
18 5
cb
a
21
Fig. 2.5 Sequence diagram
Legend:
1 Exhaust gas
2 Heat exchanger
3 Combustion chamber
4 Condensate siphon
5 Expansion vessel
6 Operating display
7 Secondary 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 pump
17 Aqua-Sensor
18 Stainless steel storage tank
19 Storage tank insulation
20 Expansion vessel
21 opt. accessory 0020057235 for integrating a circulation pump
NTC sensors shift load storage tank
a Storage tank sensor
b Infeed sensor SWT
c Storage tank charging sensor
2 Unit description, data and dimensions
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