Vailant ecoTEC plus 937 User manual

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
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eSymbol denoting danger
Risk of death from electric shock–
bSymbol denoting danger
Risk of material damage
Risk of damage to the environment
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iSymbol denoting additional useful tips and
information
>Symbol for a required task
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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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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
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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
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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
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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
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4
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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

Installation and maintenance instructions ecoTEC plus 937 0020031552_06 11
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 fed to
the heat insulated storage tank by means of a modulat-
ing storage tank charging pump.
The provision of hot water takes place directly from the
combi boiler without the need for a copper cylinder, a
cold water tank or a supply and expansion vessel with
the corresponding pipework. The provision of hot water
has priority over the central heating.
The combi unit supplies the shift load storage tank with
electrical energy for the storage tank charging pump.
The combi unit is equipped with a warm start function
which keeps the heat exchanger hot so that hot water is
immediately available.
The temperature in the hot water heat exchanger is lim-
ited by the control system.
Fitting a water softener on the mains cold water inlet of
the combi boiler is not necessary. In regions with
extremely hard water (greater than 300 mg/l of CaCO3)
however a water softener may still be fitted in order to
prevent the formation of scale build up in the water
pipes.
The heating 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 kit.
3 Safety
3.1 Safety and warning information
When conducting installation and maintenance work,
observe the general safety instructions and the warning
notes that appear before each of the actions.
3.1.1 Classification of warnings
The following warning signs and signal words are used
to classify the warning notices in accordance with the
severity of the possible danger:
Warning sign Signal
word Explanation
aDanger! Immediate danger to life or risk
of severe
personal injury
eDanger! Risk of death from
electric shock
aWarning! Risk of slight personal injury
bCaution! Risk of material or environmental
damage
3.1.2 Structure of warnings
Warning signs are identified by an upper and lower sep-
arating line. They are laid out according to the following
basic principle:
aSignal word!
Type and source of danger.
Explanation of the type and source of danger.
Measures for averting the danger
3.2 Intended use
The ecoTEC plus 937 is a state-of-the-art appliance
which has been constructed in accordance with recog-
nised safety regulations. Nevertheless, there is still a
risk of injury or death to the user or others or of dam-
age to the equipment and other property in the event of
improper use or use for which they are not intended.
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Unit description, data and dimensions 2
Safety 3

12 Installation and maintenance instructions ecoTEC plus 937 0020031552_06
The unit is not intended for use by persons (including
children) with reduced physical, sensory or mental capa-
bilities, or lack of experience and/or knowledge, unless
they have been given supervision or instruction con-
cerning use of the unit by a person responsible for their
safety.
Children must be watched to ensure that they do not
play with the unit.
The appliance is designed to generate heat for closed
hot water central heating systems and for instantane-
ous hot water supply.
The use of the ecoTEC plus 937 in vehicles, such as
mobile homes and caravans, is not classed as intended
use. Units that are not classed as vehicles are those that
are installed in a fixed and permanent location and that
do not have any wheels (fixed installation).
Any other use, or use beyond that specified, shall be
considered improper use. Any direct commercial or
industrial use is also deemed as improper. The manufac-
turer/supplier is not liable for any damage resulting
from improper use. The user alone bears this risk.
Intended use includes the observance of the operating
and installation manual and the adherence to the
inspection and maintenance conditions.
Any improper use is forbidden.
3.3 General safety instructions
European installation directive
Installation and maintenance of the appliance should
only be undertaken by a competent person approved at
the time by the Health and Safety executive and in
accordance with the gas safety (installation and use)
regulations 1998. The existing regulations, rules and
guidelines must be observed when doing so. He is also
responsible for inspection, maintenance and repairs to
the unit, as well as alterations to the gas volume setting.
Only IE: The installation must comply with the current
Version of I.S.813 "Domestic Gas Installations" and the
current Building Regulations.
The current ETCI Regulations for installing electrical
equipment must also be observed.
What to do in an emergency if you smell gas
A malfunction may mean that there is a smell of gas and
it may lead to a risk of poisoning or explosion. If there is
a smell of gas in the building, proceed as follows:
Avoid rooms that smell of gas.
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 or other communication systems in the
building.
Close the gas meter isolator device or the main isola-
tor device.
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If possible, close the gas stop cock on the unit.
Warn other occupants in the building by knocking or
calling.
Leave the building.
If you can actually hear gas leaking, leave the build-
ing immediately and ensure that no third parties
enter the building.
Alert the police and fire brigade when you are outside
the building.
Use a telephone outside the building to inform the
emergency service department of the gas supply
company.
What to do in an emergency if you smell exhaust
fumes
A malfunction may mean that there is a smell of exhaust
fumes and may lead to a risk of poisoning. If there is a
smell of exhaust fumes in the building, proceed as fol-
lows:
Open doors and windows fully and ensure air is circu-
lating.
Switch off the gas-fired wall-hung boiler.
Changes to the surroundings of the heating device
Changes may not be made to the following equipment:
the heating appliance
the gas, water and power supply pipes/cables
the exhaust gas delivery pipe
the structural conditions that may influence the oper-
ating safety of the appliance, especially supply air
openings.
Personal injury and/or material damage caused by
improper use and/or unsuitable tools
Improper use and/or unsuitable tools may result in dam-
age (e.g. gas or water leaks).
Always use a suitable open-ended spanner to tighten
or undo threaded connections.
Do not use pipe wrenches, extensions, etc.
Important instructions for propane appliances
Bleeding the liquid gas tank when installing the system:
System:
Before installing the device, make sure that the gas
tank has been bled.
The liquid gas supplier is responsible for ensuring that
the tank is bled properly. If the tank is not bled properly,
this may result in Ignition problems.
In such cases, first contact the person in charge of
filling the tank.
Affixing the tank sticker
Affix the enclosed tank sticker (propane quality) on
the tank where it is clearly visible or on the bottle
cabinet, as close to the filler nozzle as possible.
Avoid ignition and combustion noise as well as fault
shutdowns caused by incorrect gas types.
Only use propane gas in accordance with DIN 51622.
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3 Safety

Installation and maintenance instructions ecoTEC plus 937 0020031552_06 13
Preliminary remarks for room sealed appliances
This appliance should only be installed in conjunction
with either a Vaillant flue system or an alternative
approved system (details of flue approval categories
can be found in the technical section of the installation
manual).
Install the flue system as detailed in the separate flue
installation instructions supplied with this boiler.
3.4 General requirements
3.4.1 Preliminary remarks
This appliance must only be installed and commissioned
by a competent person approved at the time by the
Health and Safety Executive. Please check with your
installer that he is able to carry-out all the necessary
works including official notification of the works to the
relevant body upon completion.
3.4.2 Related documents
The installation of the appliance and any associated hot
water system must be in accordance with (but not lim-
ited to) the following; COSHH regulations, Gas Safety
(Installation and Use) Regulations 1998, Health and
Safety Document No. 635 (The Electricity at Work Regu-
lations 1989), BS7671 (IEE Wiring Regulations) and the
Water Supply (Water Fitting) Regulations 1999, or The
Water Bylaws 2000 (Scotland). It should also be in
accordance with the relevant requirements of the Local
Authority, Building Regulations, The Building Regula-
tions (Scotland), The Building Regulations (Northern Ire-
land) and the relevant recommendations of the follow-
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 6891: Specification for installation of low pressure
gas pipework up to 28 mm (R1) in domestic premises
(2nd family gas).
BS 7593: Treatment of water in domestic hot water
central heating systems.
Institute of Gas Engineers Publication IGE/UP/7/1998:
”Guide for gas installations in timber framed housing”
BS. 5482 Pt. 1 Domestic butane and propane gas burn-
ing installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2 Gas installation pipework, boosters and com-
pressors on industrial and commercial premises.
IGE/UP10 Installation of gas appliances in industrial and
commercial premises.
BS. 6644: Installation of gas fired hot water boilers of
rated inputs between 60 kW and 2 MW (2nd and 3rd
family gases).
>
BS. 5449: Forced circulation hot water central heating
systems for domestic premises. Note: only up to 45 kW.
BS. 6880: Low temperature hot water heating systems
of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS. 4814: Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water heating sys-
tems.
BS. 5440: Installation and maintenance of flues and
ventilation for gas appliances of rated input not exceed-
ing 70 kW net (1st, 2nd and 3rd family gases).
Part 1 Specification for installation of flues.
Part 2 Specification for installation and maintenance
of ventilation for gas appliances.
Safety 3

14 Installation and maintenance instructions ecoTEC plus 937 0020031552_06
4 General requirements
4.1 Scope of supply and accessories
1 1
10
9
8
7
65
4
3
2
1
Fig. 4.1 Scope of supply and accessories
The shift load storage tank and the combi boiler are
delivered pre-assembled in one packaging unit.
Check that all parts have been delivered undamaged
(see Fig. 4.1 and Table 4.1 ).
iAt this stage do not yet remove the combi
boiler and the shift load storage tank from
the expanded polystyrene base to prevent any
damage.
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
56 Connecting pipes (gas, heating, water, safety
valve)
65
Adapter set, consisting of connecting pipes
between the shift load storage tank and the
combi boiler for gas, heating flow and return and
water flow and return
7 2 Installation and connection accessories:
83 User, installation and service, flue installation
manuals
9 1 Bottom cover for shift load storage tank
10 1 Shift load storage tank
11 1 Hanging bracket
Table 4.1 Scope of supply and accessories
4.2 Installation location
When selecting the installation location observe the
regulations and recommendations 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
must be sufficient space for maintenance work and air
circulation around the combi boiler and the shift load
storage tank.
The Combi boiler and shift load storage tank can be
mounted together in any room you wish to choose.
In rooms with a bath or a shower, the special require-
ments of BS 7671 (IEE Regulations), the electro-techni-
cal stipulations of the Building Standards (Scotland)
Regulations and, in IE, the current issue of IS 813 and
the current ETCI Stipulations must especially be
observed.
eDanger!
Risk of electrocution when installing an
appliance that depends on room air in a
room with a bath or shower.
If electric switches and controls are installed
too close to a bath or shower, there is a risk
of electric shock for the person using the
facility.
Install electric switches and controls that
are operated via mains voltage out of
reach of the bath or shower.
In the event of installation in unusual locations, special
provisions may have to be made. Detailed instructions
for this can be found in BS 5546 and in BS 6798.
The ecoTEC plus 937 must be mounted on a flat, verti-
cal wall which is sufficiently strong to hold the weight of
the shift load storage tank and the combi boiler.
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4 General requirements

Installation and maintenance instructions ecoTEC plus 937 0020031552_06 15
It is possible to mount onto a wall made of flammable
material if the regulations of the Local Authority and
the legal building regulations are fulfilled. In this case
however, the unit would have to be mounted in a spe-
cially made enclosure. (You can also use an existing
cabinet or existing enclosure as long as it can be modi-
fied accordingly to suit the new application.) Further
details concerning the fundamental characteristics when
modifying existing cabinets or enclosures, including the
requirements for ventilation, are described in BS 6798.
iIf the boiler is to be installed in a half-tim-
bered house, the installation must be under-
taken in accordance with the Institute of Gas
Engineers Publication IG/UP/7 Edition 2 „Gas
installations in timber framed and light steel
framed buildings“.
iIf the boiler is to be installed in an airing
cupboard it is not required to separate the
boiler with a non-combustible partition. How-
ever installation and servicing clearances
must be maintained, and the appliance kept
clear of any clothing.
Please note the following instructions before choos-
ing where to install the boiler:
bCaution!
Possible material damage due to an unsuit-
able installation location.
The appliance may be damaged by frost,
aggressive vapours or dust.
Do not install the appliance in rooms that
are susceptible to frost.
Do not operate the appliance in rooms with
aggressive vapours or dust unless it is
operated in way that does not depend on
the room air.
Make sure that, when selecting the installation location
and when operating the unit, the combustion air is free
from chemical substances which contain fluorine, chlo-
rine, sulphur etc. Sprays, solvents and cleaning agents,
paints, adhesives etc.can contain 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 finishing, cleaning facilities, the appliance must be
operated independent of the ambient air! Otherwise, a
separate installation room is required to guarantee that
the combustion air supply is free from the afore men-
tioned substances.
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4.3 Gas supply
The gas provider must guarantee the availability of an
adequate gas supply. The connection of a gas meter in
the supply line is only permitted when carried out by the
gas provider and a company appointed by him.
If there is an existing gas meter you must check that it
is suitable for the required gas flow rate.
Installation pipes should be fitted in accordance with
BS 6891. In IE in accordance with the current issue of
IS 813. The pipework between the gas meter and the
combi boiler must be of an appropriate size. Do not use
any pipes that are smaller than the connection to the
combi boiler (22 mm). The entire installation must be
checked for leaks and purged in accordance with
BS 6891.
4.4 Flue pipe
aDanger!
Risk of personal injury and material dam-
age as a result of malfunctions.
Malfunctions may be caused by using acces-
sories that are not specified in the Vaillant
installation manual for air/exhaust ducts.
Only use genuine Vaillant air/exhaust
ducts.
Vaillant appliances are only system-certified if genuine
Vaillant air/exhaust ducts are used.
The CE mark is only valid if the appliance is operated
with Vaillant air/exhaust ducts.
4.4.1 100 mm standard flue duct
667 87 65
30
74
48
Fig. 4.2 Item No. 303 933
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.
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General requirements 4

16 Installation and maintenance instructions ecoTEC plus 937 0020031552_06
84
1456
542
901
Fig. 4.3 Item No. 0020060570, 0020060571 and
0020065937 (60/100)
4.4.2 Optional 125 mm flue pipe
A concentric flue pipe having an outside diameter of
125 mm is available, which can be extended to a length
of up to 21 m.
You can also get a vertical system. Further information
can be obtained from the installation instructions for
the flue pipe.
70
1103
70
15
Fig. 4.4 Item No. 303 209
1530
880 650
70
Fig. 4.5 Item No. 303 200 (80/125)
4.5 Flue termination
The following information applies to both flue pipe
systems.
a) The 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
could be a nuisance should be avoided.
c) If the terminal is less than 2 m above a balcony,
the ground or a flat roof that is accessible by
persons, a suitable terminal guard should be fit-
ted (manufactured by Tower Flue Components,
Tonbridge, TN9 1TB, Model K3, plastic-coated).
A
BCD
A
G
H, I
FJ
BFM
L
L
K
K
G
G
FF
E
A
A
Fig. 4.6: Flue termination
iVertical flue pipes must not terminate within
600 mm of an opening window, air vent or
any other ventilation opening.
The flue pipe must be fitted, or shielded, in such a way
that ignition or damage to sections of the building are
avoided.
4 General requirements

Installation and maintenance instructions ecoTEC plus 937 0020031552_06 17
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 vertical drainpipes and down-pipes 25
F From external and internal corners 300
G Above the ground, a roof or a balcony 300
H Opposite another surface 600
I Opposite another termination 1200
J Next to an opening (e.g. a door, window) within a
car-port 1200
K Vertically away from a junction on the same wall 1500
L Horizontally away from a junction on the same wall 300
M Distance away from an adjoining vertical flue pipe 500
Table 4.2 Position of the terminal in a fan-assisted concentric
flue
iIn addition, the terminal should not be located
closer than 150 mm from an opening in the fab-
ric of the building formed for the purpose of
accommodating a built-in element such as a
window.
BS 5440–1: We recommend that the terminal of a
fan-assisted flue system be positioned as follows:
a) At least 2 m from an opening in the building
directly opposite, and
b) so that products of combustion are not directed
to discharge across a boundary.
1) Dimensions B, C and D:
These dimensions can be reduced to 25 mm
without having a negative effect on the per-
formance of the boiler. In order to ensure that
condensate plume does not affect adjacent sur-
faces the terminal 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 the condensate plume doe not affect adja-
cent surfaces a clearance of 300mm is pre-
ferred. For IE, recommendations are given in
the current edition of IS813.
Fig. 4.7 Flue termination under balcony/eaves
4.6 Air supply
Detailed recommendations for air supply are given in
BS 5440, Part 2.
It is not necessary to have an air vent in the room or
internal space in which the boiler is installed.
Ventilating a cabinet or enclosure
This appliance is highly efficient. As a consequence the
heat loss from the casing is very small. For cupboard or
compartment installations it is not necessary to provide
any high or low permanent air vents for cooling or ven-
tilation purposes.
4.7 Electrical connection
eDanger!
Risk of death from electric shock.
If the appliance is not earthed, it may hold
voltage if a defect occurs.
Earth the appliance.
In accordance with BS 7671 (IEE Wiring Regulations) and
any other local regulations which may apply, a 3 A
fused single phase AC supply (230 V, 50 Hz) must be
provided. In IE the current issue of the ETCI regulations
must be observed. The method of connection to the
mains electricity supply must provide a means of
completely isolating the boiler and ancillary controls.
Isolation is preferably by the use of a fused three pin
plug and unswitched shuttered socket outlet, both com-
plying with the requirements of BS 1363. Alternatively, a
3 A fused double pole switch with 3 mm contact separa-
tion on both poles may be used.
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General requirements 4

18 Installation and maintenance instructions ecoTEC plus 937 0020031552_06
4.8 System requirements
4.8.1 Water circulation system
Detailed recommendations concerning the water circu-
lation system can be taken from BS 6798 and BS 5449,
Part 1 (for "Small Bore” and "Micro Bore” central heat-
ing systems). Pipework which does not form part of the
usable heating surface should be insulated to prevent
heat losses and possible freezing up, especially where
the pipes run through roof spaces and ventilated under-
floor spaces. The drain connections must be located in
easily-accessible locations, so that draining the entire
system including the combi boiler and the hot water sys-
tem is possible. The drain connections should be at least
1/2 " (BSP nominal size) and must be in accordance with
BS 2879.
The combi boiler is suitable for Minibore and Microbore
Systems. Copper tubing in accordance with BS 2871
should be used for all water carrying pipework. All capil-
lary joints in all Domestic Hot Water (DHW) pipework
must be made with lead free solder. When a new boiler
is to be fitted to an existing system, it is good practise
that the system is thoroughly flushed before the boiler
if installed in the system. See BS 7593 for full details.
bCaution!
Risk of equipment and system damage
caused by improper use of cleaning agents.
If you do not use cleaning agents in accord-
ance with the manufacturer's instructions or
if you leave the cleaning agents in the system
for too long, this may lead to deposits and
severe damage to your appliance and system.
Observe the instructions provided by the
manufacturer of the cleaning agent.
Leave cleaning agents in the system for no
longer than 24 hours.
Then flush the system thoroughly.
The cleaning must take place before fitting a new boiler
and in accordance with BS 7593. Recommendations for
use of system cleaning agents can be obtained from
Sentinel, Betz Dearborn Ltd. Widnes, Cheshire, WA8
8UD, Tel. [phone], or Fernox, Alpha Fry Technolo-
gies, Tandem House, Marlow Way, Croydon, CR0 4XS,
Tel. [phone].
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>
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4.8.2 Filling and preparation of the heating system
bCaution!
The use of unsuitable heating water may
cause aluminium corrosion and therefore
lead to leaks.
In contrast to steel, grey cast iron or copper,
for example, aluminium reacts with alkaline
heating water (pH value > 8.5) to produce
substantial corrosion.
When using aluminium, make sure that the
pH value of the heating water is between
6.5 and a maximum of 8.5.
bCaution!
Risk of material damage if the heating
water is treated with unsuitable frost or
corrosion protection agents.
Frost and corrosion protection agents may
cause changes in the seals, noises during
heating and may lead to subsequent damage.
Do not use any unsuitable frost or corro-
sion protection agents.
The system can be filled using the incorporated filling
device. This connection must be removed again after
the filling process is complete. If the local Water Author-
ity regulations do not allow temporary connection a
sealed system filler pump with break tank must be used.
The heating system will not be filled automatically from
the domestic hot water side. (Alternative methods of
filling sealed systems are given in BS 5449)
Mixing additives with the heating water can result in
material damage. However, up to now, no incompatibil-
ity with Vaillant appliances has been detected with
proper use of the following products.
When using additives, follow the additive manufactur-
er‘s instructions without exception.
Vaillant accepts no liability for the compatibility of any
additive or its effectiveness in the entire heating sys-
tem.
Additives for cleaning purposes
(subsequent flushing required)
Fernox F3
Jenaqua 200
Jenaqua 300
Jenaqua 400
Sentinel X 300
Sentinel X 400
Additives intended to remain permanently in the sys-
tem
Fernox F1
Fernox F2
Jenaqua 100
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–
–
–
–
–
–
–
–
–
4 General requirements

Installation and maintenance instructions ecoTEC plus 937 0020031552_06 19
Jenaqua 110
Sentinel X 100
Sentinel X 200
Additives for frost protection intended to remain per-
manently in the system
Fernox Antifreeze Alphi 11
Sentinel X 500
Inform the operator of the necessary measures in
case you have used any of these additives.
Inform the operator of the required procedures for
frost protection.
Observe the applicable national regulations and tech-
nical standards for the treatment of filling and top-up
water.
Provided the national regulations and technical stand-
ards do not specify any higher requirements, the follow-
ing applies:
You must treat the heating water
if the total volume of filling and top-up water
exceeds thrice the nominal volume of the heating
system over the service life of the system
or
if the limits given in the following tables are not
adhered to.
Total heating
output Total hardness for the smallest boiler heating surface2)
at 20 l/kW > 20 l/kW
< 50 l/kW > 50 l/kW
kW mol/m3mol/m3mol/m3
50 No requirement or
31) 2 0,02
50 to 200 2 1,5 0,02
200 to 600 1,5 0,02 0,02
600 0,02 0,02 0,02
1) with systems equipped with wall-hung boiler and systems with
electric heating elements
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 the system volume for filling
and top-up water. Once this triple system volume is exceeded,
the water will have to be treated exactly the same as in case
of exceeding the limit values given in table 4.4 (softening,
desalination, hardness stabilisation and desludging).
Table 4.3 Guidelines for the heating water: Water hardness
–
–
–
–
–
>
>
>
>
–
–
Heating water
qualities Unit Low-salt saline
Electric conductivity
at 25 °C S/cm 100 100-1500
Appearance Free of sedimentary substances
pH-value at 25 °C 8,2-10,01) 8,2-10,01)
Oxygen mg/L 0,1 0,02
1) With aluminium and aluminium alloys, the ph value range is
restricted from 6.5 to 8.5.
Table 4.4 Guidelines for heating water: Salinity
4.8.3 Pressure relief valve
The boiler is equipped with a pressure relief valve. This
safety device is required for all sealed central heating
systems, is preset to 3 bar and is fitted with a 15 mm
compression connection for the discharge pipe, whose
diameter must not be less than 15 mm. The pressure
relief valve must not be used for draining purposes.
4.8.4 Pressure gauge
The pressure gauge is fitted to the boiler in the factory
and indicates the pressure of the primary circuit, to
make filling and testing easier.
General requirements 4

20 Installation and maintenance instructions ecoTEC plus 937 0020031552_06
4.8.5 Heating circuit expansion vessel
The boiler of the ecoTEC series are equipped with a
10 litre expansion vessel which is suitable for a sealed
heating
system with a maximum water volume of 100 litres.
If the nominal capacity of the boiler expansion vessel is
not adequate for the heating system (e.g. when modern-
ising old open systems) an additional expansion vessel
can be fitted outside the boiler. The pressure gauge
must be fitted in the return pipe, in accordance with
BS 5449: Part 1, as close as possible to the boiler.
In Table 4.5 you will find an overview of the required
size of an additional expansion vessel.
Vessel volume
(in l)
Initial system pressure (in bar) 1.0 1.5
Setting of the excess pressure valve (in
bar) 3.0
Total water volume of the system (in l)
25 2.7 3.9
50 5.4 7.8
100 10.9 15.6
125 13.6 19.5
150 16.3 23.4
175 19.1 27.3
200 21.8 31.2
225 24.5 35.1
250 27.2 39.0
275 30.0 42.9
300 32.7 46.8
325 35.7 50.7
350 38.1 54.6
375 40.9 58.5
400 43.6 62.4
425 46.3 66.3
450 49.0 70.2
475 51.8 74.1
500 54.5 78.0
With other system volumes than shown above,
multiply the volume 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 vessel.
4.9 Details for the pumps
4.9.1 Circulation pump
The circulation pump is integrated in the combi boiler.
The remaining head of the pump with respect to the
bypass valve is shown in Fig. 4.8.
The operating mode of the 2-speed pump can be
adjusted using diagnostic number d.19, see Section 9.1.2.
400
300
200
100
0
0 200 400 600 800 1000 1200 1600
Lift [mbar]
Volumeflow [l/h]
18001400
2. Step1. Step
2000
Fig. 4.8 Technical data of the pump in the combi boiler
4.9.2 Shift load storage tank circulation pump
The shift load storage tank is equipped with a mainte-
nance-free charging pump.
4.10 System-Bypass
The boiler is fitted with an automatic system by-pass.
The installation can be used in systems with thermo-
static radiator valves without the need for an additional
by-pass. The by-pass valve is adjustable, see Section
6.8.
4.11 Venting
The boiler is fitted with an automatic air vent. Other
measures need to be taken to allow the heating system
to be either automatically or manually vented during
filling and during commissioning.
4.12 Condensate siphon
The boiler is fitted with a condensate siphon incorporat-
ing a water seal of 145 mm.
4 General requirements