Vaillant ecoMAX 665 Installation And Maintenance Manual
For the installer
Installation and maintenance manual
ecoMAX
Wall hung room sealed fan assisted condensing boiler
ecoMAX 665
GB
Contents
Information on the documentation ........................... 3
Other relevant documentation and service aids ........... 3
Service aids ............................................................................. 3
Attachment and storage of the documents ................... 3
Symbols used .......................................................................... 3
1 Description of the appliance ........................... 4
1.1 Design .......................................................................... 4
1.3 Data badge .................................................................. 5
1.4 CE mark ....................................................................... 5
1.5 Intended use ............................................................... 5
1.6 Declaration of conformity ....................................... 6
2 Safety instructions and regulations .............. 7
2.1 Safety instructions ................................................... 7
2.1.1 Installing and setting the appliance ..................... 7
2.1.2 Smell of gas ................................................................ 7
2.1.3 Changes to the surroundings of the boiler ........ 7
2.2 General requirements .............................................. 7
2.2.1 Preliminary remarks for roomsealed appliances 7
2.2.2 Related documents ................................................... 7
3 Mounting ............................................................ 8
3.1 Scope of delivery and accessories ....................... 8
3.2.1 Select position of boiler .......................................... 9
3.2.2 Unpack the boiler ...................................................... 9
3.2.3 Using boiler template ............................................... 9
3.4 Required minimum gaps/assembly clearances . 11
3.5 Mounting the appliance ........................................... 11
3.6 Removing/Attaching the appliance casing ......... 11
5.2.2 Gas inlet working pressure ..................................... 21
5.2.3 Checking the CO
needed (air ratio setting) ........................................ 22
5.3 Functional test ........................................................... 23
5.4 Instructing the user .................................................. 23
5.4.1 Instructing the user about the heating system . 24
5.4.2 Vaillant warranty ........................................................ 24
6 Adapting the appliance to the heating
system ................................................................ 25
6.1 Setting central heating output (range rating) ... 25
6.2 Setting the pump over-run time ........................... 26
6.3 Setting the burner anti-cycle time ....................... 26
6.4 Adapting the appliance to larger flue pipe
lengths ......................................................................... 26
7 Inspection and maintenance ........................... 27
7.1 Inspection and maintenance intervals ................. 27
7.2 Inspection and maintenance instructions ........... 27
7.2.1 Servicing the compact thermal module .............. 29
7.2.2 Clean the heat exchanger ...................................... 30
7.2.3 Cleaning the condensate paths and siphon ....... 30
7.2.4 Checking the burner ................................................. 30
7.3 Draining the appliance and the system ............... 31
7.3.1 Draining the appliance ............................................. 31
7.3.2 Draining the entire system ..................................... 31
7.3.3 Cleaning the air separator ...................................... 31
7.4 Filling and venting the system ............................... 31
7.5 Checking the gas rate check .................................. 31
7.6 Test operation............................................................ 31
content and adjusting it if
2
4 Installation ......................................................... 12
4.1 Preparing the installation ....................................... 12
4.2 Technical instructions for the heating system .. 12
4.2.1 Connection to heating system via a low loss
header .......................................................................... 12
4.3 Technical instructions for recharging ................. 13
4.4 Gas connection .......................................................... 13
4.5 Heating side connection .......................................... 13
4.6.1 Flue termination ........................................................ 14
4.6.2 Flue pipe ...................................................................... 14
4.7 Condensate discharge ............................................. 15
4.8 Electrical connection ................................................ 15
4.8.1 Mains connection ...................................................... 16
4.8.2 Connecting controllers ............................................ 16
4.8.3 Connecting accessories and external system
components ................................................................ 16
4.8.4 Connection diagram ................................................. 18
4.8.5 Wiring diagram .......................................................... 19
5 Putting the boiler into service ........................ 20
5.1 Water circulation system ........................................ 20
5.1.1 Treating the heating water..................................... 20
5.1.2 Heating side filling and bleeding ........................... 20
5.1.3 Final system flush (”Hot”) ...................................... 20
5.1.4 Filling the siphon ....................................................... 21
5.2 Checking the gas setting ......................................... 21
5.2.1 Factory gas setting ................................................... 21
8 Troubleshooting ................................................ 32
8.1 Diagnostics ................................................................. 32
8.1.1 Status codes ............................................................... 32
8.1.2 Diagnosis codes ......................................................... 33
8.1.3 Error codes ................................................................. 34
8.1.4 Error memory ............................................................ 34
8.1.5 Test programs ............................................................ 36
9 Vaillant Service ................................................. 36
10 Recycling and disposal ..................................... 36
10.1 Appliance ..................................................................... 36
10.2 Packaging .................................................................... 36
11 Technical data ................................................... 37
Benchmark gas boiler commissioning checklist .... 38
2 Installation and maintenance manual ecoMAX 665 / 0020020159_03
Information on the documentation
The following information is intended to guide you through
the entire documentation.
Further documents apply in combination with this installation and maintenance manual.
We accept no liability for any damage caused by not
following these instructions.
Other relevant documentation and service aids
For the owner of the system
1 brief operating instructions no. 00 20 00 64 61
1 operating manual no. 00 20 01 46 08
For the installer
1 installation instructions
flue accessories no. 00 20 01 46 06
1 sticker with name of appliance no. 83 42 24
1 installation instructions for siphon no. 83 53 11
1 checklist for start-up no. 00 20 02 01 61
1 installation template no. 17 90 73
1 safety sticker no. 83 55 93
Information on the documentation
Service aids
The following test and measuring equipment is required
for inspection and maintenance:
– Flue gas analyser
– manometer (u gauge)
– auxiliary tool for gas fitting (comes with appliance)
Attachment and storage of the documents
Please pass on this installation and maintenance manual
as well as the aids to the owner of the system, whose
responsibility it is to ensure that the manuals and auxiliary equipment are available whenever required.
Symbols used
Please observe the safety instructions in this installation
manual when installing the appliance!
Danger!
d
Immediate risk of serious injury or death.
Caution!
a
Potentially dangerous situations for the product
and environment.
Note!
h
Useful information and instructions.
• Symbol for a necessary task
3Installation and maintenance manual ecoMAX 665 / 0020020159_03
1 Description of the appliance
1 Description of the appliance
1.1 Design
13
1
2
3
4
12
11
10
9
Fig. 1.1 Function elements
5
6
7
8
1 Connection to flue pipe 80/125
2 Primary heat exchanger
3 Air intake pipe
4 Compact thermal module with burner, flange,
mixing tube, fan and electronic gas valve
5 Ignition electrode
6 Pump
4 Installation and maintenance manual ecoMAX 665 / 0020020159_03
7 Drain valve point
8 Electronics box
9 Water pressure switch
10 Discharge for supply
11 Electronic gas valve
12 Air separator with strainer
13 Water flow switch
Description of the appliance 1
Appliance type Country of destination
(designations
according to ISO 3166)
ecoMAX 665 GB (Great Britain)
IE (Eire)
License
category
I
2H
1.3 Data badge
The data badge of the Valliant ecoMAX 665 is attached
at the factory to the bottom of the appliance.
Type of gas Nominal heat output
range P (kW)
Natural gas H - G
20 - 20 mbar
15.0 - 69.6 (40/30 °C)
13.7 - 63.7 (80/60 °C)
Storage charging output
(kW)
65.0
1.5 Intended use
The Vaillant ecoMAX 665 is a state-of-the-art appliance
which has been constructed in accordance with recognised technical safety regulations. Nevertheless, danger
to the life and limb of the user or third parties can still
occur or the appliance or other material assets be damaged when using it.
The appliance is designed to be used as a boiler for
closed hot water central heating systems. Any other
use or extended use is considered to be improper. The
manufacturer/supplier is not liable for any resulting
damage. The user alone bears the risk.
Appropriate use includes the observance of the operating and installation manual and the adherence to the inspection and maintenance conditions.
Fig. 1.2 Data badge (example)
1.4 CE mark
CE marking is used to document the fact that the appliances, in accordance with the type summary, meet the
basic requirements of the directive on appliances burning gaseous fuels (Council Directive 90/396/EEC) and
the EC directive on electromagnetic compatibility
(Council Directive 89/336/EEC).
The appliances meet the basic requirements of the efficiency requirements directive (Council Directive 92/42/EEC)
as condensing appliances.
The appliances named above emit less than 80 mg/kWh
nitrogen dioxide (NOx) when natural gas is used.
5Installation and maintenance manual ecoMAX 665 / 0020020159_03
1 Description of the appliance
1.6 Declaration of conformity
6 Installation and maintenance manual ecoMAX 665 / 0020020159_03
Safety instructions and regulations 2
2 Safety instructions and regulations
2.1 Safety instructions
2.1.1 Installing and setting the appliance
Important!
The appliance must be installed and serviced by
a competent person as stated in the Gas Safety
(Installation and Use) Regulations 1998. In IE,
the installation must be in accordance with the
current edition of IS 813 ‚Domestic Gas Installations‘, the current Building Regulations and
reference should be made to the current ETCI
rules for electrical installation.
2.1.2 Smell of gas
If you smell gas, the following safety instructions should
be observed:
• don‘t switch on any electrical switch in the danger area
• don‘t smoke in the danger area
• don‘t use a telephone in the danger area
• close the gas stop cock
• air the danger area
• Contact your gas supplier or national Grid Transco
0800 111999
2.1.3 Changes to the surroundings of the boiler
No changes must be made to the following:
– the boiler
– the gas, air, water and electricity supply pipes
– the flue system
– the discharge pipe and the safety valve for the hot water
– the constructional conditions that could affect the op-
erational reliability of the appliance.
Important!
a
When tightening or slackening screwed connections always use suitable open-ended spanners
(not pipe wrenches or extensions etc.). Incorrect use and/or unsuitable tools can lead to
damage being caused (e.g. gas or water leakage)!
2.2 General requirements
2.2.1 Preliminary remarks for roomsealed 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.
2.2.2 Related documents
The installation of the boiler must be in accordance with
the relevant requirements of Gas Safety (Installation
and Use) Regulations 1998, Health and Safety Document
No. 635 (The Electricity at Work Regulations 1989), BS
7671 (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 Regulations (Scotland). The
Building Regulations (Northern Ireland) and the relevant
recommendations of the following British Stan-dards:
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/UP7 Edition 2
BS. 5482 Pt. 1 Domestic butane and propane gas bur-
ning 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.
IG/UP/7 Edition 2 "Gas installations in timber framed
and light steel framed buildings"
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 systems.
BS. 5440 Installation and maintenance of flues and ventila-
tion for gas appliances of rated input not exceeding 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.
Important!
a
When tightening or loosening screwed connections always use suitable open-ended spanners
(not pipe wrenches or extensions etc.). Incorrect
use and/or unsuitable tools can lead to damage
being caused (e.g. gas or water leakage)! Preliminary remarks: This appliance should only be
installed in conjunction with a Vaillant flue system. Install the flue system as detailed in the
separate flue installation instructions supplied
with this boiler.
7Installation and maintenance manual ecoMAX 665 / 0020020159_03
2 Safety instructions and regulations
3 Mounting
Boiler location
The location chosen for the boiler must permit the provision of a satisfactory flue termination. The location
must also provide adequate space for servicing and air
circulation around the boiler. The boiler may be installed
in any room, although particular attention is drawn to
the requirements of BS7671 (IEE Regulations), the electrical provisions of the Building Regulations (Scotland)
and in IE the current edition of IS 813 and the current
ETCI rules, in respect of the installation of a boiler in
a room containing a bath or shower.
Note!
h
Where a room sealed boiler is installed in a
room containing a bath or shower, any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be
touched by a person using the bath or shower.
Where the installation of the boiler will be in an unusual
location, special procedures may be necessary and
BS 5546 and BS 6798 give detailed guidance on this
aspect. The boiler must be mounted on a flat, vertical
wall, which must be sufficiently robust to take the
weight of the boiler. The boiler may be installed on a
combustible wall, subject to the requirements of the
Local Authorities and Building Regulations. A compartment used to enclose the boiler must be designed and
constructed specifically for this purpose. (An existing
cupboard or compartment may be used provided that
it is modified for the purpose).
Details of essential features of cupboard/compartment
design including airing cupboard installations are given
in BS 6891. In IE the current edition of IS 813.
Note!
h
If the boiler is to be installed in a timber framed
building, it should be fitted in accordance with
IGE/UP7 Edition 2 "Gas installations in timber
framed and light steel framed buildings".
Gas Supply
The gas supplier should ensure the availability of an
adequate supply of gas. A gas meter may only be connected to the service pipe by the supplier of gas or their
contractor. An existing meter should be checked to
ensure that it is capable of passing the rate of gas supply required. Installation pipes should be fitted in accordance with BS 6891. Pipework from the meter to the
boiler must be of an adequate size. Do not use pipes of
a smaller size than the boiler gas connection. The complete installation must be tested for soundness and
purged as described in BS 6891.
3 Mounting
The Vaillant ecoMAX 665 is delivered in a package unit.
3.1 Scope of delivery and accessories
Scope of delivery
Check that all the parts have been delivered intact (see
fig. 3.1 and table 3.1).
8
7
6
5
4
Fig. 3.1 Scope of delivery
Position Number Name
1
2
3
4
5
6
7
1
1
1
1
1
1
3
Hanging bracket
Boiler
Siphon
Condensate discharge hose
Bag with fixing screws, wall plugs and washers
Installation template
Manuals:
Operating manual
Installation instructions
Assembly manual for flue pipe
8
1
Auxiliary tool for gas valve adjustment
Table 3.1 Scope of delivery
e
co
T
E
C
3
1
a.
2
1
/
3
b
.
c
.
2
/
3
4
200
10
0
1_0
31
5
3
8
1
2
3
8 Installation and maintenance manual ecoMAX 665 / 0020020159_03
Mounting 3
3.2 Installation site
Please note the following safety instructions below before choosing where to install the appliance:
Caution!
a
Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance should be room sealed, to prevent
damage.
When choosing the place of installation and while operating the appliance, make sure that the combustion air is
technically free of chemical substances containing fluorine, chlorine, sulphur etc. Sprays, solvents and cleaning
agents, paints, adhesives etc. contain these kinds of
substances, which - in the worst case scenario - can lead
to corrosion, even in the exhaust system, during ambient
air dependent operating of the appliance.
The appliance must be operated independently of the
ambient air particularly in hairdressing salons, carpenter‘s shops or paint shops, cleaning companies.
Caution!
a
When the appliance is installed on an open flue
type system ventilation requirements shall be
taken from BS 6644 and IGE UP10. Design
consideration for the cooling of plant rooms
shall also be taken from BS 6644 and IGE UP10
Packed in the boiler carton are the following:
• Boiler
• Boiler installation template
• Boiler hanging bracket
• Fixing screws, wall plugs and washers
• Installation and user instructions
• Flue installation instructions
• Guarantee card and envelope
3.2.3 Using boiler template
Fix the paper template to the wall ensure that the
template is vertical.
The template shows:
– The position of the fixing holes for the boiler mount-
ing bracket.
– The position of the connections.
– The position of the flue exit hole.
• Mark the position of the hanging bracket fixing holes
• Drill 2 holes Ø 8 mm for the hanging bracket.
Note!
h
Use alternative fixing holes where necessary.
3.2.1 Select position of boiler
Refer to section ‘Boiler location’ for information regarding siting the appliance. In general the boiler must be
positioned such that:
• There is adequate space around the boiler for service
and maintenance
• The boiler can be correctly flued, i.e. the flue terminal
position is sited in accordance with these instructions
and the air/flue duct can be installed in accordance
with the flue installation instructions supplied.
• All necessary pipework can be connected, including
the pressure relief valve and condensate drain.
3.2.2 Unpack the boiler
To unpack the boiler, cut both plastic carton straps,
open box and lift out the polystyrene top packing. Lift
the cardbox upwards.
Note!
h
Care should be taken not to scratch the white
surface of the boiler casing.
9Installations- und Wartungsanleitung ecoMAX 665
3 Mounting
3.3 Dimensional drawing and connection dimensions
800
480
472
Ø 80/125
211
A
1
119
94
2
R3/4
23,2
7
6
Rp1 Rp1
R1
Ø2
5
87
172 172
Fig. 3.2 Connection dimensions
1 Flue connection Ø 80/125 mm
Dimension A with 87° elbow: 297 mm
2 Mounting bracket
3 Heating return
4 DHW primary return (only in conjunction with cylinder)
10 Installation and maintenance manual ecoMAX 665 / 0020020159_03
31
R1
87
4
3
61,5
8
5
66
121
5 Gas connection
6 DHW primary flow (only in conjunction with cylinder)
7 Heating flow
8 Siphon connection
9 Connection safety valve 3/4”
9
Mounting 3
3.4 Required minimum gaps/assembly clearances
Both for the installation/assembly of the appliance and
for carrying out maintenance tasks later, you need the
minimum gaps and assembly clearances given below:
,''
, ,
+''
Fig. 3.3 Required minimum gaps/assembly clearances (mm)
Note!
h
It is very important that you keep the prescribed gap below the appliance in order to
make sure you will be able to mount and service the siphon.
Combustible materials may be safely placed next to the
appliance provided the minimum side clearance of 5 mm
is maintained for servicing, and if required ventilation
purposes. The external temperature of the appliance will
never be such as to cause combustion.
3.5 Mounting the appliance
• Hang the appliance up onto the bracket (1) from above
with the bracket (3).
• Mount the cable connections to the appliance, making
sure they are disconnected from the power supply.
3.6 Removing/Attaching the appliance casing
Removing the casing
To dismount the front casing of the appliance, proceed
as follows:
• Loosen the screw (1) on the bottom of the appliance.
• Press in both retaining clips (2) on the bottom of the
appliance so that the casing is released.
• Pull the casing (3) forwards by its bottom edge and lift
the casing up and off (4).
4
2
1
3
Fig. 3.5 Removing/Attaching the appliance casing
Attaching the casing
To mount the casing, proceed as follows:
• Place the casing on the upper appliance ensuring that
the casing and appliance lips engage.
• Push the casing onto the appliance so that the retaining clips (2) on the casing click into place.
• Fix the casing by tightening the screw (1) on the bottom of the appliance.
240
75
75
50
50
85
1
3
Fig. 3.4 Mounting the appliance on the bracket
2
23
11Installation and maintenance manual ecoMAX 665 / 0020020159_03
4 Installation
4 Installation
When installing, please observe the following points in
particular:
- ensure that the isolation valve with the non return
valve is installed on the flow connection.
- mount the siphon cartridge
When used with direct connection to an indirect DHW
cylinder using the connections provided:
• Install a primary loading pump
• Install a non-return valve in both heating and DHW
primary flows to prevent reverse circulation
• please also refer to section 4.3
AB
JJ
4.2 Technical instructions for the heating system
Caution!
a
The schematics are for diagrammatical representation only. - the system may demand further safety devices and depends fully on the
control system employed. Unvented cylinders
must comply with the building regulations document G3. Always refer to British Standards,
Good Practice Guides and CIBSE guidelines
4.2.1 Connection to heating system via a low loss
header
OS
3
230V~
3
1
3
13
2
2
3
3
J
3
4
17a
45
J
2
3
3
13a
Fig. 4.1: Appliance circuit (A) and heating circuit (B)
Caution!
a
The ecoMAX 665 may only be put into operation when a sufficiently dimensioned low loss
header has been installed between appliance
circuit and heating circuit.
4.1 Preparing the installation
Safety equipment for an emergency
• The outlet of the pressure relief valve must be suitably
terminated in accordance with BS 6798 or BS 6644
• The boiler is suitable for connection to plastic central
heating pipes. It is preferred that the connections to
the boiler are made in copper for the first 1.5 metres
prior to the transition to plastic.
• Should a system be found to include non-oxygen barrier
pipe then it is essential that a plate heat exchanger be
installed in between the boiler and the non-oxygen barrier pipe. It is then essential that the boiler and the system have provision for water make up and expansion.
Fig. 4.2 Example 2: radiator heating and floor heating, low loss
header, appliance-internal pump
1 ecoMAX 665
2 integral boiler pump
13 weather-compensated controller VRC 630
13a mixer valve
17a supply temperature sensor
45 low loss header
OS outside sensor
The pump is sized adequately to provide the correct
amount of flow through the primary circuit.
Selection of the hydraulic switch
A suitable WH model low loss header (accessories) can
be selected with the aid of table 4.1.
A sufficiently large water volume (minimum circulating
water volume) is constantly supplied through the boiler
via the low loss header in conjunction with the Vaillant
system pump (item no. 178 728) built into the boiler.
heating system output heating system spread
10 K 15 K 20 K
ecoMAX 665 WH 160 WH 95 WH 95
double cascade WH 280 WH 160 WH 95
triple cascade WH 280 WH 280 WH 160
12 Installation and maintenance manual ecoMAX 665 / 0020020159_03
Table 4.1: Selection of the low loss header, WH model
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