2
Installation and maintenance manual ecoMAX 665 / 0020020159_03
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
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
5.2.2 Gas inlet working pressure ..................................... 21
5.2.3 Checking the CO
2
content and adjusting it if
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
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
Summary of Contents for ecoMAX 665
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