Vaillant ecoMAX 665, Installation And Maintenance Manual

Page 1: ...For the installer ecoMAX 665 Installation and maintenance manual ecoMAX Wall hung room sealed fan assisted condensing boiler GB ...

Page 2: ...ram 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 CO2 content and adjusting it if needed air ra...

Page 3: ... checklist for start up no 00 20 02 01 61 1 installation template no 17 90 73 1 safety sticker no 83 55 93 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...

Page 4: ...lements 11 12 10 9 13 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 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 ...

Page 5: ...ecoMAX 665 is a state of the art appliance which has been constructed in accordance with recog nised 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 dam aged when using it The appliance is designed to be used as a boiler for closed hot water central heating systems Any other use or exten...

Page 6: ...6 Installation and maintenance manual ecoMAX 665 0020020159_03 1 Description of the appliance 1 6 Declaration of conformity ...

Page 7: ...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 excee...

Page 8: ...hat 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 hNote 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 ...

Page 9: ...efer to section Boiler location for information regard ing 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 instruc...

Page 10: ... 87 R1 2 5 3 7 4 94 119 1 A Ø 80 125 6 8 9 R3 4 Fig 3 2 Connection dimensions 3 Mounting 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 5 Gas connection 6 DHW primary flow only in conjunction with cylinder 7 Heating flow 8 Siphon connection 9 Connection safety valve 3 4 ...

Page 11: ...liance 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 85 50 240 75 75 23 50 3 1 2 Fig 3 4 Mounting the appliance on the bracket 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 t...

Page 12: ...ipe It is then essential that the boiler and the sys tem have provision for water make up and expansion 4 2 Technical instructions for the heating system a Caution The schematics are for diagrammatical repre sentation only the system may demand fur ther safety devices and depends fully on the control system employed Unvented cylinders must comply with the building regulations doc ument G3 Always r...

Page 13: ...ng the gas control block by exceeding the testing pressure The gas con trol block may only be tested for leaks up to a maximum pressure of 110 mbar The operating pressure may not exceed 60 mbar If these pressures are exceeded the electronic gas valve may be damaged Screw the appliance s gas supply pipe 1 gas tight with the pre installed gas ball cock 2 To do this use the R1 compression fitting sup...

Page 14: ...ponents Tonbridge TN9 1TB Note Vertical flues must not terminate within 600 mm of an openable window air vent or any other ventilation opening The flue assembly shall be so placed or sheilded as to prevent ignition or damage to any pary of the building Note In addition the terminal should not be nearer than 150 mm to an opening in the building fab ric formed for the purpose of accommodating a buil...

Page 15: ...hieved by maintaining an offset between branch pipes of at least 110 mm on a 100 mm diameter stack and 250 mm on a 150 mm diameter stack b connecting into the internal discharge branch e g sink waste with an external termination the condensate discharge pipe should have a minimum diameter of 22 mm with no length restriction and should incorporate a trap with a 75 mm 3 built into the boiler seal Th...

Page 16: ...ots of the electronics Vaillant controllers are intended to be plugged into the front of the appliance without the need for additional wiring If a remote wall mounted controller is required then the patress box provided can be used Additional wiring will be required as described a Caution Do not connect 230 V mains to terminals 7 8 or 9 The electronics could be destroyed by this If no room clock t...

Page 17: ... by fig 4 10 4 11 to the ProE plugs or slots of the electronics Please note that the jumper on the ProE plug should be removed when connecting a maximum thermostat feed thermostat for floor heating Should a remote safety circuit for a mini pressurisation device or a pump flow switch This will prevent the boiler firing should such an external device fail Close the rear cover of the electronics box ...

Page 18: ...247 2 of 6 Safety circuit 20V connection Vaillant controllers 24 V connections 7 8 and 9 Caution Do not connect supply voltage Risk of electronics being destroyed Mains supply 230 V 50 Hz Room thermostat 230 V 50 Hz remove bridge on connection Connection 230 V 50 Hz fan Boiler integral pump Connection storage charging pump Use of other functions via module 1 of 5 306 253 or module 2 of 6 306 247 s...

Page 19: ...ck X 4 X 10 X 7 X 8 X 6 X 2 X 2 9 red 22 VDC X 2 24 blue earth X 2 12 blue earth X 2 7 grey PWM X 2 3 black hall signal X 2 17 red 22 VDC X 2 23 black earth X 2 6 brown signal C1 C2 connector volt free switching cylinder thermostat Cylinder NTC connection Article number 306 257 tank sensor plug colour white Coding resistance 13 1 1 1 1 1 X 2 24 black earth X 2 2 orange signal Plug in coupling Wate...

Page 20: ...s contact Sentinel Betz Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 495 1861 or Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 01483 793200 5 1 1 Treating the heating water If you enrich the heating water with frost or corrosion protection fluid changes can be caused in the seals and noises may arise during the heating operation Vaillant assumes no liability for this o...

Page 21: ...etting 5 2 1 Factory gas setting a Caution This appliance is suitable for use on G20 natural gas only It is important to check the gas rate of the appliance and perform a flue gas analysis check The appliances are set ex works to the values listed in table Check the CO2 percentage as described in chapter 5 2 3 ecoMAX 665 Appliance design Natural gas H Designation on the appliance badge I2H Factory...

Page 22: ...e the pressure gauge and replace the seal plug 1 fig 5 3 back on with the auxiliary tool supplied Check that the seal plug is fit tight Put the front casing back on Do not start up the appliance 5 2 3 Checking the CO2 content and adjusting it if needed air ratio setting Take off the appliance casing Activate test program P 1 Press Mains ON or press the reset key Now press the key until P 0 appears...

Page 23: ...nd hot water generation are working properly Pass the appliance on to the user The Vaillant ecoMAX 665 possesses status codes that display the operating status of the appliance in the DIA system display A functional test of the hot water opera tion and heating operation can be carried out using these status codes by pressing the i key Filling the storage tank Switch on the appliance and the connec...

Page 24: ...g For continuous and safe operation the front cover must be fitted together with a correctly fitted and sealed flue system 5 4 2 Vaillant warranty Vaillant provide a full parts and labour warranty for this appliance The appliance must be installed by a suitably competent person in accordance with the Gas Safety Installation and Use Regulations 1998 and the manu facturer s instructions In the UK CO...

Page 25: ... tial load is displayed in kW By pressing the or keys you can now increase or decrease the value in 1 kW increments The displayed value flashes during the setting proce dure The possible setting ranges are to be found in table 6 1 Then hold down the i key for about 5 seconds until the display stops flashing The value is now saved The standard display appears again in the display current heating su...

Page 26: ...r operation during a burner anti cycle time in progress does not affect the timer The maximum burner anti cycle time can be set under diagnosis point d 2 between 2 and 60 minutes factory setting 20 minutes The anti cycle time effective in each case is then automatically calculated from the current set supply temperature and the set maximum burner anti cycle time The timer can be reset or deleted b...

Page 27: ...ation the front cover must be fitted together with a correctly fitted and sealed flue system 7 2 Inspection and maintenance instructions Only original Vaillant spare parts may be used for in spections maintenance and repair work to ensure the perfect long term working order of all functions of the Vaillant appliance Please contact Vaillant Service Solutions 0870 850 3072 for further details h Note...

Page 28: ...out 1 0 2 0 bar depending on the static height of the system start the venting program X 9 Check the overall condition of the appliance remove general dirt from the appliance and the vacuum chamber X X 10 Check the condensate siphon in the appliance and clean and fill it if necessary X X 11 Clean the condensate paths in the appliance X 12 Open the gas supply and switch on the appliance X X 13 Perf...

Page 29: ...ull off the cable 8 at the fan motor coupling the PWM signal cable beneath the fan 9 and the cable for the gas fitting 11 Undo the six nuts 4 a Caution Under no circumstances may the compact ther mal module be suspended from the flexible ap pliance gas pipe Pull the entire compact thermal module 5 off the in tegral condensation heat exchanger 1 Mounting the compact thermal module d Danger The seal...

Page 30: ...Observe also the siphon installation instructions provided d Danger If the appliance is operated with an empty con densate siphon there is the danger of poisoning through escaping flue gases Therefore refill the siphon after each cleaning Remove the condensate water trap beneath the appli ance and clean it Remove the clips beneath the primary heat exchanger and pull off the connection elbow Remove...

Page 31: ...adiator that is highest up and then continue downward When the water has run out close the radiators vents and the draining cock again 7 3 3 Cleaning the air separator d Danger There is danger of being injured or scalded at all components carrying water Only carry out work on these components once they have cooled down Dismount the air separator as shown in fig 7 6 and rinse it with hot water Remo...

Page 32: ... S 2 Heating fan start S 3 Heating ignition S 4 Heating burner on S 5 S 6 Heating fan over run S 7 Heating pump over run S 8 Remaining anti cycle time heating S 10 Hot water request S 11 Hot water fan start S 13 Hot water ignition S 14 Hot water burner on S 15 S 16 Hot water fan over run S 17 Hot water pump over run S 20 Hot water cycle mode S 21 Hot water fan start S 23 Hot water ignition S 24 Ho...

Page 33: ...p only this function can be used for other functions use module 1 of 5 item no 306 253 or module 2 of 6 item no 306 247 d 17 Control type 0 supply temperature control 1 return temperature control d 22 Hot water request 1 on 0 off d 23 Operating mode summer winter mode 1 on 0 off d 25 Hot water enabling via warm restart clock 1 yes 0 no d 33 Fan target value target value in r p m 10 d 34 Fan actual...

Page 34: ...limitation of the storage charging temperature in C d 80 Operating hours heating in h d 81 Operating hours hot water generation in h d 82 Burner starts heating number of hystereses in the heating mode x 100 d 83 Burner starts hot water mode number of hystereses in the hot water mode x 100 d 87 Type of gas natural gas liquid gas not necessary must stay at 0 natural gas d 90 Digital controller 1 det...

Page 35: ...mostat interrupted water pressure switch has been triggered flow switch has been triggered F 27 Flame simulation flame signal despite gas valve being switched off gas solenoid valve leaking electronics flame detector defective dampness on the electronics F 28 No ignition when starting no or too little gas ignition system ignition transformer ignition cable ignition plug defective interruption of t...

Page 36: ... service provider Vaillant Applied System Sales Vaillant Ltd Unit D1 Lowfields Business Park Elland West Yorkshire HX5 9DG Training Telephone 01634 29 23 70 Fax 01634 29 23 54 email training vaillant co uk Commercial Service Telephone 0870 8 50 30 72 Mon Fri 8 30 17 30 Fax 01773 52 59 46 email aftersales vaillant co uk 10 Recycling and disposal Recycling and disposal have already been taken into a...

Page 37: ...ithout non return valve 280 mbar residual delivery head of the pump with non return valve 190 mbar max flow temperature approx 85 C maximum operating pressure 3 bar min required total overpressure on the heating side 0 8 bar condensate volume pH value 3 0 4 0 6 5 l h water content 6 5 l flue gas mass flow min max 7 2 29 6 g s flue gas temperature min max 52 75 C maximum length of concentric flue h...

Page 38: ...Benchmark gas boiler commissioning checklist ...

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Page 40: ...0020020159_03GB 06 2007 ...