Vaillant ecoMAX 646 Manual

Installation and maintenance manual
ecoMAX
ecoMAX 646
For the installer
Wall hung room sealed fan assisted condensing boiler
GB

Installation and maintenance manual ecoMAX 6462
Contents
Notes on the documentation...................................... 3
Other relevant documentation and service aids........... 3
For the installer ..................................................................... 3
Symbols used.......................................................................... 3
1 Description of the appliance ........................... 4
1.1 Design .......................................................................... 4
1.2 Type summary ........................................................... 5
1.3 Data badge.................................................................. 5
1.4 CE marking.................................................................. 5
1.5 Intended use............................................................... 5
2 Safety instructions and regulations .............. 6
2.1 Safety instructions ................................................... 6
2.1.1 Installing and setting the appliance ..................... 6
2.1.2 Smell of gas.. .............................................................. 6
2.1.3 Changes to the surroundings of the boiler ........ 6
2.1.4 Important instructions for propane
appliances ................................................................... 6
2.2 General requirements.............................................. 6
2.2.1 Preliminary remarks for roomsealed appliances 6
2.2.2 Related documents...................................................... 6
3 Mounting ............................................................ 8
3.1 Scope of delivery and accessories ....................... 8
3.2 Installation site .......................................................... 8
3.3 Dimensional drawing and connections................ 9
3.4 Required minimum gaps/
assembly clearances ................................................ 10
3.5 Mounting the appliance ........................................... 10
3.6 Removing/Attaching the appliance casing......... 10
4 Installation......................................................... 11
4.1 Preparing the installation ....................................... 11
4.2 Technical instructions for the heating
system.......................................................................... 11
4.2.1 Direct feeding with heating pump located
in the interior of the device ................................... 11
4.2.2 Hydraulic decoupling with heating pump
located on the appliance side ................................ 12
4.3 Technical instructions for recharging ................. 12
4.4 Gas connection .......................................................... 13
4.5 Heating side connection.......................................... 13
4.6 Flue pipe ...................................................................... 13
4.7 Condensate discharge ............................................. 14
4.8 Electrical connection................................................ 14
4.8.1 Mains connection ...................................................... 14
4.8.2 Connecting controllers ............................................ 14
4.8.3 Connecting accessories and external
system components ................................................. 15
4.8.4 Connection diagram ................................................. 16
4.8.5 Wiring diagram .......................................................... 17
5 Start-up.............................................................. 18
5.1 Water circulation system ........................................ 18
5.1.1 Treating the heating water..................................... 18
5.1.2 Heating side filling and bleeding........................... 18
5.1.3 Hot water side filling and bleeding....................... 19
5.1.4 Filling the siphon....................................................... 19
5.2 Checking the gas setting......................................... 19
5.2.1 Factory gas setting................................................... 19
5.2.2 Checking the connection pressure
(gas flow pressure)................................................... 20
5.2.3 Checking the CO2content and adjusting it
if needed (air ratio setting) .................................... 20
5.3 Functional test........................................................... 21
5.4 Instructing the user.................................................. 22
5.4.1 Instructing the user about the
heating system .......................................................... 22
5.4.2 Vaillant warranty....................................................... 22
6 Adapting the appliance to the heating
system................................................................ 23
6.1 Setting partial-load heating.................................... 23
6.2 Setting the pump run-out time.............................. 24
6.3 Setting the pump output......................................... 24
6.3.1 Setting the pump output with direct feeding .... 24
6.3.2 Setting the pump output with hydraulic
decoupling................................................................... 24
6.4 Setting the burner lockout time............................ 24
7 Inspection and maintenance ........................... 25
7.1 Inspection and maintenance intervals................. 25
7.2 Inspection and maintenance instructions........... 25
7.2.1 Servicing the compact thermal module .............. 26
7.2.2 Cleaning the integral condensation heat
exchanger ................................................................... 27
7.2.3 Checking the burner................................................. 27
7.2.4 Cleaning the condensate siphon........................... 27
7.2.5 Cleaning the condensate paths............................. 27
7.3 Checking the gas setting......................................... 28
7.4 Filling and bleeding the system............................. 28
7.5 Draining the appliance and the system............... 28
7.5.1 Draining the appliance............................................. 28
7.5.2 Draining the entire system..................................... 28
7.5.3 Cleaning the air barrel............................................. 28
7.6 Test operation............................................................ 28
8 Troubleshooting ................................................ 29
8.1 Diagnostics ................................................................. 29
8.1.1 Status codes............................................................... 29
8.1.2 Diagnosis codes ......................................................... 30
8.1.3 Error codes ................................................................. 31
8.1.4 Error memory ............................................................ 31
8.1.5 Test programs............................................................ 32
9 Vaillant Service................................................. 32
10 Recycling and disposal..................................... 32
10.1 Appliance..................................................................... 32
10.2 Packaging.................................................................... 32
11 Technical data................................................... 33
Benchmark gas boiler commissioning checklist...... 34

3Installation and maintenance manual ecoMAX 646
Notes on the documentation
Notes on the documentation
The following information is intended to guide you
through the entire documentation.
Further documents apply in combination with this instal-
lation and maintenance manual.
We accept no liability for any damage caused by non-ob-
servance of these instructions.
Other relevant documentation and service aids
For the owner of the system
Brief operating instructions No. 00 20 00 64 61
Operating manual No. 00 20 01 46 08
Warranty cards No. 80 29 22
For the installer
Installation Manual
Flue accessories No. 00 20 01 46 06
Checklist No. 00 20 02 01 60
Sticker with name of appliance No. 83 42 24
Installation template No. 12 41 82
Safety sticker No. 83 55 93
Service aids:
The following test and measuring equipment is required
for inspection and maintenance:
– CO2measuring device
– U-pipe pressure gauge
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 re-
sponsibility 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!
Immediate risk of serious injury or death!
Caution!
Potentially dangerous situations for product
and environment!
Note!
Useful information and instructions.
• Symbol for a necessary task

Installation and maintenance manual ecoMAX 6464
1 Description of the appliance
1 Description of the appliance
1.1 Design
1
2
3
4
7
8
9
10
11
5
6
Fig. 1.1 Function elements
1 Connection for the flue pipe
2 Heat exchanger
3 Pressure switch
4 Pump
5 Electronics box
6 KFE cock
7 Air separator
8 Gas fitting
9 Ignition electrode
10 Compact thermal module
11 Air intake pipe

5Installation and maintenance manual ecoMAX 646
Description of the appliance 1
1.2 Type summary
Appliance
type
Country of destination
(designations
according to ISO 3166)
License
category Type of gas Nominal heat output range P (kW)
Storage charg-
ing output
(kW)
ecoMAX 646 GB (Great Britain) II2H3P Natural gas H - G 20 -20 mbar
(Propane - G 31 - 37 mbar)
13.3 - 47.7 (40/30 °C)
12.3 - 44.1 (80/60 °C)
44.1
Table 1.1 Type summary
1.3 Data badge
The data badge of the Valliant ecoMAX 646 is attached
at the factory to the bottom of the appliance.
Fig. 1.2 Data badge (example)
1.4 CE marking
CE marking is used to document the fact that the appli-
ances, in accordance with the type summary, meet the
basic requirements of the directive on appliances burn-
ing gaseous fuels (Council Directive 90/396/EEC) and
the EC directive on electromagnetic compatibility (Coun-
cil Directive 89/336/EEC). The appliances meet the basic
requirements of the efficiency requirements directive
(Council Directive 92/42/EEC).
The appliances meet the basic requirements of the effi-
ciency requirements directive (Council Directive 92/42/
EEC) as condensing appliances.
1.5 Intended use
The Vaillant ecoMAX 646 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 heater for
closed hot water central heating systems. Any other use
or extended use is considered to be improper. The manu-
facturer or supplier is not liable for any damage result-
ing from improper use. The user alone bears the risk.
Appropriate use includes the observance of the operat-
ing and installation manual and the adherence to the in-
spection and maintenance conditions.

Installation and maintenance manual ecoMAX 6466
2 Safety instructions
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 Instal-
lations‘, 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,
• notify a gas supplier or recognised gas fitting company.
2.1.3 Changes to the surroundings of the boiler
No changes must be made to the following devices:
– the boiler
– the gas, air, water and electricity supply pipes
– the exhaust pipe
– the discharge pipe and the safety valve for the hot
water
– the constructional conditions that could affect the
operational reliability of the device.
2.1.4 Important instructions for propane appliances
Bleeding the liquid gas tank when installing the system:
before installing the device, make sure that the gas tank
has been bled. The liquid gas supplier is responsible for
the proper bleeding of the tank. Ignition problems can
be caused if the tank is not bled properly. 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, if
possible close to the filler nozzle.
Installing underground:
When installing in underground places, the requirements
of the TRF 1996 (technical rules for liquid gas) are to be
observed. We recommend the use of an external sole-
noid valve.
Connection set for external solenoid valve:
Item no.: 306 253 or 306 248
Danger!
Only propane in accordance with DIN 51622
may be used.
Important!
When tightening or slackening screwed connec-
tions 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 leak-
age)!
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 ap-
proved 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 in-
stallation 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),
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, Build-
ing Regulations, The Building Regulations (Scotland).
The Building Regulations (Northern Ireland) and the
relevant recommendations of the following 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 cen-
tral heating systems. Institute of Gas Engi-
neers 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).

7Installation and maintenance manual ecoMAX 646
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 mainte-
nance.
BS. 4814 Specification for: Expansion vessels using
an internal diaphragm, for sealed hot water
heating systems.
BS. 5440 Installation and maintenance of flues and
ventilation 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 main-
tenance of ventilation for gas appliances.
Important!
When tightening or loosening screwed connec-
tions always use suitable open-ended spanners
(not pipe wrenches or extensions etc.). Incor-
rect use and/or unsuitable tools can lead to
damage being caused (e.g. gas or water leak-
age)! 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 in-
structions supplied with this boiler.
Boiler location
The location chosen for the boiler must permit the provi-
sion of a satisfactory flue termination. The location must
also provide adequate space for servicing and air circu-
lation 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!
Where a room sealed boiler is installed in a
room containing a bath or shower, any electrical
switch or boiler control utilising mains electrici-
ty 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 pro-
vided that it is modified for the purpose). Details of es-
sential features of cupboard/compartment design includ-
ing airing cupboard installations are given in BS 6891. In
IE the current edition of IS 813. If the boiler is to be fit-
ted in a timber framed building, it should be fitted in ac-
cordance with Institute of Gas Engineers Publication
IGE/UP/7/1998 “Guide for Gas Installation in Timber
Framed Housing”.
Gas Supply
The gas supplier should ensure the availability of an
adequate supply of gas. A gas meter may only be con-
nected 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 (15 mm,
22 mm for 837/637). The complete installation must be
tested for soundness and purged as described in BS
6891.
Safety instructions 2

Installation and maintenance manual ecoMAX 6468
3 Mounting
3 Mounting
The Vaillant ecoMAX 646 is delivered pre-mounted 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).
1
2
3
5
6
7
8
4
Fig. 3.1 Scope of delivery
Position Quantity Name
1 1 Bracket
2 1 Appliance
3 2 Connector - storage charging circuit
4 1 Condensate discharge hose
5 1 Bag containing consumables
6 1 Installation template
7 3 Manuals:
Operating manual
Installation manual
Assembly manual for flue pipe
Table 3.1 Scope of delivery
3.2 Installation site
Please note the following safety instructions below be-
fore choosing where to install the appliance:
Caution!
Do not install the appliance in rooms prone to
frost. In rooms with aggressive steam or dust,
the appliance must be operated independently
of the ventilation!
When choosing the place of installation and while oper-
ating 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, dur-
ing ambient air dependent operating of the appliance.
The appliance must be operated independently of the
ambient air particularly in hairdressing salons, carpen-
ter‘s shops or paint shops, cleaning companies. Other-
wise, a separate installation room is required to guaran-
tee that the combustion air supply is technically free of
the above mentioned substances.

9Installation and maintenance manual ecoMAX 646
3.3 Dimensional drawing and connections
70
190
480
800
2
100 144
450
7
100 100
Rp1 Rp1
5
3
7
R 3/4
fl 20
R 1
180
4
94
1
A
fl 80/125
6
Fig. 3.2 Connection dimensions
1 Flue connection Ø 80/125 mm
Dimension A with 87° elbow: 253 mm
Dimension A with 87° T-piece: 270 mm
2 Appliance holder
3 Heating return
4 Charging circuit return (only in conjunction with cylinder)
5 Gas connection
6 Charging circuit supply (only in conjunction with cylinder)
7 Heating supply
Mounting 3

Installation and maintenance manual ecoMAX 64610
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:
250
350
Fig. 3.3 Required minimum gaps/assembly clearances
Leaving gaps to the sides is not necessary.
Furthermore, it is not necessary to keep a gap between
the appliance and components made of combustible
constituents, since at the rated heating power of the ap-
pliance, the temperature here is never higher than the
permitted temperature of 85 °C.
3.5 Mounting the appliance
• Hang the appliance up into the appliance holder (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
3.6 Removing/Attaching the appliance casing
Removing the casing
To dismount the front casing of the appliance, proceed
as follows:
• Unscrew the screw (1) on the bottom of the appliance.
• Press in both holding clips (2) on the bottom of the ap-
pliance so that the casing comes loose.
• Pull the casing (3) forwards by its bottom edge and lift
the casing up and off (4).
1
2
4
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 holders.
• Push the casing onto the appliance so that the holding
clips (2) on the casing click into place.
• Fix the casing by screwing in the screw (1) on the bot-
tom of the appliance.
3 Mounting

11Installation and maintenance manual ecoMAX 646
4 Installation
When installing, please observe the following points in
particular:
- Install the filling device in the return
- Guarantee minimum circulation by means of an over-
flow valve or hydraulic switch
When recharging:
- Install the storage charging pump
- Install gravity brake in the heating supply and in the
storage charging circuit
4.1 Preparing the installation
Safety equipment for an emergency
• From the safety valve‘s blow-out line, a drain pipe with
intake guide and siphon must be led to a suitable out-
let. The outlet must be visible!
• If plastic pipes are used in the heating system, a suita-
ble maximum thermostat must be mounted on the
heating supply (e.g. Vaillant feed thermostat 009 642).
This is necessary in order to protect the heating sys-
tem from temperature-related damage in the event of
a malfunction.
• When using plastic pipes that are not diffusion tight in
the heating system, a system separation between the
heater and system by means of an external heat ex-
changer must be performed in order to avoid corrosion
occurring in the heater circuit or in the boiler.
4.2 Technical instructions for the heating system
Caution!
The following system diagrams are schematic
diagrams. They do not replace the full profes-
sional diagrams!
The system diagrams do not contain the shut-
off devices and safety devices necessary for
correct mounting.
Observe the applicable standards and guidelines.
4.2.1 Direct feeding with heating pump located in
the interior of the device
1
2
53
230V~ 3
3
3
Fig. 4.1 Example 1: radiator heating, direct feeding, appliance-
internal pump
1 ecoMAX 646
2 heating pump
53 overflow valve (on site)
Pump layout; system dimensioning
The system planning is to be done such that in the de-
sign point optimally a water volume of:
V = 2000 l/h with T = 20 K
flows through the device and system.
The resulting residual delivery head for the system di-
mensioning is to be taken from fig. 4.2.
Setting the overflow valve
In order to guarantee the minimum circulating water vol-
ume of 1150 l/h through the appliance, install and set the
overflow valve.
We recommend you set the overflow valve to 250 mbar
with regard to possible noises at thermostat valves. The
overflow valve can, however, be set at up to 400 mbar.
0
900
Druck in mbar
Volumenstrom in l/h
800
700
600
500
400
300
200
100
850
750
650
550
450
350
250
150
50
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
Restförderhöhe ohne Schwerkraftbremse
Restförderhöhe mit Schwerkraftbremse
Nennpunkt
(Zubehör, Art.-Nr. 306 715)
Fig. 4.2 Resulting characteristic curve (residual delivery head)
ecoMAX 646
Installation 4

Installation and maintenance manual ecoMAX 64612
4.2.2 Hydraulic decoupling with heating pump
located on the appliance side
JJ
45
17a
2
1
3
3
3
2
3
3
4
2
230V~
3
33
Fig. 4.3 Example 2: radiator heating and floor heating, hydrau-
lic separation, appliance-internal pump
1 ecoMAX 646
2 heating pump (appliance-internal)
13 weather-based controller VRC 420s
13a mixer module
17a supply temperature sensor
Pump layout in the heater circuit
The appliance pump is set according to table 4.1.
with gravity brake without gravity brake
Pump
output 100 % 80 %
Table 4.1: pump output
The pump output must be set to the values in the table
(in the DIA system under point d.14).
Selection of the hydraulic switch
A suitable WH model hydraulic switch (accessory) can be
selected with the aid of table 4.2.
A sufficiently large water volume (minimum circulating
water volume) is constantly supplied through the boiler
via the hydraulic switch in conjunction with the pump
built into the boiler.
heating system output
heating system spread
10 K 15 K 20 K
ecoMAX 646 WH 95 WH 40 WH 40
double cascade WH 160 WH 95 WH 95
triple cascade WH 280 WH 160 WH 160
quadruple cascade WH 280 WH 160 WH 160
Table 4.2: Selection of the hydraulic switch, WH model
4.3 Technical instructions for recharging
Recharging kit (accessory)
Mounting instructions are to be taken from the manual
supplied with the recharging kit.
1
2
230V~
3
3
3
3
13
Fig. 4.4 Example 3: use of a cylinder, direct heating circuit
1 ecoMAX 646
2 heating pump (appliance-internal; accessory)
13 weather-based controller VRC 410
Recharging without accessories
It is imperative to keep to the minimum volume flow of
the charging circuit of 1800 l/h.
When dimensioning, pay attention to the pressure losses
of the gravity brake, the piping and the cylinder.
The heating circuit‘s gravity brake is to be put in the
heating supply; the storage charging circuit‘s gravity
brake can be mounted anywhere you like.
0
900
Druck in mbar
Volumenstrom in l/h
800
700
600
500
400
300
200
100
850
750
650
550
450
350
250
150
50
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
Fig. 4.5 The appliance‘s storage charging circuit without brake
and cylinder (the appliance‘s pressure loss characteris-
tic curve)
4 Installation

13Installation and maintenance manual ecoMAX 646
4.4 Gas connection
Caution!
Ensure the gas line is disconnected from the
power supply when mounting it so that no leaks
are caused.
Caution!
The checking of the gas ducts for leaks may
only be carried out with a maximum pressure of
50 mbar, since otherwise the gas valve might
get damaged.
The appliance must be connected to your gas line via a
gas ball cock with a fire protection apparatus.
• Screw the appliance‘s gas supply pipe (1) gas-tight with
the (pre-installed) gas ball cock (2). To do this, use the
R3/4 compression fitting supplied with the appliance.
This is suitable for the connection of a R3/4 gas ball
cock.
• Inspect the gas connection for leakage.
2
1
Fig. 4.6 Gas connection (only surface installation possible)
4.5 Heating side connection
Caution!
Ensure the connecting cables are disconnected
from the power supply when mounting them so
that no leaks are caused in the heating system.
The appliance is connected to the heating supply and re-
turn via maintenance cocks. An installation set for the
ecoMAX 646 is available (item no. 306 715).
Caution!
It is imperative that the filling device be mount-
ed in the return; otherwise, the bleeding of the
appliance is not guaranteed.
Note!
When using a cylinder, a gravity brake is to be
mounted in the supply.
• Screw in supply (3) and return (4) with the mainte-
nance cocks.
3
4
Fig. 4.7 Mounting the heating supply and return
4.6 Flue pipe
Danger!
Only use original Vaillant flue pipes, since these
are authorized together with the boiler. Mal-
functions can occur if you use other accesso-
ries. These may result in damage and injury.
X
*
Fig. 4.8 Mounting example - vertical roof duct
* In case of x > 1 m an inspection hole has to be provided
Installation 4

Installation and maintenance manual ecoMAX 64614
4 Installation
Concentric systems made of plastic (diameter - 80/125
mm) are combined with the appliance as flue pipes. The
most suitable system depends on the specific installa-
tion and application conditions (see also the installation
manual 83 44 49 for the flue pipes).
• Mount the flue pipes consulting the installation manu-
al contained in the scope of delivery of this appliance.
4.7 Condensate discharge
The condensate generated during combustion is led
from the condensate discharge pipe to the waste water
connection via a draining funnel.
Caution!
The condensate discharge pipe may not be con-
nected tight to the waste water line.
• Connect the supplied condensate discharge hose (1) to
the pre-installed draining funnel (2).
The draining funnel also serves to drain off any heating
water that may be escaping at the safety valve.
If the condensate discharge line needs to be extended
during installation, only use DIN 1986/EN 12056 compli-
ant drain pipes.
2
1
Fig. 4.9 Condensate discharge
4.8 Electrical connection
Danger!
Risk of fatal electric shock from touching live
connections. Always switch off the power sup-
ply to the boiler first. Only once this is done
may you carry out the installation.
There is continuous operating voltage at the
power supply terminals L and N even when the
main switch is switched off.
4.8.1 Mains connection
Caution!
Supplying power to false plug terminals of the
Pro E system can destroy the electronics.
Only connect the mains supply to the terminals
that are marked as being for that purpose.
The rated voltage of the mains must be 230 V; at rated
voltages above 253 V and under 190 V, functional im-
pairments are possible.
The mains supply must be connected via a fixed connec-
tion and a separator with a contact opening of at least
3 mm (e.g. fuses, circuit breakers).
4.8.2 Connecting controllers
Mounting is to be carried out as instructed in the rele-
vant installation manual. The necessary connections to
the boiler‘s electronics (e.g. when using external control-
lers, external sensors or similar devices) are to be per-
formed as follows:
• Take off the front casing of the appliance and lift the
electronics box (1) forward.
• Unclip the back cover (2) of the electronic box from its
fixings (3) and lift it up.
• Guide the connecting cables of each of the compo-
nents to be connected through the cable routes (4) lo-
cated on the bottom of the appliance to the left.
4
2
1
3
Fig. 4.10 Opening the rear of the switch box

15Installation and maintenance manual ecoMAX 646
3
NL987543
RT 24V 230V RT 230V
Fig. 4.11 Example of cable insertion
• Then insert the connecting cables (5) into the elec-
tronics box and cut them to length.
• Strip the connecting cable by about 2-3 cm and bare
the wires.
• Connect the connecting cables to the corresponding
ProE plugs or slots of the electronics.
Caution!
Do not connect the mains voltage supply to ter-
minals 7, 8, or 9. The electronics could be de-
stroyed by this!
• If no room/clock thermostat is in place, provide a
jumper between terminals 3 and 4 if not already
present. Remove the jumper if a room/clock thermo-
stat is connected to terminals 3 and 4.
• When connecting a weather-controlled temperature
controller or room temperature controller (continuous
controlling - terminals 7,8,9), the jumper between ter-
minals 3 and 4 must remain in place.
• Close the rear cover of the electronics box and press it
in until you hear it click into place.
• Lift up the electronics box and press it by the two clips
on its left and right against the lateral appliance cas-
ings until you hear the clips click into place.
• Attach the front casing.
• In order to attain pump mode I (continuous pump) for
VRC-MF-TEC or the multicircuit controller, increase the
pump run-out time to 15-20 minutes (diagnosis point
d.1, see chapter 6.2).
4.8.3 Connecting accessories and external system
components
The Vaillant ProE system facilitates a quick and trouble-
free connection of accessories and external system com-
ponents to the appliance electronics. Proceed with the
wiring up as follows:
• Take off the front casing of the appliance and lift the
electronics box forward.
• Unclip the back cover of the switch box (1) from its fix-
ings (2) and lift it up.
• Guide the connecting cables of each of the compo-
nents to be connected through the PG screw connec-
tions (4) located on the bottom of the appliance to the
left.
• Then insert the connecting cables (5) into the elec-
tronics box and cut them to length.
• Strip the connecting cable by about 2-3 cm and bare
the wires.
• Connect the connecting cables to the corresponding
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.
• Close the rear cover of the electronics box and press it
in until you hear it click into place.
• Lift the electronics box up and press it by the two clips
on its left and right against the lateral appliance cas-
ings until you hear the clips click into place.
• Attach the front casing.
Installation 4

Installation and maintenance manual ecoMAX 64616
4.8.4 Connection diagram
987 543 NL
NL
Pump 2. Pump
Contact - Therm
L N
24V I 230V
RT 24V 230V RT 230V
X 10 X 7
X 2
13
X 6
1 1
1
Coding Resistance
X 8
1
Fig. 4.12 Connection diagram ecoMAX 646
4 Installation
Diagnostics
PWM pump signal
Connection accessory box 306 248
and multi-function module 306 253 (1 of 5)
or multi-function module 306247 (2 of 6)
Maximum thermostat for floor heating, 20 V
(remove bridge on connection)
Room thermostat 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
Connection heating pump
Connection storage charging pump
Use of other functions via
module 1 of 5 (306 253) or
module 2 of 6 (306 247)
(diagnosis point d.16 except function)
sensor for circulation pump/
sensor for underfloor-heating system
DCF-77 signal
supply or return sensor
hydraulic
decoupler
sensor
outside temperature sensor
edge connector is included with the weather compensator

17Installation and maintenance manual ecoMAX 646
4.8.5 Wiring diagram
Electronics box
Fan
230 V connection
Ignition electrode
Forward
flow NTC
Gas fittingWater pressure switch
Return
flow NTC
987 543 N
L
NL
Pump
Contact-
Therm
24V I
230V
RT 24V 230V RT 2 3 0 V
X 2/4 red
X 2/10 white
X 2/15 blue
X 2/8 black
X 2/20 black
X 4 X 10 X 7
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) BW contact C1/C2
Cylinder NTC connection
or upper solar storage tank sensor
(plug colour: white)
Coding resistance
13
1
11
1
X 2/24 black (earth)
X 2/2 orange (signal)
Plug-in coupling
Plug-in coupling
Pump
Fig. 4.13 Wiring diagram ecoMAX 646
Start-up 5

Installation and maintenance manual ecoMAX 64618
5 Start-up
Particularly observe the following when putting the boil-
er into service:
• Open the cover of the exhaust fan before filling the
heating circuit/storage charging circuit.
• Start the bleeding program for the heating circuit/stor-
age charging circuit.
5.1 Water circulation system
Detailed recommendations for the water circulation sys-
tem are given in BS 6798 and BS 5449: Part 1 (for small
bore and micro bore central heating systems). Pipework
not forming part of the useful heating surface should be
insulated to help prevent heat loss and possible freezing,
particularly where pipes are run through roof spaces
and ventilated underfloor spaces. Draining taps must be
located in accessible positions which permit the draining
of the whole system including the boiler and the hot
water system. Draining taps should be at least 1/2 in.
BSP nominal size and be in accordance with BS 2879.
The boiler is suitable for use with minibore or microbore
systems. Copper tubing to BS 2871: Part 1 should be used
for water carrying pipework. All capillary joints in all
DHW pipework must be made with lead free solder. Par-
ticularly where a new boiler is to be fitted to an existing
system, it is good practice that the system is thoroughly
cleansed.
Important!
To prevent the formation of deposits and pre-
vent serious damage to the appliance and sys-
tem, cleansers must be used carefully and must
be completely removed by thoroughly flushing
the system. Cleansers should only be left in
systems for a maximum of 24 hours.
This cleansing must take place prior to the fitting of the
new boiler and be in accordance with BS 7593. For ad-
vice on the application of system cleansers contact:
Sentinel, Betz Dearborn Ltd. Widnes,
Cheshire, WA8 8UD. Tel: [phone] — or
Fernox, Alpha Fry Technologies, Tandem House,
Marlow Way, Croydon, CR0 4XS. Tel: [phone]
5.1.1 Treating the heating water
Caution!
Do not enrich the heating water with frost or
corrosion protection fluid.
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 (or for any subsequent re-
sulting damage).
Please inform the user as to how to go about frost pro-
tection.
Caution!
Softening the heating water when water hard-
ness is 20° dH or more is absolutely necessary.
To do this, you can use the water softening cartridge,
item no. 30 13 63. Please observe the instructions sup-
plied with it.
5.1.2 Heating side filling and bleeding
For the heating system to function perfectly, a water
pressure/filling pressure of between 1.0 and 2.0 bar is
necessary. If the heating system stretches out over sev-
eral storeys, higher values for the water level of the sys-
tem at the pressure gauge can be necessary (maximum
pressure for safety valve: 3 bar).
Caution!
Only fill the system via the appliance-internal
KFE cock. Otherwise bleeding problems may
arise.
• Rinse the heating system thoroughly before filling it
proper.
• Open the cap of the appliance-internal exhaust fan (1)
(fig. 5.1).
• Open all thermostat valves in the system.
• Connect the system‘s filling and draining cock to the
appliance return via a hose.
• Slowly unscrew the filling cock and tap valve und fill
with water until the required system pressure at the
pressure gauge (2) has been reached (at least 1 bar).
• Close the tap valve.
• Bleed all radiators.
• Then check the filling pressure of the system again
(and repeat filling procedure if necessary).
• Start the “P.O” bleeding program (see chapter 8.1.5).
Note!
The bleeding program runs for approx. 6.5 min-
utes.
Caution!
For the bleeding of the system, the minimum
pressure must be 0.8 bar.
If pressure is too low, the gas valve jams when the burn-
er starts up.
• Open the filling cock and tap valve again if necessary.
Caution!
If there is still too much air in the system after
the bleeding program has finished, the program
must be started anew.
5 Start-up

19Installation and maintenance manual ecoMAX 646
Caution!
After the filling process has finished
The system pressure should be at least 0.2 bar above
the back pressure from the expansion tank (ET) Psys-
tem PET + 0.2 bar
• Close the filling unit and remove the filling hose.
• Inspect all connections for leakage.
1
Fig. 5.1 Bleeding the appliance
5.1.3 Hot water side filling and bleeding
To fill the storage charging circuit, proceed as described
in point 5.1.2.
• Restart the bleeding program (P.0).
5.1.4 Filling the siphon
1
Fig. 5.2 Filling the siphon
Danger!
If the device is operated with an empty conden-
sate siphon, there is the danger of poisoning
through escaping flue gases.
Therefore, it is mandatory to fill the siphon as
described below before start-up.
• Screw off the bottom (1) of the condensate siphon
(fig. 5.2).
• Fill the bottom about 3/4 full with water.
• Screw the bottom back on the condensate siphon.
5.2 Checking the gas setting
5.2.1 Factory gas setting
Caution!
Before starting up the appliance, compare the
data on the set gas type on the data badge with
the gas on site. Checking the amount of gas is
not necessary. The setting takes place with re-
gard to the percentage of CO2in the flue gas.
The appliances are set ex works to the values listed in
table 5.1. An on site adjustment can be necessary in
some supply areas.
The appliance design corresponds to the gas family
available on site:
• Check the CO2percentage as described in chapter 5.2.3.
The appliance design doesn‘t correspond to the gas fam-
ily available on site:
• Carry out a gas conversion.
Note!
Please ask Vaillant customer service about the
gas conversion of the appliance.
• Check the CO2percentage as described in chapter 5.2.3.
Appliance type ecoMAX 646
Appliance design Natural gas H
Designation on the appliance badge II2H3P
Factory setting to Wobbe index Ws (in kWh/m3),
corresponding to 0 °C / 1013 mbar 15.0
Factory setting of the hot water output (in kW) 45
Factory setting of the heating output (in kW) 35
Table 5.1 Overview of factory gas settings
Start-up 5

Installation and maintenance manual ecoMAX 64620
5.2.2 Checking the connection pressure (gas flow
pressure)
To check the connection pressure, proceed as follows
(cf. fig. 5.3):
• Take the front casing off the appliance.
• Close the appliance‘s gas stop cock.
• Unscrew the seal plug (1) marked “in” on the gas fit-
ting.
• Connect a digital pressure gauge or U-pipe pressure
gauge (2).
• Open the appliance‘s gas stop cock.
• Start up the appliance.
• Measure the connection pressure against the atmos-
pheric pressure.
1
2
Fig. 5.3 Measuring the connection pressure
Caution!
Natural gas:
If the connection pressure lies outside the range
from 17 to 25 mbar, you mustn‘t make a setting
or start up the appliance.
Liquid gas:
If the connection pressure lies outside the range
from 47.5 to 57.5 mbar, you mustn‘t make a
setting or start up the appliance.
If the connection pressure lies within the permissible
range, proceed as follows:
• Put the appliance out of operation.
• Close the appliance‘s gas stop cock.
• Remove the pressure gauge and screw the seal plug (1)
back on.
• Open the appliance‘s gas stop cock.
• Check that the seal plug is fit tight.
• Put the front casing back on and start the appliance
up again.
If the connection pressure does not lie within the per-
missible range and you can‘t correct the error, notify the
gas supplier. Proceed as follows:
• Put the appliance out of operation.
• Close the appliance‘s gas stop cock.
• Remove the pressure gauge and screw the seal plug (1,
fig. 5.3) back on.
• 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 CO2content 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 in the display
(approx. 5 s).
• Then press the “+” key once. The display shows P.1.
• The test program P.1 is started by pressing the “i” key.
The appliance then runs for 15 minutes at full power.
• Wait at least 5 minutes until the appliance reaches op-
erating temperature.
• Measure the CO2 content at the flue gas test nozzle
(3) (fig. 5.4). Compare the value measured with the
corresponding value in table 5.2.
• If a setting of the flue gas value is necessary, unscrew
the screw (4) and move the air intake pipe (5) forward
by 90°.
Do not remove the air intake pipe!
• If necessary, set the corresponding flue gas value
(table 5.2) by turning the screw (6).
Note!
Natural gas:
Adjust only in 1/8 of a full revolution increments
and wait about a minute after every adjustment
until the value becomes stable.
Liquid gas:
Adjust only in very small increments (approx.
1/16 of a full revolution) and wait about a
minute after every adjustment until the value
becomes stable.
5 Start-up