Vaillant ecoMAX 665 Manual

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

2Installation 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 CO2content 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

3Installation 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 instal-
lation 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
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 auxil-
iary equipment are available whenever required.
Symbols used
Please observe the safety instructions in this installation
manual when installing the appliance!
dDanger!
Immediate risk of serious injury or death.
aCaution!
Potentially dangerous situations for the product
and environment.
hNote!
Useful information and instructions.
• Symbol for a necessary task
Information on the documentation

4Installation and maintenance manual ecoMAX 665 / 0020020159_03
1 Description of the appliance
1 Description of the appliance
1.1 Design
2
1
6
3
5
4
7
8
Fig. 1.1 Function elements
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

5Installation and maintenance manual ecoMAX 665 / 0020020159_03
1.3 Data badge
The data badge of the Valliant ecoMAX 665 is attached
at the factory to the bottom of the appliance.
Fig. 1.2 Data badge (example)
1.4 CE mark
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
(Council Directive 89/336/EEC).
The appliances meet the basic requirements of the effici-
ency 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.
1.5 Intended use
The Vaillant 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 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 operat-
ing and installation manual and the adherence to the in-
spection and maintenance conditions.
Description of the appliance 1
Appliance type Country of destination
(designations
according to ISO 3166)
License
category
Type of gas Nominal heat output
range P (kW)
Storage charging output
(kW)
ecoMAX 665 GB (Great Britain)
IE (Eire)
I2H Natural gas H - G
20 - 20 mbar
15.0 - 69.6 (40/30 °C)
13.7 - 63.7 (80/60 °C)
65.0

6Installation and maintenance manual ecoMAX 665 / 0020020159_03
1 Description of the appliance
1.6 Declaration of conformity

7Installation and maintenance manual ecoMAX 665 / 0020020159_03
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
• 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.
aImportant!
When tightening or slackening 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 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 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
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 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 ventila-
tion for gas appliances of rated input not excee-
ding 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.
aImportant!
When tightening or loosening 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 leakage)! Preli-
minary remarks: This appliance should only be
installed in conjunction with a Vaillant flue sys-
tem. Install the flue system as detailed in the
separate flue installation instructions supplied
with this boiler.
Safety instructions and regulations 2

8Installation and maintenance manual ecoMAX 665 / 0020020159_03
Boiler location
The location chosen for the boiler must permit the pro-
vision 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 elec-
trical 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.
hNote!
Where a room sealed boiler is installed in a
room containing a bath or shower, any electri-
cal switch or boiler control utilising mains elec-
tricity 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 compart-
ment 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.
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 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 sup-
ply required. Installation pipes should be fitted in accor-
dance 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 com-
plete 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).
1/3
2/3
b.
c.
a.
835311_00 102004
ecoTEC
1
2
3
1
2
5
4
6
7
8
3
Fig. 3.1 Scope of delivery
Position Number Name
1
2
3
4
5
6
7
8
1
1
1
1
1
1
3
1
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
Auxiliary tool for gas valve adjustment
Table 3.1 Scope of delivery
2 Safety instructions and regulations
3 Mounting

9Installations- und Wartungsanleitung ecoMAX 665
Mounting 3
3.2 Installation site
Please note the following safety instructions below be-
fore choosing where to install the appliance:
aCaution!
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 opera-
ting the appliance, make sure that the combustion air is
technically free of chemical substances containing fluo-
rine, 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, carpen-
ter‘s shops or paint shops, cleaning companies.
aCaution!
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
3.2.1 Select position of boiler
Refer 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 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.
hNote!
Care should be taken not to scratch the white
surface of the boiler casing.
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.
hNote!
Use alternative fixing holes where necessary.

10 Installation and maintenance manual ecoMAX 665 / 0020020159_03
3.3 Dimensional drawing and connection dimensions
480 472
211
800
23,2
61,5
31
Rp1 Rp1
66
121
R1
Ø25
87
172 172
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”

11Installation and maintenance manual ecoMAX 665 / 0020020159_03
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)
hNote!
It is very important that you keep the pre-
scribed gap below the appliance in order to
make sure you will be able to mount and serv-
ice 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.
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 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).
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 ensuring that
the casing and appliance lips engage.
• Push the casing onto the appliance so that the retain-
ing clips (2) on the casing click into place.
• Fix the casing by tightening the screw (1) on the bot-
tom of the appliance.
Mounting 3

12 Installation and maintenance manual ecoMAX 665 / 0020020159_03
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
JJ
AB
Fig. 4.1: Appliance circuit (A) and heating circuit (B)
aCaution!
The ecoMAX 665 may only be put into opera-
tion 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 bar-
rier pipe. 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
aCaution!
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 refer to British Standards,
Good Practice Guides and CIBSE guidelines
4.2.1 Connection to heating system via a low loss
header
J
J
45
17a
2
1
3
3
3
2
3
3
4
2
230V~ 3
33
13
13a
OS
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
Table 4.1: Selection of the low loss header, WH model
4 Installation

13Installation and maintenance manual ecoMAX 665 / 0020020159_03
4.3 Technical instructions for recharging
1
2
230V~ 3
3
3
3
45
OS
Fig. 4.3 Example 3: use of a cylinder, direct heating circuit
1 ecoMAX 665
2 Pump (internal within the appliance)
45 Low Loss header
OS outside sensor
Cylinder connection specification
It is imperative to keep to the minimum volume flow of
the charging circuit of 2,200 l/h. A pump with a constant
speed must be used.
When designing such a system, consideration must be
made for the pressure losses of any non-return valves
and piping to the system.
0
1000
Pressure [mbar]
Volume flow [l/h]
900
800
700
600
500
400
300
200
100
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
2200
Min. volume flow
Pressure loss in
storage charging
circuit of the boiler
Fig. 4.4 Pressure loss characteristics of connecting a DHW
cylinder.
4.4 Gas connection
aCaution!
Ensure the gas line is unstressed when mount-
ing it so that no leaks are caused.
aCaution!
Risk of damaging 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 supplied with the appli-
ance. This is suitable for the connection of a R1 gas
ball cock.
• Inspect the gas connection for leakage.
2
1
Fig. 4.5 Gas connection (only surface installation possible)
4.5 Heating side connection
aCaution!
Ensure the connection lines are unstressed
when mounting them so that no leaks are
caused in the heating system.
The appliance is connected to the heating flow and
return via maintenance cocks.
aCaution!
Ensure that a filling loop or pressurisation
device is installed in the return to maintain
pressure in the system.
hNote!
When installing a direct connection to a DHW
cylinder (indirect type) ensure that the non
return valve in the isolation valve is installed in
the correct orientation.
• Screw in flow (3) and return (4) with the maintenance
cocks.
Installation 4

14 Installation and maintenance manual ecoMAX 665 / 0020020159_03
3 4
5
Fig. 4.6 Mounting the heating flow and return service valves
4.6.1 Flue termination
A
BCD
A
G
H, I
FJ
BFM
L
L
KK
G
G
FF
E
A
A
Fig. 4.7 Flue termination
Terminal position mm
A Directly below an opening, above an opening or ho-
rizontal to an opening, air brick, opening window, etc. 300
B Below gutters, soil pipes or drain pipes 75
C Below eaves 200
D Below balconies 200
E From vertical drain pipes and soil pipes 25
F From internal or external corners 300
G Above ground, roof or balcony 300
H From a surface facing a terminal 600
I From a terminal facing a terminal 1200
K Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
M Distance from adjacent for vertical Flue 500
Table 4.2 Terminal position for a fan assisted concentric flue
The following details refer to both flue systems.
a. The terminal must be positioned such that the prod-
ucts of combustion can disperse freely at all times.
b. A plume of water vapour will sometimes be visible
from the flue terminal. Positions where this could be
a nuisance should be avoided.
c. If the terminal is fitted less than 2 m above a balcony,
above ground or above a flat roof to which people have
access then a suitable terminal guard must be provided and
fitted (contact Tower Flue Components, 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
built–in element such as a window.
BS 5440–1 It is recommended that the fanned flue ter-
minal should be positioned as follows:
a) at least 2m from an opening in the building directly
opposite, and
b) so that the products of combustion are not directly
directed to discharge across a boundary.
1) Dimensions B, C and D:
These clearances may be reduced to 25 mm without
affecting the performance of the boiler. In order to
ensure that the condensate plume does not affect
adjacent surfaces the terminal should be extended as
shown in fig. 4.8.
2) Dimension F:
This clearance may be reduced to 25 mm without
affecting the performance of the boiler. However, in
order to ensure that the condensate plume does not
affect adjacent surfaces a clearance of 300 mm is
preferred. For IE, recommendations are given in the
current edition of IS 813.
balcony/eaves
flue extended to
clear any overhang
flue adequately
supported
gutter
Fig. 4.8
4.6.2 Flue pipe
dDanger!
Only Vaillant original 80/125 mm flue pipes may be
used when installed in a room sealed application
(type C). Malfunctions can occur if you use other
accessories. These may result in damage and injury.
4 Installation

15Installation and maintenance manual ecoMAX 665 / 0020020159_03
Fig. 4.9 Example of installation with horizontal air/flue duct
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 instal-
lation and application conditions (see also the installa-
tion manual 0020014606_00GB 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
Internal
stack
p
i
p
e
Internal
dischar
g
e system
Gulley Soakaway
ab c d
3
5
6
3
7
4
Fig. 4.10.1
The condensate generated during combustion is led
from the condensate discharge pipe to the waste water
connection via a draining funnel.
Note!
The discharge pipe from the boiler condensate
drain must have a continuous fall (45 mm per
meter) and preferably be installed and terminated
within the building to prevent possible freezing.
The condensate discharge pipe must terminate in a suit-
able position, e.g.:
a) preferably the discharge pipe should run and termi-
nate internally to the house soil and vent stack (at
least 450 mm above the invert of the stack). A trap
giving a water seal of at least 75 mm (3) (built into
the boiler) should be incorporated into the pipe run,
and there must be an air break (4) in the discharge
pipe upstream of the trap. The connection to the
stack should not be made in a way that could cause
cross flow into any other branch pipe, or from that
branch pipe into the condensate drainpipe. This can
be achieved 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. The
connection should preferably be made down stream of
the sink waste trap. If the connection is only possible
upstream, then an air break is needed between the two
traps. This is normally provided by the sink waste.
c) terminating in a gully (5) below grid level (6) and
above the water level. The external pipe length
should be kept as short as possible to minimise the
risk of freezing and should not be more than 3 m.
d) at a condensate absorption point (soakaway) (7). The
external pipe length should not be more than 3 m.
2
1
Fig. 4.10.2 Condensate discharge
Refer to ‘BS 6798 Specification for installation of gas–
fired boilers of rated input not exceeding 70 kW net’ for
further information. Before operating the boiler the con-
densate trap (1) must be filled with water as described in
relevant section.
dDanger!
Before connecting the condensate discharge it
is absolutely important to install the syphon kit
included correctly and filling up with water.
4.8 Electrical connection
dDanger!
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
appliance on/off switch is switched off.
Attention - this appliance must be earthed!
Installation 4

16 Installation and maintenance manual ecoMAX 665 / 0020020159_03
4.8.1 Mains connection
aCaution!
Supplying power to the wrong plug terminals of
the Pro E system can destroy the electronics.
Only connect the 230 Vac live supply to boiler
terminal connections marked LNE.
The rated voltage of the mains must be 230 V; at rated
voltages above 253 V and under 190 V, damage may occur.
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 stated in the relevant instal-
lation manual. The necessary connections to the boiler‘s
electronics (e.g. when using external controllers, external
sensors or similar devices) are to be performed as follows:
• Remove the front casing of the appliance and lower
the electronics box (1) forward.
• Unclip the back cover (2) of the electronic box from
its fixings (3) and lift it up (see fig. 4.9).
• Pass the connecting cables of each of the components
to be connected through the grommets (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 (see fig. 4.9).
• Strip the connecting cable by about 2-3 cm and bare
the wires (see fig. 4.10).
• Connect the connecting cables as shown by fig. 4.10/4.11
to the corresponding ProE plugs or slots 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.
aCaution!
Do not connect 230 V mains to terminals 7, 8,
or 9. The electronics could be destroyed by this!
• If no room/clock thermostat is in place, provide a jum-
per between terminals 3 and 4 if not already present.
Remove the jumper if a room/clock thermostat is con-
nected to terminals 3 and 4.
• 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.
• In order to attain pump mode I (continuous pump) for
the multicircuit controller (e.g. VRC 630), increase the
pump over-run time to 15-20 minutes (diagnosis point
d.1, see chapter 6.2).
4
3
Fig. 4.11 Opening the rear of the electronics box
4.8.3 Connecting accessories and external system
components
LN
230V
5
Fig. 4.12 Example of cable insertion
The Vaillant ProE plug in terminal system facilitates
a quick and trouble-free connection of accessories and
external system components to the appliance electron-
ics. 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 electronics box (1) from
its fixings (2) and lift it up.
4 Installation

17Installation and maintenance manual ecoMAX 665 / 0020020159_03
Installation 4
• Guide the connecting cables of each of the components
to be connected through the PG screw connections
(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 (see fig. 4.10).
• Connect the connecting cables as shown 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 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
casings until you hear the clips click into place.
• Attach the front casing.

18 Installation and maintenance manual ecoMAX 665 / 0020020159_03
4 Installation
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. 4.13 Connection diagram ecoMAX 665
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)
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)
sensor for circulation pump/
FB - sensor for underfloor-heating system
RF - flow or return sensor Sensor
for low
loss
header
AF - outside temperature sensor
edge connector is included with the weather compensator
(DCF)
0
0

19Installation and maintenance manual ecoMAX 665 / 0020020159_03
4.8.5 Wiring diagram
Electronics box
Fan
230 V connection
Ignition electrode
Gas fitting
Water pressure switch
987 543 N
L
NL
Pump 2. Pump
Contact-
Therm
L N
24V I
230V
RT 24V 230V RT 230V
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 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
Water flow switch
Plug-in couplings
Integral pump
Flow NTC Return NTC
Fig. 4.14 Wiring diagram ecoMAX 665
Installation 4

20 Installation and maintenance manual ecoMAX 665 / 0020020159_03
5 Putting the boiler into service
hNote!
Vaillant offer a commissioning service. If used
a 2 year warranty is given, if not only a 1 year
warranty is available
Observe the following when putting the boiler into service:
• Remove the cap of the automatic air vent (see 10 / fig.
5.1) before filling the heating circuit/DHW primary circuit.
• Start the venting program for the heating circuit/DHW
primary circuit (see chapter 8.1.5).
aCaution!
The front cover should only be removed
• for initial installation access
• for servicing
• for testing
For continuous and safe operation the front
cover must be fitted together with a correctly
fitted and sealed flue system.
5.1 Water circulation system
Detailed recommendations for the water circulation
system are given in BS 6798 and BS 5449: Part 1 (for
small bore and micro bore central heating systems). Pipe-
work not forming part of the useful heating surface should
be insulated to help prevent heat loss and possible freez-
ing, particularly where pipes are run through roof spaces
and ventilated underfloor spaces. Draining points must be
located in accessible positions which permit the draining of
the whole system including the boiler and the hot water
system. Draining points should be at least 1/2 in. BSP nomi-
nal size and be in accordance with BS 2879. The boiler is
suitable for use with minibore or microbore systems. Cop-
per tubing to BS 2871: Part 1 should be used for water car-
rying pipework. All capillary joints in all DHW pipework
must be made with lead free solder. Particularly 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
prevent serious damage to the appliance and
system, 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, 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 (or for any subsequent re-
sulting damage). Please inform the user as to how to go
about frost protection.
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
several storeys, higher values for the water level of the
system at the pressure gauge can be necessary (maxi-
mum pressure for safety valve: 3 bar).
aCaution!
Filling the system must only be carried using
a proprietary filling loop in domestic applications.
For commercial applications a pressurisation
unit shall be installed.
5.1.3 Final system flush (”Hot”)
• Turn on the boiler for central heating and allow the
boiler and system to reach temperature.
• Check that the heating system is watertight.
• Turn the boiler off and rapidly drain both boiler and
system while still hot
• Refill the system and release all air.
• Release water from the system until the system design
pressure of 1.0 bar is attained. (The actual reading on
the pressure gauge should ideally be 0.5 bar plus an ad-
ditional pressure corresponding to the highest point of
the system above the base of the boiler – 10 m head
equals an additional 1 bar reading on the pressure gauge.
The minimum pressure should not be less than1 bar in
any installation.) If the system is to be treated with an
inhibitor it should be applied at this stage in accordance
with the manufacturer’s instructions. Further informa-
tion can be obtained from Sentinel, Betz Dearborn Ltd.,
Tel: [phone], or Fernox, Tel: [phone]
• Disconnect the temporary filling connection.
• Refit the boiler casing.
hNote!
The venting program (“P.0”) runs for approx.
6.5 minutes.
aCaution!
For the venting of the system, the minimum
pressure must be 1.0 bar.
If pressure is too low, the boiler will not fire.
Do not allow the water pressure to drop below the above
minimum during venting.
5 Putting the boiler into service