Vaillant ecoMAX 665 Manual

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

2Installation and maintenance manual ecoMAX 665
Contents
Information on the documentation . . . . . . . . . . . . 3
Other relevant documentation and service aids . . . . 3
For the installer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Scope of delivery and accessories . . . . . . . . . . 9
3.2 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Dimensional drawing and connection
dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 Hydraulic decoupling with heating pump
located on the appliance side. . . . . . . . . . . . . . . 12
4.3 Technical instructions for recharging. . . . . . . . 13
4.4 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Heating side connection . . . . . . . . . . . . . . . . . . . 13
4.6 Flue pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7 Condensate discharge . . . . . . . . . . . . . . . . . . . . . 14
4.8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . 15
4.8.1 Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.8.2 Connecting controllers . . . . . . . . . . . . . . . . . . . . 15
4.8.3 Connecting accessories and external
system components . . . . . . . . . . . . . . . . . . . . . . . 16
4.8.4 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . 17
4.8.5 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Putting the device into service. . . . . . . . . . 19
5.1 Water circulation system. . . . . . . . . . . . . . . . . . . 19
5.1.1 Treating the heating water . . . . . . . . . . . . . . . . . 19
5.1.2 Heating side filling and bleeding . . . . . . . . . . . . 19
5.1.3 Filling the siphon. . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Checking the gas setting . . . . . . . . . . . . . . . . . . . 20
5.2.1 Factory gas setting. . . . . . . . . . . . . . . . . . . . . . . . 20
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) . . . . . . . . . . . . . . . 21
5.3 Functional test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Instructing the user . . . . . . . . . . . . . . . . . . . . . . . 23
5.4.1 Instructing the user about the heating
system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4.2 Vaillant warranty . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Adapting the appliance to the heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Setting partial-load heating . . . . . . . . . . . . . . . . 24
6.2 Setting the pump run-out time . . . . . . . . . . . . . 25
6.3 Setting the burner lockout time. . . . . . . . . . . . . 25
6.4 Adapting the appliance to larger flue
pipe lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Inspection and maintenance . . . . . . . . . . . . 26
7.1 Inspection and maintenance intervals . . . . . . . 26
7.2 Inspection and maintenance instructions . . . . 26
7.2.1 Servicing the compact thermal module . . . . . . 28
7.2.2 Clean the integral condensation heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.3 Cleaning the condensate paths and siphon . . . 29
7.2.4 Checking the burner. . . . . . . . . . . . . . . . . . . . . . . 30
7.3 Draining the appliance and the system . . . . . . 30
7.3.1 Draining the appliance . . . . . . . . . . . . . . . . . . . . . 30
7.3.2 Draining the entire system . . . . . . . . . . . . . . . . . 30
7.3.3 Cleaning the air barrel . . . . . . . . . . . . . . . . . . . . . 30
7.4 Filling and bleeding the system . . . . . . . . . . . . . 30
7.5 Checking the gas setting . . . . . . . . . . . . . . . . . . . 30
7.6 Test operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.1 Status codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.2 Diagnosis codes. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.3 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.4 Error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.5 Test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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
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 non-
observance of 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
1 warranty card no. 80 29 22
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:
– CO2measuring device
– U-pipe pressure 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!
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
Information on the documentation

4Installation and maintenance manual ecoMAX 665
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 gas fitting
5 Ignition electrode
6 Pump
7 KFE cock for filling and emptying
8 Elektronics box
9 Pressure switch
10 Discharge for supply
11 Gas fitting
12 Air separator with strainer
13 Flow switch

5Installation and maintenance manual ecoMAX 665
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.
In accordance with the requirements specified by §7 of
the ordinance concerning small furnace installations from
07.08.1996 (first Federal Immission Control Ordinance),
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 heater for
closed hot water central heating systems. Any other use
or extended use is considered to be improper. The manu-
facturer/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
inspection 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)
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
1 Description of the appliance
1.6 Declaration of conformity

7Installation and maintenance manual ecoMAX 665
2 Safety instructions and regulations
2.1 Safety instructions
2.1.1 Installing and setting the appliance
Important!
The appliance must be installed and serviced by
a competent person as stated in the Gas Safety
(Installation and Use) Regulations 1998. In IE,
the installation must be in accordance with
the current edition of IS 813 ‚Domestic Gas
Installations‘, the current Building Regulations
and reference should be made to the current
ETCI rules for electrical installation.
2.1.2 Smell of gas
If you smell gas, the following safety instructions should
be observed:
• don‘t switch on any electrical switch in the danger area,
• don‘t smoke in the danger area,
• don‘t use a telephone in the danger area,
• close the gas stop cock,
• air the danger area,
• 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:
– 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 appliance.
Important!
When tightening or slackening screwed con-
nections always use suitable open-ended span-
ners (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
installation instructions supplied with this boiler.
2.2.2Related 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 Standards:
BS 6700: Services supplying water for domestic use
within buildings and their curtilages.
BS 6798: Specification for installation of gas fired
boilers not exceeding 60 kW input.
BS 6891: Specification for installation of low pres-
sure 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/UP/7/1998:
”Guide for gas installations in timber
framed housing”
BS. 5482 Pt. 1 Domestic butane and propane gas
burning installations.
IGE/UP1 Soundness testing and purging of industrial
and commercial gas installation.
IGE/UP2 Gas installation pipework, boosters and
compressors 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).
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 sys-
tems
of output greater than 45 kW.
Part 1 Fundamental and design considera-
tions.Part 2 Selection of equipment.
Part 3 Installation, commissioning and
maintenance.
BS. 4814 Specification for: Expansion vessels using
an internal diaphragm, for sealed hot water
heating systems.
BS. 5440 Installation and maintenance of flues and
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
maintenance of ventilation for gas appli-
ances.
Safety instructions and regulations 2

8Installation and maintenance manual ecoMAX 665
Important!
When tightening or loosening screwed connec-
tions always use suitable open-ended span-
ners (not pipe wrenches or extensions etc.).
Incorrect use and/or unsuitable tools can lead
to damage being caused (e.g. gas or water
leakage)! Preliminary remarks: This appliance
should only be installed in conjunction with a
Vaillant flue system. Install the flue system
as detailed in the separate flue installation
instructions supplied with this boiler.
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 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. If the boil-
er is to be fitted in a timber framed building, it should be
fitted in accordance 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 sup-
ply required. Installation pipes should be fitted in accord-
ance with BS 6891. Pipework from the meter to the boil-
er 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.
2 Safety instructions and regulations

9Installations- und Wartungsanleitung ecoMAX 665
Mounting 3
3 Mounting
The Vaillant ecoMAX 665 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).
1/3
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
Bracket
Appliance
Siphon holder
Condensate discharge hose
Bag containing consumables (installation
set)
Installation template
Manuals:
Operating manual
Installation instructions
Assembly manual for flue pipe
Auxiliary tool for gas fitting
Table 3.1 Scope of delivery
3.2 Installation site
Please note the following safety instructions below
before 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 flu-
orine, chlorine, sulphur etc. Sprays, solvents and clean-
ing 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.
Caution!
Gas firing appliances with a total nominal heat
output of more than 50 kW must be installed
in special rooms that meet the following condi-
tions:
• The installation rooms may not be used
for any other purpose
• Except for the doors, they may not have any
openings to other rooms
• The doors must be impermeable and
self-closing
• The room must be able to be aired.
The combustion air hole must lead outdoors and have
a minimum cross sectional area of 150 cm2. For every
increase in nominal heat output of more then 50 kW, the
opening is to be increased by 2 cm2for every 1 kW.
So that the firing can be switched off at any time, an
emergency switch must be put in place in front of the
installation room. A clearly visible sign with the inscrip-
tion “Emergency switch - firing” is to be put in place.
In addition, the heating room guideline, the regional
building regulations and the state firing ordinances are
to be met.

10 Installation and maintenance manual ecoMAX 665
3.3 Dimensional drawing and connection dimensions
480 472
211
800
23,2
61,5
31
Rp1 Rp1
66
121
R1
Ø20
87
172 172
87
R1
2
5
3
7
4
94
119
1
A
Ø 80/125
6
8
9
7
R3/4
Fig. 3.2 Connection dimensions
3 Mounting
1 Flue connection Ø 80/125 mm
Dimension A with 87° elbow: 297 mm
Dimension A with 87° T-piece: 314 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
8 Siphon connection
9 Connection safety valve 3/4”

11Installation and maintenance manual ecoMAX 665
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:
400
500
Fig. 3.3 Required minimum gaps/assembly clearances
Note!
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 service
the siphon.
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
appliance, 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
appliance 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.
Mounting 3

12 Installation and maintenance manual ecoMAX 665
4 Installation
When installing, please observe the following points in
particular:
- the installion of a pump in the appliance circuit
- guarantee minimum circulation between appliance and
switch
- mount the siphon cartridge
When recharging:
- install the storage charging pump
- install gravity brake in the heating supply and in
the storage charging circuit if the cylinder is heated
directly by the appliance
- guarantee minimum circulation for recharging
JJ
AB
Fig. 4.1: Appliance circuit (A) and heating circuit (B)
Caution!
The ecoMAX 665 may only be put into opera-
tion when a sufficiently dimensioned hydraulic
switch has been installed between appliance cir-
cuit and heating 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 suit-
able 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
system 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
exchanger must be performed in order to avoid corro-
sion 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 Hydraulic decoupling with heating pump located
on the appliance side
ϑϑ
17a
2
1
3
3
3
2
3
3
4
2
230V~
3
33
45
Fig. 4.2: radiator heating and floor heating, hydraulic separa-
tion, appliance-internal pump
1 ecoMAX 665
2 heating pump
17a supply temperature sensor
45 hydraulic switch
A pump dimensioning doesn‘t have to be carried out.
The appliance pump is set up at the factory.
The pump output doesn‘t have to be set.
Selection of the hydraulic switch
A suitable WH model hydraulic switch (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 hydraulic switch 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 hydraulic switch, WH model
4 Installation

13Installation and maintenance manual ecoMAX 665
4.3 Technical instructions for recharging
Recharging kit (accessory)
Mounting instructions are to be taken from the manual
supplied with the recharging kit (item no. 307 592)
1
2
230V~
3
3
3
3
45
Fig. 4.3 Example 3: use of a cylinder, direct heating circuit
1 ecoMAX 665
2 heating pump (appliance-internal; accessories)
45 hydraulic switch
Recharging without accessories
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 dimensioning, pay attention to the pressure losses
of the gravity brake, the piping and the cylinder. The
gravity brake of the heating circuit is to be put in the
heating supply; that of the storage charging circuit can
be mounted anywhere you like when the cylinder is con-
nected directly to the ecoMAX 665.
0
1000
Druck in mbar
Volumenstrom in l/h
900
800
700
600
500
400
300
200
100
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
Mindest-Volumenstrom
Druckverlust
Speicherladekreis
des Gerätes
2200
Fig. 4.4 The appliance‘s storage charging circuit without brake
and cylinder (the appliance‘s pressure loss character-
istic curve)
4.4 Gas connection
Caution!
Ensure the gas line is unstressed when mount-
ing it so that no leaks are caused.
Caution!
The gas control 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
gas fitting may be damaged.
The appliance must be connected to your gas line
(Vaillant accessory: gas cock, 1 inch, item no. 300 849)
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
R1 compression fitting supplied with the appliance.
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
Caution!
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 supply and
return via maintenance cocks. An installation set for the
ecoMAX 665 is available (item no. 306 728).
Caution!
Make sure you use the KFE cock (5) in the
return for filling up, since otherwise the bleed-
ing of the appliance is not guaranteed.
Note!
When using a cylinder directly on the appliance,
a gravity brake is to be mounted in the supply.
Installation 4

14 Installation and maintenance manual ecoMAX 665
• Screw in supply (3) and return (4) with the mainte-
nance cocks.
3 4
5
Fig. 4.6 Mounting the heating supply and return
4.6 Flue pipe
X
*
Fig. 4.7 Mounting example - vertical roof duct
* In case of x > 1 m an inspection hole has to be provided
Danger!
Only use original Vaillant flue pipes, since
these are authorized together with the boiler.
Malfunctions can occur if you use other acces-
sories. These may result in damage and injury.
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 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).
If the condensate discharge line needs to be extended
during installation, only use DIN 1986/EN 12056 compli-
ant drain pipes.
2
1
Fig. 4.8 Condensate discharge
4 Installation

15Installation and maintenance manual ecoMAX 665
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
impairments 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).
4.8.2Connecting 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 (see fig. 4.9).
• Guide the connecting cables of each of the compo-
nents to be connected through the cable routes (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.
Caution!
Do not connect the mains voltage supply to
terminals 7, 8, or 9. The electronics could be
destroyed 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 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
VRC 410 or the multicircuit controller, increase the
pump run-out time to 15-20 minutes (diagnosis point
d.1, see chapter 6.2 and 8.1.2).
4
2
1
3
Fig. 4.9 Opening the rear of the switch box
Installation 4

16 Installation and maintenance manual ecoMAX 665
4.8.3Connecting accessories and external system
components
3
NL987543
RT 24V 230V RT 230V
Fig. 4.10 Example of cable insertion
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 (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.
• 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.
4 Installation

17Installation and maintenance manual ecoMAX 665
Installation 4
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 8
X 2
13
X 6
111
1
Coding Resistance
Fig. 4.11 Connection diagram ecoMAX 665
Diagnostics
Connection accessory box 306 248,
multi-function module 306 253 (1 of 5)
or multi-function module 306 247 (2 of 6)
Room thermostat 24 V: Connections 7, 8 and 9
Caution: Do not connect the mains voltage!
Danger of electronics being destroyed!
Room thermostat 230 V/50 Hz
(remove the bridge when connecting)
Connection heating pump
Mains connection: 230 V/50 Hz
PWM pump signal
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)
Maximum thermostat for floor heating, 20 V
(remove the bridge when connecting)
Connection V/50 Hz-fan
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

18 Installation and maintenance manual ecoMAX 665
4 Installation
4.8.5 Wiring diagram
Electronics box
Fan
230 V connection
Ignition electrode
Forward
flow NTC
Gas fitting
Water pressure switch
Return
flow NTC
987 543 NL
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) Service water contact C1/C2
Cylinder NTC connection
or upper solar storage tank sensor
Coding resistance
13
1
11
1
1
X 2/24 black (earth)
X 2/2 orange (signal)
(plug colour: white)
Plug-in coupling
Flow switch
Plug-in couplings
Pump
Fig. 4.12 Wiring diagram ecoMAX 665

19Installation and maintenance manual ecoMAX 665
5 Putting the device into service
Particularly observe the following when putting the boil-
er into service:
• Open the cover of the exhaust fan (10) before filling
the heating circuit/storage charging circuit.
• Start the bleeding program for the heating circuit/
storage charging circuit (see chapter 8.1.5).
Caution!
The appliance may only be used
• for initial operation
• for testing
• for continuous operation
with the chamber cover closed and with the flue
system fully mounted and sealed.
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.
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 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
advice 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
resulting damage). Please inform the user as to how to
go about frost protection.
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,
Vaillant item no. 301 363. Please observe the instruc-
tions supplied 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
(10) (fig. 5.1).
• Open all thermostat valves in the system.
• Connect the filling unit to the appliance return by
means of a hose.
• Slowly unscrew the filling cock and tap valve und fill
with water until the required system pressure at the
pressure gauge 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 burner starts up.
• Open the filling cock and tap valve again if necessary.
Putting the device into service 5

20 Installation and maintenance manual ecoMAX 665
Caution!
If there is still too much air in the system after
the bleeding program has finished, the program
must be started anew.
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) Psystem P
ET + 0.2 bar
• Close the filling unit and remove the filling hose.
• Inspect all connections for leakage.
10
Fig. 5.1 Bleeding the appliance
5.1.3 Filling the siphon
A seal water cartridge comes with the appliance as an
installation set. Mount the siphon as described in the
accompanying installation instructions.
1
1/3
2/3
b.
c.
a.
835311_00 102004
ecoTEC
1
2
3
Fig. 5.2 Filling the siphon
Caution!
If the installation set is not there, do not start
up the appliance, rather contact Vaillant cus-
tomer service.
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
per the accompanying description before start-up.
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
regard 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.
ecoMAX 665
Appliance design Natural
gas H
Designation on the appliance badge I2H
Factory setting to Wobbe index Ws (in kWh/m3), cor-
responding to 0 °C/1013 mbar 15.0
Factory setting of the hot water output (in kW) 65.0
Factory setting of the heating output (in kW) 60.0
Table 5.1 Overview of factory gas settings
5.2.2Checking 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 with the auxiliary tool supplied.
• 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.
5 Putting the device into service