Vaillant ecoMAX 646 Installation And Maintenance Manual

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Installation and maintenance manual ecoMAX 646 / 0020020158_022ContentsNotes on the documentation...................................... 3Other relevant documentation and service aids ..... 3For the installer ..................................................................... 3Symbols used.......................................................................... 31 Description of the appliance ........................... 41.1 Design .......................................................................... 41.2 Type summary ........................................................... 51.3 Data badge.................................................................. 51.4 CE marking.................................................................. 51.5 Intended use ............................................................... 52 Safety instructions and regulations .............. 62.1 Safety instructions ................................................... 62.1.1 Installing and setting the appliance ..................... 62.1.2 Smell of gas ................................................................ 62.1.3 Changes to the surroundings of the boiler ........ 62.1.4 Important instructions for propane appliances 62.2 General requirements .............................................. 62.2.1 Preliminary remarks for roomsealed appliances.. 62.2.2 Related documents ................................................... 63 Mounting ............................................................ 83.1 Scope of delivery and accessories ....................... 83.1.1 Unpack the boiler ...................................................... 83.2 Installation site .......................................................... 83.2.1 Select position of boiler .......................................... 83.2.2 Air supply .................................................................... 83.2.3 Compartment ventilation ........................................ 83.2.4 Electrical supply ........................................................ 83.3 Dimensional drawing and connections ................ 93.4 Required minimum gaps/assembly clearances... 103.4.1 Using boiler template ............................................... 103.5 Mounting the appliance on the bracket .............. 103.6 Removing/Attaching the appliance casing......... 104 Installation......................................................... 114.1 Preparing the installation ....................................... 114.2 Technical instructions for the heating system.... 114.2.1 Direct connection to the heating circuitusing the integral boiler pump. ............................. 114.2.2 Connection to heating circuit containinga low loss header. ..................................................... 114.3 Technical instructions for recharging ................. 124.4 Gas connection .......................................................... 124.5 Heating connections................................................. 134.6.1 Flue termination ........................................................ 134.6.2 Flue pipe ...................................................................... 144.7 Condensate discharge ............................................. 144.8 Electrical connection ................................................ 154.8.1 Mains connection ...................................................... 154.8.2 Connecting controllers ............................................ 154.8.3 Connecting accessories and externalsystem components ................................................. 164.8.4 Connection diagram ................................................. 174.8.5 Wiring diagram .......................................................... 185 Initial start up and commissioning ................ 195.1 Water circulation system ........................................ 195.1.1 Treating the heating water..................................... 195.1.2 Heating side filling and bleeding ........................... 195.1.3 Final system flush (”Hot”) ...................................... 195.1.3 Hot water side filling and bleeding ....................... 205.1.4 Filling the siphon ....................................................... 205.2 Checking the gas setting ......................................... 205.2.1 Factory gas setting ................................................... 205.2.2 Gas inlet working pressure ..................................... 205.2.3 Checking the CO 2 content and adjustingit if needed (air ratio setting) ................................ 215.3 Functional test ........................................................... 225.4 Instructing the user .................................................. 235.4.1 Instructing the user about the heating system. 235.4.2 Vaillant warranty....................................................... 236 Adapting the appliance to the heating system 246.1 Adjusting the central heating output(range rating) ............................................................. 246.1.1 Setting the DHW part load output ........................ 246.2 Setting the pump over-run time ........................... 256.3 Setting the burner anti-cycling time .................... 257 Inspection and maintenance ........................... 267.1 Initial inspection ........................................................ 267.1.1 Safety instructions ................................................... 267.1.2 Maintenance ............................................................... 267.1.3 Overview of the inspection and maintenancetasks ......................................................................................... 277.1.4 Functional check of boiler operation ................... 277.2 Servicing the compact thermal module .............. 277.2.1 Removing the compact thermal module ............. 277.2.2 Cleaning the heat exchanger ................................. 287.2.3 Checking the burner ................................................. 297.2.4 Cleaning the condensate siphon ........................... 297.2.5 Cleaning the condensate paths ............................. 297.3 Checking the gas setting ......................................... 297.4 Filling and venting the system............................... 297.5 Draining the appliance and the system ............... 297.5.1 Draining the appliance ............................................. 297.5.2 Draining the entire system ..................................... 297.5.3 Cleaning the air separator ...................................... 297.6 Test operation............................................................ 298 Troubleshooting ................................................ 308.1 Diagnostics ................................................................. 308.1.1 Status codes ............................................................... 308.1.2 Diagnosis codes ......................................................... 318.1.3 Error codes ................................................................. 328.1.4 Error memory ............................................................ 328.1.5 Test programs............................................................ 339 Vaillant Service ................................................. 3410 Recycling and disposal ..................................... 3410.1 Appliance..................................................................... 3410.2 Packaging .................................................................... 3411 Technical data ................................................... 35Benchmark gas boiler commissioning checklist .... 36