Vaillant ecoMAX 646 Installation And Maintenance Manual
Wall hung room sealed fan assisted condensing boiler
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Also See for ecoMAX 646:
- Instructions for use manual (12 pages) ,
- Installation and maintenance manual (36 pages)
Related Manuals for Vaillant ecoMAX 646
Summary of Contents for Vaillant ecoMAX 646
- Page 1 For the installer Installation and maintenance manual ecoMAX Wall hung room sealed fan assisted condensing boiler ecoMAX 646...
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Page 2: Table Of Contents
4.8.5 Wiring diagram ............18 Technical data ........... 35 Initial start up and commissioning ....19 Water circulation system ........19 Benchmark gas boiler commissioning checklist ..36 5.1.1 Treating the heating water........19 Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 3: Notes On The Documentation
Danger! Immediate risk of serious injury or death! Caution! Potentially dangerous situations for product and environment! Note! Useful information and instructions. • Symbol for a necessary task Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 4: Description Of The Appliance
4 Pump 11 Air intake pipe 5 Electronics box 12 Gas inlet 6 Return connection (with drain point) 13 Connection for pressure relief valve 7 Air separator 14 Connection for condensate discharge Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 5: Type Summary
Table 1.1 Type summary Data badge Intended use The data badge of the Valliant ecoMAX 646 is attached The Vaillant ecoMAX 646 is a state-of-the-art appliance at the factory to the bottom of the appliance. which has been constructed in accordance with recog- nised technical safety regulations. -
Page 6: Safety Instructions And Regulations
This appliance should only be installed in conjunction tenance of ventilation for gas appliances. 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). - Page 7 In- stallation pipes should be fitted in accordance with BS 6891. Pipework from the meter to the boiler must be of an ade- Installation and maintenance manual ecoMAX 646 / 0020020158_02...
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Page 8: Mounting
Mounting Caution! Do not install the appliance in rooms prone to The Vaillant ecoMAX 646 is delivered in a package unit. frost. In rooms with aggressive steam or dust, the appliance must be operated independently Scope of delivery and accessories... -
Page 9: Dimensional Drawing And Connections
Dimension A with 87° elbow: 253 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 Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 10: Required Minimum Gaps/Assembly Clearances
• 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. Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 11: Installation 4
If an automatic type by-pass valve is fitted the operating pressure should be able to be set between 250-400 mbar. Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 12: Technical Instructions For Recharging
• Inspect the gas connection for leakage. 230V~ Fig. 4.4 Example 3: direct heating circuit and indirect cylinder schematic ecoMAX 646 integral boiler pump 13 weather-compensated controller VRC 410 OS outside sensor Fig. 4.6 Gas connection Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 13: Heating Connections
300 mm is from the flue terminal. Positions where this could be preferred. For IE, recommendations are given in the a nuisance should be avoided. current edition of IS 813. Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 14: Flue Pipe
Fig. 4.10 Example of installation with horizontal air/flue duct For detailed design guidance of the flue system please refer to the flue installation manual. Condensate discharge Internal Internal Gulley Soakaway stackpipe discharge system Fig. 4.11 Fig. 4.12 Condensate discharge Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 15: Electrical Connection
• Remove the front case and lower the control panel. • Unclip the bottom of the terminal box cover and hinge back to reveal the connection plugs. Fig. 4.13 Opening the rear of the electronics box Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 16: Connecting Accessories And External System Components
The Vaillant ProE (plug in terminal connections) system facilitates a quick and trouble-free connection of acces- sories and external system components to the appliance electronics. Proceed with the wiring up as follows: Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 17: Connection Diagram
(DCF) loss header 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) -
Page 18: Wiring Diagram
X 10 Contact- T he r m R T 2 4 V 2 3 0V R T 2 3 0 V Pump Coding resistance Electronics box Fig. 4.16 Wiring diagram ecoMAX 646 Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 19: Initial Start Up And Commissioning 5
Vaillant must be started again. assumes no liability for this (or for any subsequent resulting damage). Please inform the user as to how to go about frost protection. Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 20: Hot Water Side Filling And Bleeding
• Put the boiler into service (refer to the Instructions for Use supplied with the boiler). • Check the U gauge reading and ensure the inlet gas pressure is between the pressures detailed below. Fig. 5.2 Filling the siphon Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 21: Checking The Co Content And Adjusting It If Needed (Air Ratio Setting)
• Check that the seal plug is fit tight. • Put the front casing back on. Fig. 5.4 Carrying out a CO measurement, carrying out an air ratio setting (gas setting) Do not start up the appliance! Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 22: Functional Test
CO value with full load < 250 < 250 The Vaillant ecoMAX 646 possesses status codes that Table 5.2 Factory gas setting display the operating status of the appliance in the DIA system display. A functional test of the hot water opera-... -
Page 23: Instructing The User
Heating 5.4.2 Vaillant warranty • Switch on the appliance. Vaillant provide a full parts and labour warranty for this • Make sure that heat is being requested. appliance. The appliance must be installed by a suitably • Press the “i” key. -
Page 24: Adapting The Appliance To The Heating System
The same process can also be carried out using the code d.77 for DHW output to a directly connected cylinder. The displayed value flashes during the setting proce- dure. The possible setting ranges are to be found in table 6.1. Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 25: Setting The Pump Over-Run Time
• Switch the appliance main switch to the “l” position. • Press the “i” and “+” keys simultaneously and hold down the “+” key until the diagnosis code “d.2” appears in the display. • Press the “i” key. Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 26: Inspection And Maintenance
The boiler is fitted with a combustion analysis test point. A suitable combustion analyser can Only genuine Vaillant spare parts may be used for in- be connected to this point to establish the spections, maintenance and repair work to ensure the combustion performance of the boiler. -
Page 27: Overview Of The Inspection And Maintenance Tasks
• Pull the cables (9) off the fan motor and the cable (8) up the complete assembly that is the compact thermal off the electronic gas valve. module. Proceed as follows to dismount it: (see fig. 7.1) • Undo the five nuts (2). Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 28: Cleaning The Heat Exchanger
(8) to the gas fitting. • Open the gas supply to the appliance. Danger! Check the gas connection (10) for leaks with Fig. 7.4 Cleaning the heat exchanger leak spray (fig. 7.2). Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 29: Checking The Burner
After the maintenance work has been completed, carry are accessible. out a functional test (see chapter 5.3). Dirt in the front condensate discharge area can be re- moved via the lower cleaning hole (2). Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 30: Troubleshooting
Waiting time lack of water (burner on T VL-RL was > 40 K; S. 53 burner off T VL-RL was > 45 K S. 54 Low water pressure (boiler blocked) Table 8.1 Status codes Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 31: Diagnosis Codes
Burner starts - heating number of hystereses in the heating mode x 100 d. 83 Burner starts - hot water mode number of hystereses in the hot water mode x 100 Table 8.2 Diagnosis codes Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 32: Error Codes
Emergency No speed signal from the fan Hall sensor Wiring cable on the fan is not firmly located, fault in cable loom, defective run “speed” electronic control system. Table 8.3 Error codes Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 33: Test Programs
P. 5 Test program for safety thermostat test; appliance heats up by bypassing a control shutdown until the safety thermostat shutdown temperature of 97 °C is reached Table 8.4 Test programs Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 34: Vaillant Service
Telephone 01634 - 29 23 70 10.1 Appliance 01634 - 29 23 54 The Vaillant ecoMAX 646 consists 92 % of metallic ma- email training@vaillant.co.uk terials which can be melted down again at iron and steel works and therefore can be recycled practically any Commercial Service number of times. -
Page 35: Technical Data 11
Flue connection 80/125 Lift weight height width depth electrical connection 230 / 50 V / Hz electrical power consumption min./max. (with integrated pump) 138 / 180 type of protection IP X 4 D Installation and maintenance manual ecoMAX 646 / 0020020158_02... -
Page 36: Benchmark Gas Boiler Commissioning Checklist
Benchmark gas boiler commissioning checklist...
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