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Vaillant ecoCRAFT VKK GB SERIES, Installation And Maintenance Instructions Manual

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Vaillant ecoCRAFT VKK GB SERIES Installation And Maintenance Instructions Manual Download Page 3

1 

Notes on the documentation

The following instructions are intended to help you 
throughout the entire documentation.
Further documents apply in combination with this instal-
lation and maintenance manual.

We accept no liability for damage caused by a failure 
to observe these instructions.

Documents which are also valid and auxiliary service 
equipment

For the plant operator:

Operating manual  

No. 0020058717

Short-form instructions 

No. 0020063363

For the expert technician:

Installation instructions for the  
Flue pipe 

No. 0020058722

Auxiliary service equipment:

The following test and measuring equipment are re-
quired for inspection and maintenance:
–  Flue Gas analyser CO/ CO2/ ratio
– Pressure gauge
– Gas sensing equipment
– Torque wrench

System logbook

:

•  Maintain a logbook for the system.
•  Keep the logbook and all the technical data for the 

system in the service folder by the ecoCRAFT.

1.1 

Storage of the documents

Please hand this installation and maintenance instruc-
tion manual and the auxiliary equipment to the operator 
of the installation, whose responsibility it is to ensure 
the manuals and auxiliary equipment are available 
whenever required.

1.2 Symbols 

used

When installing the unit, please observe the safety in-
structions in this installation and maintenance manual!

d

 Danger!

Immediate risk of serious injury or death!

e

 Danger!

Danger of death from electric shock!

H

 Danger!

Danger of burning and scalding!

a

 Caution!

Potentially dangerous situation for the product 
and the environment!

h

 Note

Useful information and instructions.

•  Symbol for a necessary task

1.3 

Applicability of the manual

This installation and maintenance manual applies exclu-
sively to units with the following article numbers:

Unit type

Article number

VKK GB 806/3-E-H

0010005410

VKK GB 1206/3-E-H

0010005411

VKK GB 1606/3-E-H

0010005412

VKK GB 2006/3-E-H

0010005413

VKK GB 2406/3-E-H

0010005414

VKK GB 2806/3-E-H

0010005415

Table 1.1 Overview of the article numbers

The 10-digit part number for the equipment can be 
found on the identification plate (see Fig. 2.1, read from 
the 7th digit onwards).

3

Installation and maintenance instructions ecoCRAFT 0020055744_08

Notes on the documentation 1

Summary of Contents for ecoCRAFT VKK GB SERIES

Page 1: ...e expert technician Installation and maintenance instructions ecoCRAFT Gas fired condensing boiler VKK GB 806 3 E H VKK GB 1206 3 E H VKK GB 1606 3 E H VKK GB 2006 3 E H VKK GB 2406 3 E H VKK GB 2806 3 E H GB ...

Page 2: ... for maintenance and service work 24 6 4 Filling the system 26 6 4 1 Filling the heating side 28 6 4 2 Filling the siphon 28 6 5 Checking the gas setting 28 6 5 1 Checking for tightness of the flue gas system Caution 28 6 5 2 Checking the gas inlet working pressure 29 6 5 3 Checking the gas flow rate 29 6 7 Instructing the user 30 7 Adapting the unit to the heating system 31 7 1 Setting the maximu...

Page 3: ... auxiliary equipment to the operator of the installation whose responsibility it is to ensure the manuals and auxiliary equipment are available whenever required 1 2 Symbols used When installing the unit please observe the safety in structions in this installation and maintenance manual d Danger Immediate risk of serious injury or death e Danger Danger of death from electric shock H Danger Danger ...

Page 4: ... installing or using the appliance The appliance must be installed in accordance with the manufacturer s instructions and the regulations in force and only in a suitably ventilated space Please observe the maintenance instructions as outlined in the instruction manual 0063 08 Vaillant GmbH Remscheid Germany 1 2 3 5 4 Fig 2 1 Identification plate Key 1 Serial No 2 Model designation 3 Permitted flue...

Page 5: ... ºC It is suitable for operation in new installations and for modernisation of existing heating installations in multi occupancy houses and in business units The boiler is suitable for connection to commercial heat ing control systems Vaillant controls and BEMS sys tems The boiler is suitable for connection to open flue systems Air for combustion must be supplied in accordance with BS 6644 The boi...

Page 6: ...heating system 7 Reset button for resetting specific faults 8 Rotary knob for setting the heating flow temperature When operating with the VRC 430 VRC 630 or VRS 620 turn to the clockwise end stop so that the maximum flow temperature for the controller will not be limited 9 Rotary knob for setting the cylinder temperature on units with a VIH DHW cylinder connected When using the VRC 430 for contro...

Page 7: ... and block temperature sensor 15 Safety temperature limiter STL reset button 16 0 10 V pump module VR35 3 5 4 7 6 1 2 Fig 2 5 Plan view Key 1 Flow NTC 2 Flow 3 Fan 4 Safety temperature limiter STL and block temperature sensor 5 Ignition and monitoring electrodes 6 Air pressure monitor 7 Flue gas pressure monitor 2 3 5 6 1 4 Fig 2 6 Front view Key 1 Control panel 2 Supply air silencer 3 Supply air ...

Page 8: ... cinders hemp mastic rust coarse dirt and the like from the pipes Other wise such substances can be deposited in the appliance and cause damage a Caution Leaks Make sure that the connection and gas pipes are not under stress when installed to avoid leakage in the heating installation or at the gas connection Caution Damage to the screwed connections To tighten or loosen bolts only use suitable ope...

Page 9: ...laws regulations technical rules and standards pertain ing to the installation must be considered and adhered to Attention shall be paid to the regulations guidelines and standards in force In particular reference shall be made to the following regulations guidelines standards and rules The electrical connections to the boiler MUST be in ac cordance with the BS 7671 The Electricity at Work Act and...

Page 10: ...iler support foun dation 5 to 10 cm thick 4 3 1 Regulations pertaining to the installation location hNote The boiler should be installed in a purpose built boiler room in accordance with BS 6644 The approval of the relevant building regulations au thority must be obtained for the selection of the instal lation site and for the characteristics of the ventilation and exhaust gas handling systems of ...

Page 11: ... 5 214 5 695 495 819 1285 1305 90 981 5 678 R2 1 1 2 R2 Fig 4 3 Pipe connection dimensions in mm A B C D E F G Fig 4 4 Appliance dimensions VKK GB 806 1606 3 E H VKK GB 2006 2806 3 E H A 165 165 B 326 326 C 369 369 D 50 50 E 1168 1478 F 1240 1550 G 22 22 Table 4 2 Appliance dimensions in mm Boiler type VKK GB 806 3 E H VKK GB 1206 3 E H VKK GB 1606 3 E H VKK GB 2006 3 E H VKK GB 2406 3 E H VKK GB ...

Page 12: ...own temperature 110 C tolerance 6 K If plastic pipes are used in the heating installation you must fit a suitable thermostat to the heating flow line on site This is required to protect the heating installa tion from temperature related damage The thermo stat can be wired to the plug for the contact thermo stat blue ProE plug When using non diffusion resistant plastic pipes in the heating system y...

Page 13: ...60 mbar If these pressures are exceeded the gas fitting may be damaged 1 Fig 5 3 Gas connection rear of boiler Connect the gas pipe to the gas connection 1 Fig 5 3 on the boiler Check the gas connection for leaks 5 4 Heating side connection 1 2 Fig 5 4 Heating side connection rear of boiler Connect the heating flow to the heating flow connec tion 1 Fig 5 4 Connect the heating return to the heating...

Page 14: ...b 19 30 3 3 42a 2b 2c 13 21a 21b 2a 2 33 Fig 5 5 Heating circuit schematic with low loss header Key 1 ecoCRAFT gas fired condensing boiler 2a Boiler circulation pump electronically regulated 2b Heating pump mixer circuit 1 2c Heating pump mixer circuit 2 5 Domestic hot water cylinder 10 Radiator thermostat valve 13 VRC 630 weather compensator 15 3 way mixer 16 External sensor 17a Flow temperature ...

Page 15: ...air is taken from the installation room The ventilation openings in the installation room must be in accordance with the relevant regulations con densing boilers Type B 5 7 Connecting the boiler to the flue gas pipe hNote Ensure that the horizontal section of the flue gas pipe is run with a downward slope towards the boiler All condensing boilers are fitted with special connection flanges for conn...

Page 16: ...th the Electricity at Work Act and BS 7671 Danger Risk of fatal electric shock from live connec tions Always switch off the power supply to the appliance first Only after this can the instal lation be carried out Voltage is continuously present on the L and N terminals of the tur quoise coloured plug even when the main switch is turned off Danger Risk of fatal electric shock from live connec tions...

Page 17: ... the front casing in the upper section towards you and lift it in order to remove it Hinge the electronics box forwards Unhitch the rear part of the electronics box cover and hinge it upwards Pass the cables through the cable entry in the rear wall of the appliance and through the unit into the electronics box Use the cable channel on the left hand side section for feeding the cable through the un...

Page 18: ...k7 accessory Fan Mains input X11 X18 X13 F4 Accessory pink 230 V 24 V 230 V 24 V Mains voltage Extra low voltage Edge connector X12 blue blue red white white 24 V Supply 0 10V Output black Extra low voltages plug turquoise violet green grey red black grey blue red green blue red red red black red black black green transparent black blue black black white white white braun black orange black black ...

Page 19: ... thermostat can be electrically incorporated in the safety chain by connecting it to the contact thermostat terminals e g for protecting underfloor heating systems Flue gas STL Connect the flue gas STL in the line to the flue gas pressure cartridge see the enclosed accessories in structions Gas pressure monitor A gas pressure monitor can be electrically integrated into the safety chain at the cont...

Page 20: ...illant heating control unit is shown in Fig 5 7 Further information can be obtained from the regulator instructions Before opening the electronics box switch off the sup ply to the unit and secure it against unintentional switching on Cylinder sensor ϑ Heating water pump Charging pump Network Boiler Bus red 0 DCF AF DCF AF X41 AF Edge connector red 1 0 0 RF DCF blue 6 FB X13 X18 X1 Pump 1 green Ne...

Page 21: ...sor 2 KP AV Stage 2 HK 3 P HK 2 P HK 2 Mischer HK 1 P ZP LP UV 230V Network 230V Network VF 1 VF 2 VF 3 KF Sp 1x ZP Telephone Distance Switch Bus External sensor C1 C2 7 8 9 II VRC 630 VRS 620 230 V 5 V 24 V 7 8 9 I Heating circuit 3 mixer Stage 1 Heating water pump Flow sensor 1 M ϑ ϑ ϑ Heating water pump 3 Flow sensor 3 ϑ 1 6 1 2 e g ext Gas valve e g fault indication e g ecoLEVEL X40 X12 X13 23...

Page 22: ...ctor block The Installer level with parameters and system related settings can be accessed after entering the service code 6 1 Entering the service code hNote The Installer level is automatically exited after 15 minutes Each time the service code is entered the time is extended by a further 15 minutes To enter the service code proceed as follows Activate the diagnostic mode by pressing the i and b...

Page 23: ...able 6 5 Stop watch 11 CO2 measurement Target value at nominal heat loading 9 3 Vol 0 2 Vol at minimum load 9 0 Vol 0 2 Vol Flue gas analyser with current calibration certification 12 If CO2 not within tolerance Ensure CO CO2 ratio less than 0 004 13 After setting gas ratio activate P1 function then perform repeat CO2 measurement The maximum draught must not exceed 20 mbar if the draught is too gr...

Page 24: ...ration starting On Off Activate function menu Check internal connected pump Check fan Check charging pump Check circulation pump After reset After mains ON Blower started at max speed All connections designated as cylinder charging pump are supplied with 230 V PCB if d 26 1 2 from 7 module if d 27 or d 28 3 All connections designated as circulation pump are supplied with 230 V PCB if d 26 1 2 from...

Page 25: ...t the same time as the burner function menu terminated VT Target VL max ºC 3 2 Back Yes Back Forward Back Forward Back Forward Back Forward Normal operation Hot water circuit Heating circuit Yes Yes Yes Back All connections designated as external pump are supplied with 230 V 2 from 7 module if d 27 or d 28 2 Water pressure is displayed On Off Fig 6 1 Function menu continued Start up 6 ...

Page 26: ...n Vaillant accepts no liability for the compatibility of any additive or its effectiveness in the rest of the heating system Additives for cleaning purposes subsequent flushing required Fernox F3 Jenaqua 200 Jenaqua 300 Jenaqua 400 Sentinel X 300 Sentinel X 400 Additives intended to remain permanently in the system Fernox F1 Fernox F2 Jenaqua 100 Jenaqua 110 Sentinel X 100 Sentinel X 200 Additives...

Page 27: ...hardness stabilisation or desludging Table 6 2 Guidelines for the heating water water hardness Heating water charac teristics Units Low salt Saline Electrical conductivity at 25 C μS cm 100 100 1500 Appearance free of sedimentary mate rials pH value at 25 C 8 2 10 01 8 2 10 01 Oxygen mg l 0 1 0 02 1 For aluminium and aluminium alloys the pH range is restrict ed from 6 5 to 8 5 Table 6 3 Guidelines...

Page 28: ...of this boiler has been checked adjust ed and preset at the factory for operation on the type of gas defined on the identification plate No measure ment of the combustion is necessary to set up the boiler Do not adjust the multifunctional automatic gas valve Ensure that the boiler has been installed in accordance with these instructions the integrity of the flue system and the flue seals as descri...

Page 29: ...ler Remove the pressure gauge and re tighten the sealing screw 1 Turn on gas at the gas isolation valve Make sure that there is no leakage at the sealing screw Turn off gas at the gas isolation valve Put the front casing back on Turn off electrical supply to the boiler You must not start up the boiler If the gas inlet working pressure is within the permissi ble range proceed as follows Take the bo...

Page 30: ...ator 6 7 Instructing the user a Caution The unit may only be operated for start up for test purposes for continuous operation with the air flue gas system fully assembled and enclosed The operator of the appliance must be instructed in the handling and function of his Vaillant VKK GB 806 3 2806 3 E H gas fired condensing boiler Hand over any instruction manuals intended for the user as well as the...

Page 31: ...get temp po tentiometer 50 C 70 C 65 C d 26 Internal accessory relay to X 6 pink plug 1 circulation pump factory fitted 2 ext pump 3 cylinder charging pump 4 flue non return valve extractor hood Warning inverse of d27 28 5 external gas valve 6 external error message d 27 Switching of accessory relay 1 on the VR40 acces sory 1 circulation pump 2 ext pump 3 cylinder charging pump 4 flue non return v...

Page 32: ...s heat via terminals 3 4 5 and the room temperature controller or the integral con troller specifies a setpoint for the flow temperature greater than 30 C via terminals 7 8 9 or greater than 20 C via the eBUS and the boiler is in winter mode heating setpoint potenti ometer not at left hand end stop and the contact thermostat is closed The pump is switched off when one of the above noted conditions...

Page 33: ...minate any devia tions of the actual condition from the specified condi tion This normally is done by cleaning adjustment and if necessary replacing individual components that are subject to wear You must carry out an annual maintenance of the Vail lant ecoCRAFT 3 The heating engineer must perform all maintenance work in the order specified in table 8 2 a Danger Possible poisoning and burning by e...

Page 34: ...ler see section 6 3 Function menu Always check earth continuity polarity and resistance to earth with a multimeter after any service work and after replacing any electrical component 8 3 Checking the CO CO2 ratio h Note Checking adjustment of the CO CO2 Ratio is re quired in the following instances replacement of gas valve or if an incorrect combustion is suspected during annual maintenance h Note...

Page 35: ...gas value if necessary see table 8 1 by turning the screw of the zero point 1 see Fig 8 2 h Note Use a Torx Tx40 socket spanner to turn the screw Turn to the right higher CO2 concentration Turn to the left lower CO2 concentration 1 Fig 8 2 Zero point screw hNote The adjustment is very sensitive Only perform the adjustment in increments of 1 16 turn Wait ap proximately 1 minute after each adjustmen...

Page 36: ...r mains and switch on the boiler 9 Perform a test operation of the boiler and heating instal lation including water heating and bleed if necessary 10 Check the boiler for leaks of any kind gas flue gas water condensate and rectify as necessary 11 Check the function of the quick vent system 12 Visual check of safety valve Is the outlet visible and without ensure no dripping water Check the pipe wor...

Page 37: ...ig 8 4 for contamination and correct fit a Caution The hose must be connected to the connection marked P1 on the exhaust gas pressure moni tor 8 9 Checking the combustion air pressure monitor Check the hoses to the combustion air pressure moni tor 1 Fig 8 4 for contamination and correct fit a Caution The connection marked P1 on the combustion air pressure monitor must be connected to the Venturi T...

Page 38: ...to one side Unfasten the four M5 screws 5 Fig 8 6 on the gas pipe gas filter gas fitting Unfasten the four M8 nuts 9 Fig 8 6 on the heat ex changer Withdraw the entire unit consisting of manifold flange fan Venturi and gas fitting to the front and lay it carefully to one side Remove the gasket between the heat exchanger and the manifold flange Carefully withdraw the burner to the front a Caution R...

Page 39: ...tion monitoring electrode Tighten the fixing nuts 2 and 4 Fig 8 9 to 2 Nm and reconnect the leads 8 12 Checking the safety thermostat 1 Fig 8 11 Reset button Key 1 STL reset button with cover cap Switch on the mains switch Turn the heating circuit off Set the unit to maximum feed temperature and heat the unit up to switch off by the controller After waiting for two minutes temperature equalisa tio...

Page 40: ...ive S 35 Speed ramp wait time speed deviation during ramp up S 36 Target value specification of analogue regulator 20 C i e the external regulator is blocking the heating operation S 39 Contact thermostat has responded S 40 Indicate emergency operation active Unit runs in restricted Vaillant assured comfort mode Corresponding error code alternates with status message in display S 41 System pressur...

Page 41: ...d 13 Circulation pump 1 100 on 0 off d 14 Setting for speed controlled internally connected pump Setting range 0 auto 20 100 fixed value setting Default setting 0 d 15 Current output of speed controlled pump in d 17 Control type 0 flow regulation 1 return regulation Default setting 0 d 18 Pump operating mode overrun 0 overrun comfort 1 continuing eco Default setting 0 d 20 Maximum setting value of...

Page 42: ...ntroller d 75 Maximum charging time for a storage without own con troller Setting range 20 21 90 min Default setting 45 min d 77 Cylinder partial load cylinder charging output limiting in kW Default setting VKK GB 806 30 kW VKK GB 1206 30 kW VKK GB 1606 50 kW VKK GB 2006 50 kW VKK GB 2406 70 kW VKK GB 2806 70 kW d 78 Cylinder charging temperature limiting flow target tem perature in cylinder charg...

Page 43: ... fan speed out of tolerance Fault in cable harness fan fault 33 Pressure cartridge is not switching on 34 Pressure cartridge is not switching off when fan stops 37 In emergency operation increase in minimum speed Temporary problems in air path 42 Coding resistor short circuited Coding resistor short circuited or fault in cable harness 43 Coding resistor open circuit Coding resistor open circuit or...

Page 44: ... error code F 20 is displayed the safety thermostat STL has shut down the boiler automatically because the temperature was too high Proceed as follows to reset it Remove the front cover Reset the STL by pushing the pin 1 Fig 9 1 Always troubleshoot and rectify the malfunction any time the STL is triggered 9 6 General notes No indications in the display If the boiler does not start and there is no ...

Page 45: ... Recycling and disposal are already taken into account during the development of all Vaillant products Vaillant s standards lay down strict requirements The recyclability demountability and separability of ma terials and components are taken into account for the selection of materials in the same way as environmental hazards and health risks during recycling and the dis posal of unavoidable remain...

Page 46: ... g s 6 3 10 0 12 2 19 9 21 7 23 5 Qmax g s 35 4 51 2 70 7 88 4 106 1 123 8 Exhaust temperature for tV tR 80 60 C min C 60 65 max C 65 70 Nominal CO2 G20 Qmin by vol 9 1 Qmax 9 3 Residual delivery pressure Pa 100 0 100 0 150 0 150 0 150 0 150 0 NOx class 5 NOx emission DIN EN 483 mg kWh 60 CO emission mg kWh 20 Heating Rated efficiency stationary 80 60 97 8 98 4 60 40 100 5 50 30 103 0 40 30 105 1 ...

Page 47: ...tandby W 8 Level of protection IP20 Installed fuses 4 AT Dimensions and weights Height mm 1285 Width mm 695 Depth mm 1240 1550 Assembly weight kg 200 220 235 275 295 310 Weight when ready for operation kg 210 235 255 300 320 340 Heating connection R2 Condensate connection Ø mm 21 Gas connection R 1 1 2 Flue gas supply air connection mm 150 130 200 130 Miscellaneous Permissible installation types B...

Page 48: ...0020055744_08 GB 082011 Subject to alterations ...

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