Vaillant ecoCRAFT VKK GB SERIES Installation And Maintenance Instructions Manual
Gas condensing boiler
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- Operating manual (16 pages) ,
- Installation and maintenance instructions manual (48 pages)
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Summary of Contents for Vaillant ecoCRAFT VKK GB SERIES
- Page 1 For the heating engineer Installation and maintenance instructions ecoCRAFT Gas 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...
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Page 2: Table Of Contents
Removing the casing ...........13 Factory customer service/manufacturer's Gas connection .............14 guarantee ............. 41 Heating side connection ..........14 10.1 Vaillant Service .............41 Connecting the DHW cylinder ........15 10.2 Vaillant warranty............41 Air/flue gas installation ..........16 5.6.1 Flue gas connection, room-sealed ......16 Recycling and disposal ........41 5.6.2 Flue gas connection, open flued ......16... -
Page 3: Notes On The Documentation
Notes on the documentation 1 Notes on the documentation Applicability of the manual These installation instructions apply exclusively to appli- The following instructions are intended to help you ances with the following part numbers: throughout the entire documentation. Further documents apply in combination with this instal- Appliance type Part number lation and maintenance manual. -
Page 4: Description Of The Appliance
It becomes visible after using the VKK GB 2806/3-E-H as an example. the front section of the casing is removed. VKK GB 2806/3-E-H Equipment Vaillant gas-fired condensing Vaillant GmbH Remscheid / Germany boiler Serial-Nr. 21080400100054150006000000N0 VKK GB 2806/3-E-H Great Britain ecoCRAFT Typ B23, B23P, C33, C43, C53, C63, C83 GB, IE, cat. -
Page 5: Construction And Function
The boiler is suitable for connection to commercial heating control Table 2.3 Regulation ranges systems, Vaillant controls and BEMS systems. The boiler is suitable for connection to open-flue systems. Air for combustion must be supplied in accordance with BS 6644. - Page 6 2 Description of the appliance Overview of the operating controls Overview of the functional controls Note When using Vaillant controls both dials must be turned to maximum position. Fig. 2.2 ecoCRAFT operating controls To open the front panel, hold the recess and fold the panel out.
- Page 7 Description of the appliance 2 Fig. 2.4 View from the left hand side 2 Gas valve 3 Supply air silencer 4 Inspection opening for heat exchanger 5 Supply air hose 6 Siphon 7 Condensate discharge Fig. 2.6 Front view 8 Condensate trap/siphon connection 9 Flue gas STL (optional) 10 Flue gas silencer 11 Condensate trap...
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Page 8: Safety Instructions And Regulations
3 Safety instructions and regulations Safety instructions and regulations Caution! Damage to the screwed connections! The appliance may only be installed by a competent To tighten or loosen bolts, only use suitable qualified person registered with Corgi. open-ended spanners (do not use pliers or ex- tensions etc.) Improper use or unsuitable tools Safety instructions can cause damage, such as gas or water leaks! -
Page 9: Regulations
Danger of death from electric shock! noises to be created during the heating process. Vaillant The supply terminals in the terminal box of the assumes no liability for this and such consequential device are under voltage even if the mains damages. -
Page 10: Assembly
3 Safety instructions and regulations 4 Assembly Assembly BS 5854 Code of practice for flues and flue structures in buildings. The boilers are supplied ready for connection in a pack- BS EN 12828 Design of water-based heating systems. aging unit with the casing fitted. BS 6644 Specification for the installation of gas- Scope of delivery... -
Page 11: Installation Location
Assembly 4 Installation location 4.3.2 Recommended minimum distances for • The unit should be installed in a frost-protected room. installation The unit can be operated in ambient temperatures be- tween approx. 4 °C and 50 °C. When selecting the installation site, the weight of the boiler including the water inside, as determined from the "Technical Data"... - Page 12 4 Assembly Fig. 4.4 Appliance dimensions VKK GB 80-1606/3-E-H VKK GB 200-2806/3-E-H 1168 1478 1240 1550 Table 4.2 Appliance dimensions Boiler Type 806/ 1206/ 1606/ 2006/ 2406/ 2806/ 3-E-H 3-E-H 3-E-H 3-E-H 3-E-H 3-E-H Flue pipe Supply air pipe Table 4.3 Dimensions of supply air and flue pipes Installation and maintenance instructions ecoCRAFT - 0020055744_03...
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Page 13: Installation
Installation 5 Installation Removing the casing General information on the heating system Caution! Malfunctions! Flush the heating system thoroughly before connecting the appliance! In this way, residue such as cinders, hemp, putty, rust, welding residues, coarse dirt and similar substances are removed from the pipes. -
Page 14: Gas Connection
5 Installation Gas connection Heating side connection The gas installation may only be carried out by a com- petent and qualified engineer. The legal directives and any local regulations for gas supply companies must be observed while doing this. The gas supply line must be constructed in accordance with the Gas Safety (installation and use) Regulations and IGE UP1, IGE UP1A, IGE UP1B and IGE UP2. -
Page 15: Connecting The Dhw Cylinder
Installation 5 The following pumps and low loss headers are recom- mended for use with the respective boilers: Boiler Nominal water Speed regulated 3 stage conventional pump Low loss header circulation volume high-efficiency pump for 20 K difference VKK GB 806/3-E-H 3.44 Item no. -
Page 16: Air/Flue Gas Installation
5 Installation Air/flue gas installation All condensing boilers are fitted with special connection In case you use air/flue gas pipes which are licenced to flanges for connecting condensate secure and over- be used together with the boiler, please observe the en- pressure leak-tight flue gas pipes. -
Page 17: Electrical Connection
Vaillant accessories can be connected. For boilers above 200 kW: If required, an in-line neutralisation device from the range of Vaillant accessories can be connected. Electrical connection Danger! Risk of fatal electric shock from live connec-... -
Page 18: Connecting The Mains Cable
5.9.2 Connecting a controller • Open the front flap by lifting the silver handle strip. The Vaillant VRC 630 controller or an externally mount- • Unscrew the screw above the multi-function operating ed Vaillant VRC 430 controller must be connected via panel. -
Page 19: Connecting Electrical Accessories And Internal Wiring
Installation 5 5.9.3 Connecting electrical accessories and internal wiring Charging pump blue Heating water pump 0 .. 10V Pump signal Option - ext. controller/ room thermostat 3-4 (contact) Mains input 0-10V output Pump Option - ext. controller/ room thermostat 7-8-9 (analogue) module Bus connection (controller/room PWM input. - Page 20 5 Installation Boiler circulation pump, fixed speed Condensate feed pump • Connect the boiler circulation pump to the green ProE • Connect the alarm output of a condensate feed pump plug connector on the connection rail. to the "Contact thermostat" plug. Boiler circulation pump, modulating VRC 430, 630 control units •...
- Page 21 Installation 5 Connecting a VRC 630 control unit (controller out- side the electronics box) — turquoise e.g. ecoLEVEL e.g. fault indication e.g. ext. Gas valve turquoise turquoise orange natural beige yellow natural white beige grey natural yellow white white white beige yellow natural...
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Page 22: Start-Up
6 Start-up Start-up Initial start-up and operation of the appliance, and in- struction for the user, must be performed by a heating engineer. For subsequent installation/operation instruc- tions, see the relevant section of the operating manual. Caution! Before start-up, and after inspection, maintenance and repair work, the gas unit must be checked for leaks! The operation of the boiler and the setting of various... - Page 23 Start-up 6 Procedure Remarks Tools required Check the gas connection pressure Minimum inlet working pressure is not less than U-tube or digital pressure gauge 17 mbar Check whether syphon is full If necessary fill via flue gas analysis point Check electrical connection rail Mains connection: L,N, PE terminals Controller terminals: "Bus", /7-8-9 or 3-4 Switch unit on, display active...
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Page 24: Function Menu (For Maintenance And Service Work)
6 Start-up Function menu (for maintenance and service work) The function menu allows the technician to perform functional checks on individual actuators. It can always be started after a "RESET" or a "Mains ON". After a wait of approx. five seconds or if the "-" button is pressed, the unit's electronics switch to normal opera- tion. - Page 25 Start-up 6 Back All connections designated as external pump Check are supplied with 230 V. external pump? - 2 from 7 module, if d.27 or d.28 = 2. Back / Forward Back Hot water circuit Water pressure is displayed. Vent hydraulics? Heating circuit Back / Forward The internal heating pump...
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Page 26: Filling The System
6 Start-up Filling the system 6.4.2 Filling the siphon • Flush the entire heating system thoroughly before fill- • Fill the siphon with water through the opening in the ing. flue gas collector. Corrosion protection by water treatment Danger! In the case of heating water that has been conditioned Risk of poisoning from leaking flue gas! by the addition of strongly alkaline substances, alumini- If the device is operated with an empty... - Page 27 Start-up 6 6.5.1 Checking the connection pressure Caution! (Gas flow pressure) Risk of measurement errors caused by the in- gress of leakage air! Make sure that the opening for the measuring probe is well sealed during the measurement to prevent the ingress of leakage air! Note! The maximum draught must not exceed 20 mbar, as otherwise the results of the CO...
- Page 28 6 Start-up • Measure the CO content in the flue gas. Note! The maximum draught must not exceed VKK GB xx6/3-E-H % CO % CO 20 mbar, as otherwise the results of the CO at rated load at minimum load measurement will be invalid.
- Page 29 Start-up 6 Note! Note! Adjust only in increments of 1/8 turn and wait Adjust only in increments of 1/8 turn and wait approx. 1 minute after each adjustment until approx. 1 minute after each adjustment until the value stabilises. the value stabilises. After the adjustment, check the quality of combustion •...
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Page 30: Checking The Appliance Function
(inspection/mainte- nance contract). • Bring it to the operator's attention that the manuals should remain in the vicinity of the Vaillant VKK GB 806/3 -2806/3-E-H gas-fired condensing boiler. • Instruct the user about measures taken to ensure the supply of combustion air and removal of flue gas. -
Page 31: Adapting The Unit To The Heating System
Adapting the unit to the heating system 7 Adapting the unit to the heating system The adaptation of the boiler to the heating installation is carried out in the Diagnostic Mode. The operating con- cept for the selection of the various parameters and their setting is shown in Section 6.2. -
Page 32: Setting The Maximum Boiler Flow Temperature
The casing must be removed from the boiler before any To ensure all the functions of your Vaillant appliance on maintenance work. a continuing basis and in order not to change the • To do this, unscrew the screw above the multi-func- approved original condition, only original Vaillant re- tion operating panel. -
Page 33: Cleaning The Condensate Collector
Maintenance 8 Procedure Remarks Tools Check the filling pressure of the heating system Top up if necessary (approx. 2.5 bar) "-") (button Visual check for leaks in heating circuit Check function of quick vent system Visual check of safety valve In accordance with BS 6644 Check condensate collector, siphon, supply air and flue See: 8.5 and 8.6... -
Page 34: Cleaning The Siphon
8 Maintenance Cleaning the siphon Checking the flue gas pressure monitor • Remove the boiler casing. Note Condensate can escape while the drain hoses are being pulled off. Fig. 8.4 Checking the flue gas pressure monitor • Check the hose to the flue gas pressure monitor (2) for contamination and correct fit. -
Page 35: Cleaning The Burner
Maintenance 8 8.10 Cleaning the burner • Blow out the burner with compressed air outside the If cleaning of the burner is necessary, the complete installation room from the slot plate towards the burner/fan unit must be dismantled. metal fleece. If the burner is heavily contaminated it must be replaced. -
Page 36: Checking The Safety Temperature Limiter
S.39 Contact thermostat has responded remain closed during the STL test. Indicate emergency operation active; Unit runs in restricted Vaillant assured comfort mode. The boiler must switch off at 110 ºC. S.40 Corresponding error code alternates with status • Reset the safety temperature limiter after the boiler message in display (see Section 9.4) has cooled down. -
Page 37: Diagnostic Mode
Troubleshooting 9 Diagnostic mode In the diagnostic mode various parameters can be read off to allow display of the operating conditions and for fault diagnosis. • Press the "i" and "+" buttons simultaneously to call up the diagnostic mode. • Select the desired diagnostic point with the "+" and "–"... - Page 38 9 Troubleshooting Display Meaning Setting range and default setting for settable parameters d.34 Actual speed of fan [rpm x 10] d.40 Flow temperature [°C] d.41 Return temperature [°C] d.43 Boiler temperature d.44 Actual value of ionisation current d.47 Outside temperature [°C] d.50 Offset for minimum speed in rpm/10 Setting range: 0..300 Default setting: 30...
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Page 39: Error Messages
Troubleshooting 9 Error messages A malfunction is indicated on the display by an "F" fol- lowed by a number. In addition, the "crossed-out flame" symbol is displayed. Fault with Description Possible cause No. "F.." Open circuit in flow sensor Open circuit in return sensor Short circuit, flow sensor Short circuit, return sensor Short circuit, cylinder sensor... -
Page 40: Resetting The Interlock After Switch-Off By The Safety Temperature Limiter (Stl)
9 Troubleshooting Resetting the interlock after switch-off by Note! the safety temperature limiter (STL) If a bridge is applied between terminals 3 and 4 and the ecoCRAFT starts up, the external controller must be checked. Boiler does not respond to a request for hot water •... -
Page 41: Factory Customer Service/Manufacturer's Guarantee
10.2 Vaillant warranty Vaillant provide a full parts and labour warranty for this 11.1 Appliance appliance. The Vaillant boiler consists up to 92 % of metallic... -
Page 42: Technical Data
12 Technical data 12 Technical data VKK GB VKK GB VKK GB VKK GB VKK GB VKK GB Term Units 806/3-E-H 1206/3-E-H 1606/3-E-H 2006/3-E-H 2406/3-E-H 2806/3-E-H 80/60 13.6 -78.2 21.3 -113.4 26.2 -156.5 43.1 -196.8 47.0 -236.2 51.0 - 275.5 Rated heat output range for 60/40 14.1 - 80.4... - Page 43 Technical data 12 VKK GB VKK GB VKK GB VKK GB VKK GB VKK GB Term Units 806/3-E-H 1206/3-E-H 1606/3-E-H 2006/3-E-H 2406/3-E-H 2806/3-E-H Electrical equipment Nominal voltage V/Hz 230 / 50 max. elec. power consumption elec. power consumption in standby Level of protection IP 20 Fuses fitted...
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