Vaillant ecoCRAFT VKK GB SERIES Installation And Maintenance Instructions Manual
Gas-fired condensing boiler
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Summary of Contents for Vaillant ecoCRAFT VKK GB SERIES
- Page 1 For the 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...
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Page 2: Table Of Contents
Measurements on the components ....... 44 5.9.3 Connecting electrical accessories and internal wiring ...............18 Customer service and warranty ......45 5.9.4 Connecting a controller ..........20 10.1 Vaillant Service ............45 10.2 Vaillant warranty............45 Start-up ...............22 Entering the service code .........22 Recycling and disposal ........45 Start-up checklist ............22... -
Page 3: Notes On The Documentation 1
Notes on the documentation 1 Notes on the documentation Note Useful information and instructions. The following instructions are intended to help you throughout the entire documentation. • Symbol for a necessary task Further documents apply in combination with this instal- lation and maintenance manual. -
Page 4: Description Of The Appliance
VKK GB/3-E-H as an example. VKK GB 1206/3-E-H Equipment Vaillant gas-fired condensing boiler Vaillant GmbH Remscheid / Germany Great Britain Serial-Nr. 21400400100054100006000000N0 Unit size (power in kW) VKK GB 806/3-E-H ecoCRAFT... -
Page 5: Intended Use
Description of the appliance 2 Intended use Equipment Vaillant VKK GB 806/3 — 2806/3-E-H gas-fired condens- - Regulation range, see Table 2.3 - Reduced environmental impact as a result of the ing boilers are constructed in accordance with state of the art technology and recognised safety regulations. - Page 6 2 Description of the appliance Overview of the operating controls Rotary knob for setting the cylinder temperature (on units with a VIH DHW cylinder connected). When using the VRC 430 for controlling cylinder temperature, set to the clockwise end stop so that the working range of the hot water control- ler in the VRC 430 will not be restricted.
- Page 7 Description of the appliance 2 Fig. 2.4 View from the left hand side 2 Gas fitting 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! Leaks! The appliance may only be installed by a competent per- Make sure that the connection and gas pipes son approved at the time by the Health and Safety Ex- are not under stress when installed, to avoid ecutive. -
Page 9: Regulations
Safety instructions and regulations 3 Inspection and maintenance Attention shall be paid to the regulations, guidelines and Inspection, maintenance and repair work should only be standards in force. In particular, reference shall be undertaken by an approved heating installation compa- made to the following regulations, guidelines, standards ny. -
Page 10: Assembly
3 Safety instructions and regulations 4 Assembly IGE/UP/1A Soundness testing and purging of small Installation location low pressure industrial and commercial • The unit should be installed in a frost-protected room. natural gas installations. The unit can be operated in ambient temperatures be- IGE/UP/10 Installation of gas appliances in indus- tween approx. -
Page 11: Recommended Minimum Distances For Installation
Safety instructions and regulations 3 4.3.2 Recommended minimum distances for installation Fig. 4.4 Appliance dimensions VKK GB 806-1606/3-E-H VKK GB 2006-2806/3-E-H 1168 1478 1240 1550 Fig. 4.2 Recommended distances during installation (in mm) • Keep to the recommended minimum distances in Table 4.2 Appliance dimensions (in mm) order to be able to carry out assembly and mainte- nance work with as little impediment as possible. -
Page 12: Installation
5 Installation 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 res- idues, coarse dirt and similar substances are removed from the pipes. -
Page 13: Gas Connection
Installation 5 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 14: Connecting The Dhw Cylinder
5 Installation The following pumps and low loss headers are recom- mended for use with the respective boilers: Gas-fired condensing boiler Nominal water circulation volume Speed regulated high-effi- Low loss header for 20 K difference ciency pump VKK GB 806/3-E-H 3.44 Item no. -
Page 15: Air/Flue Gas Installation
Installation 5 Air/flue gas installation Connecting the boiler to the flue gas pipe Should you use air/flue gas pipes which are licensed to be used together with the boiler, please observe the en- Note closed installation instructions 0020058722. Ensure that the horizontal section of the flue gas pipe is run with a downward slope towards Should you use conventional air/flue gas pipes, please the boiler! -
Page 16: Electrical Connection
For gas-fired condensing boilers up to 200 kW: The fan is connected to a 230 V/50 Hz supply. If required, a neutralisation device with conden- sate feed pump from the Vaillant range of ac- The connection should be wired as follows: cessories can be connected. -
Page 17: Connecting The Mains Cable
5.9.2 Connecting a contro ller • Take care to ensure spatial separation of the mains The Vaillant VRC 430, 630 or VRS 620 controllers must and extra low voltage cables. be connected via the "Bus" connection (red plug) in ac- •... -
Page 18: Connecting Electrical Accessories And Internal Wiring
5 Installation 5.9.3 Connecting electrical accessories and internal wiring 4A slow-blow Charging pump blue Heating circuit pump/ Boiler circulation pump 0 .. 10 V Option - ext. controller/room thermostat Accessory Signal 3-4 (contact) pink Mains input 230 V~ blue 24 V Option - ext. - Page 19 Installation 5 Boiler circulation pump, speed regulated • Connect the boiler circulation pump to the green ProE connector on the terminal strip, and also the control line to the 0 — 10 V adapter box which is located at the top left of the unit, next to the two pressure cartridg- es.
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Page 20: Connecting A Controller
A weather-controlled outside temperature controller with modulating burner control can be used to control the heating installation. The Vaillant VRC 430 controller must be connected via the "Bus" connection (red plug) in accordance with Fig. 5.8. The bridge between the terminals 3 and 4 should remain intact (lilac plug). - Page 21 Installation 5 Connecting a VRS 620, VRC 630 control unit (con- troller outside 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...
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Page 22: Start-Up
Vaillant Ltd can offer a commissioning service for this appliance (by prior arrangement).. For subsequent in- stallation/operation instructions, see the relevant sec- tion of the operating manual. - Page 23 Start-up 6 Procedure Remarks Tools required Ensure boiler and system are full of water Check whether syphon is full If necessary fill via flue gas analysis point Check the entire gas route for leaks Gas sensing instrument is recommended (espe- U Gauge - or digital manome- cially for checking the burner gaskets for leaks), ter,...
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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 components. It can al- ways 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
• When using additives, follow the manufacturer's in- structions without exception. 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... - Page 27 Start-up 6 Total heating rating Total hardness at 20 l/kW for Total hardness at Total hardness at the smallest boiler heating sur- > 20 l/kW < 50 l/kW > 50 l/kW face for the smallest boiler heating for the smallest boiler heating surface surface mol/m...
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Page 28: Filling The Heating Side
6 Start-up 6.4.1 Filling the heating side - a visual check is carried out on the boiler combus- • Loosen the cap on the factory-fitted automatic air tion circuit and the relevant seals, vent by one or two turns. Make sure that the opening - that any defects have been corrected at this stage. -
Page 29: Checking The Gas Inlet Working Pressure
19.03 cannot correct the failure, notify the gas supply com- VKK GB 2406/3-E-H 25.37 26.64 22.83 pany or the Vaillant Service Solutions team and pro- VKK GB 2806/3-E-H 29.59 31.97 26.63 ceed as follows: Table 6.5 Gas rates (as per BS EN 483) -
Page 30: Instructing The User
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 appliance documents for safe keeping. -
Page 31: Adapting The Unit To The Heating System 7
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
7 Adapting the unit to the heating system Diagnostic Description Setting range Default setting point d.77 Cylinder partial load (cylinder charging output limit- settable values in kW ing) in kW VKK GB 806 = 14 - 80 kW VKK GB 806 = 30 kW VKK GB 1206 = 22 - 120 kW VKK GB 1206 = 30 kW VKK GB 1606 = 27 - 160 kW... -
Page 33: Inspection And Maintenance 8
The boiler may only be maintained by a compe- tent person. of all functions and long working life of your Vaillant boiler and to prevent modifications to the approved se- All service work must be carried out by a competent... -
Page 34: Checking The Co/Co Ratio
8 Inspection and maintenance Safety instructions Checking the CO/CO ratio Danger! Danger of life and limb by electric Note shock! Checking/adjustment of the CO/CO Ratio is re- The supply terminals of the boiler are under quired in the following instances: mains voltage even if the boiler main switch is - replacement of gas valve, off. - Page 35 Note and the flue gas values remain higher than al- Use a Torx Tx40 socket spanner to turn the lowed in table 8.1 call the Vaillant Customer screw. Service Centre. Do not start up the boiler! - Turn to the right: higher CO...
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Page 36: Cleaning The Siphon
8 Inspection and maintenance 8.5 Maintenance work steps Cleaning the condensate collector • Carry out proper regular maintenance once a year. Activity Check the filling pressure of the heating system (button “-”) Top up if necessary (section 6.4.1). Check the air flue gas system for leaks and for proper fixation and ensure it is not blocked or damaged and is fitted correctly, complying with the relevant installation instructions. -
Page 37: Checking The Flue Gas Pressure Monitor
Inspection and maintenance 8 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. Caution! The connection marked "P1" on the combustion air pressure monitor must be connected to the Venturi. -
Page 38: Cleaning The Burner
8 Inspection and maintenance 8.10 Cleaning the burner Caution! Risk of damage to the burner surface! Danger! Take care that the burner surface does not get Danger of personal injury and material damage! damaged during cleaning! Shut off the gas supply before dismantling the burner, as otherwise gas can escape without •... -
Page 39: Changing The Ignition And Ionisation/ Monitoring Electrodes
Inspection and maintenance 8 • Open the gas valve and check for leaks up to the gas • Tighten the fixing nuts (2 and 4, Fig. 8.9) to 2 Nm and fitting. reconnect the leads. • Switch the boiler on. •... -
Page 40: Troubleshooting
Target value specification of analogue regulator < 20 °C, i.e. the external regulator is blocking the heating operation S.39 Contact thermostat has responded Indicate emergency operation active; Unit runs in restricted Vaillant assured comfort mode. S.40 Corresponding error code alternates with status message in display S.41... -
Page 41: 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 42 9 Troubleshooting Display Meaning Setting range and default setting for settable parameters d.34 Actual speed of blower [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: -40...
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Page 43: 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 "F.." Open circuit in flow sensor Open circuit in return sensor Short circuit, flow sensor Short circuit, return sensor Short circuit, cylinder sensor... -
Page 44: Test Programs
9 Troubleshooting Test programs If error code "F.20" is displayed, the safety thermostat Special functions can be triggered on the appliances by (STL) has shut down the boiler automatically because activating various test programs. the temperature was too high. These programs are given in detail in the table 8.5. Proceed as follows to reset it: The test programs P.0 to P.6 will be started when •... -
Page 45: Customer Service And Warranty 10
10.2 Vaillant warranty hazards and health risks during recycling and the dis- Vaillant provide a full parts and labour warranty for this posal of unavoidable remains of unusable residue. appliance. The appliance must be installed by a suitably competent 11.1... -
Page 46: Technical Data
12 Technical data 12 Technical data VKK GB VKK GB VKK GB VKK GB VKK GB VKK GB Term Units 806/ 1206/ 1606/ 2006/ 2406/ 2806/ 3-E-H 3-E-H 3-E-H 3-E-H 3-E-H 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 60/40 14.1—80.4 22.1—116.5 27.1—160.8... - Page 47 Technical data 12 VKK GB VKK GB VKK GB VKK GB VKK GB VKK GB Term Units 806/ 1206/ 1606/ 2006/ 2406/ 2806/ 3-E-H 3-E-H 3-E-H 3-E-H 3-E-H 3-E-H Electrical equipment Nominal voltage V/Hz 230/50 max. elec. power consumption elec. power consumption in standby Level of protection IP20 Installed fuses...