atmoCRAFT VK 654/9 - 1654/9 DE; AT; GB
For the heating engineer Installation and maintenance instructions atmoCRAFT Gas heating boiler VK 654/9 – 1654/9 GB
Contents Contents 1 1.1 1.2 Notes on the documentation . . . . . . . . . . . . Storage of the documents . . . . . . . . . . . . . . . . . . Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Description of the appliance. . . . . . . . . . . . . Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . CE label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended use . . . . . . . . . . . . . . . . . . . . . . .
Notes on the documentation 1 Description of the appliance 2 1 Notes on the documentation The following information is intended to help you throughout the entire documentation. Further documents apply in combination with this installation and maintenance manual. We accept no liability for a damage caused by failure to observe these instructions. 2 Description of the appliance 2.1 Identification plate The identification plate is mounted on the back of the electronic box.
2 Description of the appliance 2.2 CE label CE labelling shows that the appliances comply with the basic requirements of the following directives: - Gas appliances directive (90/396/EEC) - Electromagnetic compatibility directive with threshold class B (89/336/EEC) - Low voltage directive (73/23/EEC) The appliances meet the basic requirements of the efficiency requirements directive (Council Directive 92/42/EEC) as low temperature boilers.
Description of the appliance 2 2.6 Type overview The Vaillant atmoCRAFT gas boilers are supplied with the following capacities: Appliance type Designated country Nominal heat capacity (designation in P (kW) accordance with ISO 3166) VK 654/9 65.0 (80/60 °C) VK 754/9 75.0 (80/60 °C) VK 854/9 85.0 (80/60 °C) VK 1054/9 105.0 (80/60 °C) VK 1154/9 115.0 (80/60 °C) VK 1304/9 130.0 (80/60 °C) VK 1504/9 150.0 (80/60 °C) VK 1654/9 165.
2 Description of the appliance 2.7 Functional and operating elements 10 1 11 6 5 9 8 7 2 4 3 12 15 13 14 Fig. 2.
Safety instructions and regulations 3 3 Safety instructions and regulations 3.1 Safety instructions Assembly The combustion air fed to the unit must be free of chemicals which contain, e.g. fluorine, chlorine or sulphur. Sprays, solvents or cleaning agents, paints and adhesives can contain such materials which can, in certain circumstances, lead to corrosion when operating the unit, including the exhaust gas installation.
3 Safety instructions and regulations There is danger of being injured or scalded by the boiler and by all components carrying water. Only carry out work on these components once they have cooled down. Troubleshooting Disconnect the unit from the mains before starting to work. Close the gas valve and the maintenance valves.
Assembly 4 4 Assembly 4.1 Installation site – When selecting the installation location, the weight of the boiler, including the water contained within it, shown in the table “Technical Data” and the type of chimney construction must be taken into account. 4.1.
4 Assembly 4.2 Dimensions Ød 4 4 1100 1145 1 320 665 3 565 2 64 690 100 c b 690 a 4 min. 100 Fig. 4.
Assembly 4 h D 4 DØ f e dØ 1 1 2 2 3 320 565 665 1145 b c 500 4 3 100 a 64 690 g 690 k 4 min. 550 DØ Fig. 4.
4 Assembly 4.3 Recommended minimum distance for installation 2200 100 500 A B 500 1000 Fig. 4.3 Minimum clearances When installing the boiler, the minimum clearances shown in Fig. 4.3 must be maintained to ensure unhindered access to the boiler. The height of the boiler room should be at least 2200 mm (also with VKM). The side clearances and the clearance in front of the unit shown in the drawing are for maintenance purposes.
Assembly 4 4.4 Boiler block, pre-assembled Note! Here you will find the scope of supply of the pre-assembled boiler block. For additional installation see Chapter 4.5. 4.4.1 Scope of supply, boiler block, pre-assembled Check the scope of supply in accordance with the adjacent illustration and table for completeness and lack of damage. A C B 2 1 Fig. 4.
4 Assembly 4.4.2 Scope of supply, cladding Check the scope of supply in accordance with the adjacent illustration and table for completeness and lack of damage. A 4.4.3 Scope of supply, flow safety device Check the scope of supply in accordance with the adjacent illustration and table for completeness and lack of damage. A A B E A E F G C D B H B Fig. 4.
Assembly 4 4.4.4 Aligning the boiler block 1 2 1 Fig. 4.7 Aligning boiler block The boiler block must be level. Note! Under no circumstances should there be an incline to the side of the plug in the upper boss, otherwise air bubbles could form in the boiler block. • Level the boiler block using the adjustable boiler feet (1, SW 30) on the baseplate at the site of installation. • Completely connect the boiler to the water supply and check for leaks at an excess pressure of maximum 6 bar.
4 Assembly 2 1 3 2 3 1 Fig. 4.11 Fitting the intermediate plate and side plates Fig. 4.13 Mounting the electronic box • Fix one side plate (1) to the baseframe front and back with two screws. • Screw the intermediate plate (2) in front of the boiler. The intermediate plate is placed on the brackets and screwed in position in the lower area with four screws. • Fix the other side plate (3) to the baseframe front and back with two screws.
Assembly 4 4.6 Fitting the burners 2 2 1 Fig. 4.15 Inserting the temperature sensor into the immersion sleeve 1 2 Fig. 4.17 Inserting the burners • Insert the temperature sensor into the lower immersion sleeve (1) on the left of the boiler. • Stick the enclosed identification plate (2) to the top left of the intermediate wall. • Insert four screws in the pockets in the end links. • Place the burner (1) onto the screws (2).
4 Assembly 4.7 Connection of the electrical cable 1 Fig. 4.19 Connecting the gas valves and the STL Fig. 4.21 Fitting the plinth adaptor • Connect the connection cable to the electronic box as shown in the electrical schematic drawing, see 5.4.3 and 5.4.4. • Hang the plinth adaptor (1) into the lateral receptacles in the side pieces. 4.8 Completing the boiler 5 3 4 3 Fig. 4.
Assembly 4 1 1 2 3 4 3 2 Fig. 4.23 Fitting the cover plate Fig. 4.25 Inserting the front plate • Place the cover plate (1) in position. The braces (3) of the cover plate should be inserted into the slots in the side plates (2). Then push the cover plate back until the front edge of the cover plate is in line with the side plates. • Place the front plate (1) onto the pins (2) on the plinth rail. • Push the front plate (1) using the two pins (3) into the retaining springs (4). 1 Fig. 4.
5 Installation 5 Installation 5.4 5.1 General instructions for heating system 5.4.1 Notes for electrical installation Caution! Flush the heating system thoroughly before connecting the appliance! By doing that, residue such as welds, cinder, hemp, putty, rust, rough dust and similar substances are removed from the pipes. Otherwise such substances can be deposited in the appliance and cause damage. 5.2 Gas connection The gas installation may only be established by an authorised engineer.
Installation 5 5.4.2 Connecting the mains feed 5.4.3 Connecting the sensors and setting motors 3 6 5 4 1 2 Fig. 5.1 Connecting the mains supply The nominal voltage of the mains must be 230 V; if the mains voltage is more than 253 V and below 190 V functional impairment is possible. Caution! The electronics can be destroyed by connecting the mains infeed to the wrong terminal plugs on the ProE System.
5 Installation Charging pump N L 5 4 3 Heating circuit pump N L 9 8 7 2 1 Mains infeed Option external controller/room thermostat 230V contact Option external controller /room thermostat 7-8-9, 24V, digital or analogue Option installation thermostat X2 Small voltage plug X7 Edge plug 1 External sensor Feed/return sensor (option) DCF connection Plug for controller Mass accessories (in controller set) Mass Connection accessories box / accessories module 3 13 2 14 10 23 Remote control circulatio
Charging pump N L 5 4 3 Heating circuit pump N L 9 8 7 2 1 Mains infeed Option external controller/room thermostat 230V contact Option external controller /room thermostat 7-8-9, 24V, digital or analogue Option installation thermostat X2 Small voltage plug X7 Edge plug 1 External sensor Feed/return sensor (option) DCF connection Mass Plug for controller Mass accessories (in controller set) Connection accessories box / accessories module 3 13 2 14 10 23 Remote control circulation pump External
5 Installation 5.4.5 Connection of external accessories and control units When connecting accessories, the existing bridge on the relevant plug must be removed. Take especial care that the bridge is removed when incorporating an installation thermostat.
Installation 5 Start-up 6 5.4.6 Connecting external sensors, control units (accessories) Connectable accessories with Pro E system Information concerning the electrical connection of the following accessories can be taken from the individual accessories instructions: – Hot water storage tank – Heating pump for the pipe groups - Controllers 6 Start-up Initial start-up and operation of the appliance, and instruction for the user, must be performed by a heating engineer.
6 Start-up Caution! Do not add frost or corrosion preventative to the heating water! If frost or corrosion preventative is added to the heating water this can cause changes in the seals and can cause noises to be created during the heating process. Vaillant assumes no liability for this and such consequential damages. Please inform the user of the procedure for frost protection. If the heating water hardness is above 3,6 mol/ m3 (20 °dH) it should be softened.
Start-up 6 The permissible range for the connection flow pressure is: 17.0 to 25.0 mbar - 2nd gas family (natural gases) 35.0 to 45.0 mbar - 3rd gas family (liquid gases) Caution! If the connection pressure is outside the quoted range, the cause of the deviation should be found and the fault should be rectified. If no fault can be found no adjustments should be made and the boiler must not be started up and the responsible office of the gas supply company must be informed. Setting the 1st.
6 Start-up 6.2.4 Gas setting tables Nozzle designation corresponds to the nozzle pressure diameter ø in 1/100 mm Type of gas Nozzle pressure Natural gas 2E, 2H Ws = 15.0 kWh/m3 260 13.0 Partial output (1st. stage and starting gas pressure) 5.6 Propane 3P Ws = 22.5 kWh/m3 165 29 13.2 Nominal output (2nd stage) Table 6.1 Nozzle pressure setting table Nozzle size and nozzle pressures for nominal output/partial output; Nozzle pressure in mbar at 15°C, 1013 mbar, dry.
Start-up 6 6.2.5 Function check To complete the gas setting it is necessary to carry out a function check as follows: • Open the gas-cock and start up the boiler as shown in Chapter 6. • Check the boiler and heating system for tightness. 1 Caution! Also make sure that all the gas pressure measuring nipples are tightly closed. • Check the correct exhaust gas removal on the flow safety device. • Check the over-ignition and consistent flame structure of the main burner. 6.2.
6 Start-up 6.2.7 Changeover from liquid gas P to natural gas Changing the nozzles Note! The lower the chimney draught within the permissible range, the higher is the combustion technology efficiency of the gas combustion location. 1 2 Fig. 6.5 Changing the nozzles • Turn the boiler off. • Replace the ignition burner nozzle (1x24) (1) by the nozzle for natural gas E(H) (2x27). • Unscrew the burner nozzles for liquid gas P (165) (2) and screw in the burner nozzles for natural gas E(H) (260) gas-tight.
Start-up 6 Adapting the appliance to the heating system 7 • Point out to the user the correct (economical) settings for temperatures, regulators and thermostat valves. • Instruct the owner on the need for regular inspection and maintenance of the system. Recommend a inspection/maintenance contract to the customer. You can end the diagnosis mode as follows: • Simultaneously push the buttons “i” and “+” or do not push any buttons for about 4 minutes.
7 Adapting the appliance to the heating system 7.2 Overview of the adjustable installation parameters The following parameters can be adjusted to match the unit to the heating system and to the requirements of the customer: Note! In the last column you can enter your settings after you have set the installation-specific parameters. Meaning Adjustable values Factory setting d.
Inspection and maintenance 8 8 Inspection and maintenance Note! If it is necessary to keep the main switch on for certain inspection and maintenance, this is indicated in the description of the maintenance task. 8.1 Notes for maintenance Permanent operational readiness, safety, reliability and a long service life require inspections and maintenance work to be carried out regularly every year by a heating engineer.
8 Inspection and maintenance 8.3.1 Checking the safety temperature limiter 1 8.3.2 Automatic gas firing system • Remove the plug of the ionisation cable during operation. The burner flames must go out immediately. The automatic gas combustion unit starts again after approx. 30 seconds. After the third unsuccessful ignition attempt the automatic gas combustion unit switches to fault. The error message “F.29” appears in the display. • Re-insert the plug of the ionisation cable.
Inspection and maintenance 8 8.4 Maintenance tasks 8.4.1 Cleaning the burner Caution! If possible, do not use any chemical cleaning agents, otherwise deposits could build up on the monitoring and ignition electrodes. The unit may switch to fault condition. If you do use chemical cleaning agents, make sure that the electrodes are thoroughly cleaned afterwards. Fig. 8.3 Burner removal • Pull the burner out. 1 Fig. 8.
8 Inspection and maintenance • Remove the cladding and the insulation. • Remove the burner as described in Section 8.4.1 Cleaning the burner. • Clean the exhaust gas ducts (1) thoroughly using the cleaning brush supplied (2). You can access the exhaust gas ducts through the cleaning aperture in the exhaust gas manifold. • Re-fit the burner again (see Section 8.4.1). Caution! After cleaning, the gas and exhaust gas routes must be checked for tightness.
Troubleshooting 9 9 Troubleshooting 9.1 Error codes For fault finding and fault rectification, the fault signal facility of the DIA system is normally adequate. The following fault codes are shown in the display and help with the localisation and rectification of a fault. Code Meaning Cause F.00 Interrruption - forward flow NTC F.05 Interruption - exhaust gas sensor (accessories) F.
9 Troubleshooting 9.2 Resetting the interlock after switch-off by the safety temperature limiter (STL) 1 2 Display Meaning S.00 Displays during heating operation No heat required S.02 Heating pump supply S.03 Heating ignition S.04 Heating burner on S.07 Heating pump run-out S.08 Burner lock after heating mode Page 20 Displays during storage tank charging Storage cycle mode active S.23 Storage tank charging ignition S.24 Storage tank charging burner S.
Troubleshooting 9 Display Meaning d.00 d.02 Test operation on 1st burner stage for gas setting (only for 0 = Normal operation (both stages) 2-stage boilers) 1 = After starting switching back to the 1st stage 2 = Full output (2nd stage) Heating pump overrun Starts after ending of heat demand 5 .. 60 min, “-” for continuous Burner locking time Starts after ending of heat demand 2 .. 60 min d.04 Measured value of storage temperature d.05 Flow temperature target value in °C d.
10 Vaillant service 11 Recycling and disposal 10 Vaillant Service 11 To ensure efficient and reliable operation of your boiler it is recommended that regular servicing is carried out by your service provider. Recycling and disposal are already taken into account during the development of all Vaillant products. Vaillant’s standards lay down strict requirements.
Technical data 12 12 Technical data Technical data Unit VK 654/9 VK 754/9 VK 854/9 VK 1054/9 VK 1154/9 VK 1304/9 VK 1504/9 VK 1654/9 Nominal heat output kW 65 75 85 105 115 130 150 165 Nominal heat loading kW 70.7 81.5 92.4 114 125 141.3 163 179.3 Minimum heat output kW 42.2 48.7 55.2 68.2 74.7 84.5 97.5 107.5 Minimum thermal load kW 46 53 60 74.1 81.3 91.8 106 116.
835553_02 DEATGB 092006
