For the heating engineer Installation and maintenance instructions ecoCRAFT Gas condensing boiler GB 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
Contents 1 1.1 1.2 1.3 Notes on the documentation...............................3 Storage of the documents .......................................... 3 Symbols used ................................................................. 3 Applicability of the manual......................................... 3 7 7.1 7.2 7.3 Adapting the unit to the heating system........ 31 Setting the maximum boiler flow temperature ...32 Setting pump overrun time ......................................
Notes on the documentation 1 1 Notes on the documentation The following instructions are intended to help you throughout the entire documentation. Further documents apply in combination with this installation 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 owner of the system: Operating manual Short-form instructions No. 00200587171 No.
2 Description of the appliance 2 2.1 Description of the appliance Model description Designated country (designation in accordance with ISO 3166) Appliance type Category of permit Type of gas Nominal heat output range P (kW) VKK GB 806/3-E-H 13.6 – 78.2 (80/60 °C) 14.1 – 80.4 (60/40 °C) 14.7 – 84.1 (40/30 °C) VKK GB 1206/3-E-H 21.3 – 113.4 (80/60 °C) 22.1 – 116.5 (60/40 °C) 23.1 – 121.8 (40/30 °C) VKK GB 1606/3-E-H 26.2 – 156.5 (80/60 °C) 27.1 – 160.8 (60/40 °C) 28.4 – 168.
Description of the appliance 2 2.3 Intended use Vaillant gas-fired condensing boilers VKK GB 806/3 -2806/3-E-H are constructed in accordance with state of the art technology and recognised safety regulations. Nevertheless, there is still a risk of injury or death to the user or others or of damage to the device and other property in the event of improper use or use for which it is not intended.
2 Description of the appliance Overview of the operating controls Overview of the functional controls 1 2 9 h Note When using Vaillant controls both dials must be turned to maximum position. 1 10 3 8 2 7 3 9 6 5 4 Fig. 2.2 ecoCRAFT operating controls 8 4 7 To open the front panel, hold the recess and fold the panel out. You can now see the controls, which have the following functions (cf. fig. 4.
Description of the appliance 2 15 14 16 1 13 2 1 12 11 3 10 2 9 8 4 7 6 6 5 5 Fig. 2.
3 Safety instructions and regulations 3 Safety instructions and regulations The appliance may only be installed by a competent qualified person registered with Corgi. Caution! a Damage to the screwed connections! To tighten or loosen bolts, only use suitable open-ended spanners (do not use pliers or extensions etc.) Improper use or unsuitable tools can cause damage, such as gas or water leaks! 3.1 Safety instructions The combustion air fed to the unit must be free of chemicals e.g.
Safety instructions and regulations 3 Start-up The heating system must be thoroughly cleansed before use. The boiler heat exchanger is made from aluminium and any inhibitor used must be suitable for use with aluminium. Always seek the advice of a professional water treatment company.
3 Safety instructions and regulations 4 Assembly BS 5854 Code of practice for flues and flue structures in buildings. BS EN 12828 Design of water-based heating systems. BS 6644 Specification for the installation of gasfired hot water boilers with rated inputs between 70kW (net) and 1.8MW (net) (2nd and 3rd family gases). Code of practice for low temperature heating systems with outputs greater than 45kW. Part 1 Fundamental and design considerations. Part 2 Selection of equipment.
Assembly 4 4.3 Installation location • The unit should be installed in a frost-protected room. The unit can be operated in ambient temperatures between 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" table (Chapter 12), must be taken into account. 4.3.
4 Assembly A B C G E D F Fig. 4.4 Appliance dimensions VKK GB 80-1606/3-E-H VKK GB 200-2806/3-E-H A 165 165 B 326 326 C 369 369 D 50 50 A 1168 1478 F 1240 1550 G 22 22 Table 4.2 Appliance dimensions 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 Flue pipe 150 150 150 200 200 200 Supply air pipe 130 130 130 130 130 130 Boiler Type Table 4.
Installation 5 5 5.1 Installation 5.2 Removing the casing General information on the heating system 1 a 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. Otherwise such substances can be deposited in the appliance and cause damage. • A safety valve must be fitted to the boiler as described in BS 6644.
5 Installation 5.3 Gas connection The gas installation may only be carried out by a competent 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. 5.
Installation 5 The following pumps and low loss headers are recommended for use with the respective boilers: Boiler Nominal water circulation volume for 20 K difference Speed regulated high-efficiency pump 3 stage conventional pump Low loss header VKK GB 806/3-E-H 3.44 Item no. 0020022253 Item no. 309 442 WH 95 (Item No. 306 721) VKK GB 1206/3-E-H 4.99 Item no. 0020022253 Item no. 309 442 WH 160 (Item No. 306 726) VKK GB 1606/3-E-H 6.88 Item no. 0020022253 Item no.
5 Installation 5.6 Air/flue gas installation In case you use air/flue gas pipes which are licenced to be used together with the boiler, please observe the enclosed installation instructions 0020058722. In case you use customary air/flue gas pipes, please overserve the following notes: The flue gas system must be suitable for the flue gas duct of the boiler (e.g. range oftemperature, pressure and leak-tightness).
Installation 5 Note! h For boilers up to 200 kW: If required, a neutralisation device with condensate feed pump from the range of 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. 3 5.9 Electrical connection Danger! 1 2 Fig. 5.
5 Installation Danger! Note e Danger of death from electric shock! h Ensure that the boiler room complies wit the The connection should be wired as follows: • Open the front flap by lifting the silver handle strip. • Unscrew the screw above the multi-function operating panel. • Pull the front casing in the upper section towards you and lift it in order to remove it. • Hinge the electronics box forward. • Unclip the rear part of the electronics box cover and hinge it upwards.
Installation 5 Connecting electrical accessories and internal wiring green X18 Option - ext. controller/ room thermostat 3-4 (contact) 3 Mains input N L Option - ext. controller/ room thermostat 7-8-9 (analogue) 7 + - Bus connection (controller/room thermostat, digital) Contact thermostat 2 1 AF X22 X40 Edge connector RF DCF 1 0 0 Pump module PWM input.
5 Installation Boiler circulation pump, fixed speed • Connect the boiler circulation pump to the green ProE plug connector on the connection rail. Condensate feed pump • Connect the alarm output of a condensate feed pump to the "Contact thermostat" plug. Boiler circulation pump, modulating • Connect the boiler circulation pump additionally to the 0-10V adapter box in the unit.
Installation 5 Connecting a VRC 630 control unit (controller outside the electronics box) 230 V~ "2 from 7" DCF / AF 0 - DCF - AF Network 2 1 N e.g. ext. Gas valve Boiler X12 X40 X13 L N rel 2 rel 1 rel 1 green brown yellow white L N X18 L N X1 7 8 9 Network Pump Pump Network 1 2 purple green grey 3 4 5 X14 Edge connector Bus red blue red white — + X3 Cylinder sensor 7 8 9 7-8-9 II 7-8-9 I C1 C2 External sensor Bus Telephone Distance Switch.
6 Start-up 6 Start-up Initial start-up and operation of the appliance, and instruction for the user, must be performed by a heating engineer. For subsequent installation/operation instructions, see the relevant section of the operating manual.
Start-up 6 No.
6 Start-up 6.3 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 operation.
Start-up 6 2 Back Check external pump? Yes On Off All connections designated as external pump are supplied with 230 V. - 2 from 7 module, if d.27 or d.28 = 2. Back / Forward Back Vent hydraulics? Yes Hot water circuit Heating circuit Water pressure is displayed. Back / Forward Test burner? Yes On Off The internal heating pump is energised at the same time as the burner; function menu terminated.
6 Start-up 6.4 Filling the system • Flush the entire heating system thoroughly before filling. 6.4.2 Filling the siphon • Fill the siphon with water through the opening in the flue gas collector. Corrosion protection by water treatment In the case of heating water that has been conditioned by the addition of strongly alkaline substances, aluminium and its alloys are at risk from corrosion. The pH of the heating water must not exceed a value of 8.5. Danger! d Risk of poisoning from leaking flue gas! 6.
Start-up 6 6.5.1 Checking the connection pressure (Gas flow pressure) 1 Caution! a 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! h The maximum draught must not exceed 20 mbar, as otherwise the results of the CO2 measurement will be invalid.
6 Start-up • Measure the CO2 content in the flue gas. VKK GB xx6/3-E-H % CO2 at rated load % CO2 at minimum load G20 20 mbar 9.3 ± 0.2 9.0 ± 0.2 Table 6.2 CO2 target values for rated and minimum load No further adjustment is required if the measurement corresponds with the relevant value in the table. If the measured CO2 content lies outside this range, adjustment of the gas/air mixture is required.
Start-up 6 h Note! h 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 the value stabilises. approx. 1 minute after each adjustment until the value stabilises. After the adjustment, check the quality of combustion through the display opening: — no lifting of the flame evident — no glowing of the burner surface • To increase the CO2 content, turn the zero point screw in a clockwise direction (right).
6 Start-up 6.6 Checking the appliance function After installation and setting the gas ratio, perform a functional check before commissioning the appliance and handing it over to the user. • Draw special attention to the safety instructions which the owner must follow. • Point out to the owner the need for regular inspection and maintenance of the system (inspection/maintenance contract).
Adapting the unit to the heating system 7 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 concept for the selection of the various parameters and their setting is shown in Section 6.2. Some settings are only intended for the heating engineer and can only be called up after service code "17" has been entered at diagnostic point 97.
7 Adapting the unit to the heating system 8 Maintenance 7.1 Setting the maximum boiler flow temperature The maximum boiler flow temperature for heating mode can be set at diagnostic point d.71, and for cylinder charging mode at d.78 (see Table 9.2). 7.2 Setting pump overrun time The overrun time of the boiler circulation pump can be set at diagnostic point d.1. The overrun time for a cylinder charging pump directly connected to the boiler can be set under Parameter d.72 if necessary.
Maintenance 8 No. Procedure Remarks Top up if necessary (approx. 2.5 bar) 2 Check the filling pressure of the heating system (button "-") Visual check for leaks in heating circuit 3 Visual check of safety valve In accordance with BS 6644 4 Check condensate collector, siphon, supply air and flue See: 8.5 and 8.6 gas paths for contamination and leaks.
8 Maintenance 8.7 Cleaning the siphon • Remove the boiler casing. h 8.8 Checking the flue gas pressure monitor 1 Note Condensate can escape while the drain hoses are being pulled off. 2 1 2 Fig. 8.4 Checking the flue gas pressure monitor • Check the hose to the flue gas pressure monitor (2) for contamination and correct fit. Caution! a The hose must be connected to the connection marked "P1" on the flue gas pressure monitor. 8.
Maintenance 8 8.10 Cleaning the burner If cleaning of the burner is necessary, the complete burner/fan unit must be dismantled. Danger! d Danger of personal injury and material damage! • Blow out the burner with compressed air outside the installation room from the slot plate towards the metal fleece. If the burner is heavily contaminated it must be replaced. • Re-assemble all the components in reverse order.
8 Maintenance 9 Troubleshooting 8.11 9 Checking the safety temperature limiter 1 Troubleshooting 9.1 Status messages • Press the "i" button to read the current operating status. • Press the "i" button again to quit the display mode. All the parameters are summarised in the following table. Display Status messages Heating mode Fig. 8.9 Reset button Key 1 STL reset button with cover cap • Switch on the mains switch. • Turn the heating circuit off.
Troubleshooting 9 9.2 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 "–" buttons. • Press the "i" button to display the relevant value. Display Meaning Setting range and default setting for settable parameters d.
9 Troubleshooting Display Meaning 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 Setting range and default setting for settable parameters d.47 Outside temperature [°C] d.50 Offset for minimum speed in rpm/10 d.51 Offset for maximum speed in rpm/10 Setting range: -99..-0 Default setting: -45 d.54 Switch-on hysteresis 0K - 10K, default setting: -2 d.
Troubleshooting 9 9.3 Error messages A malfunction is indicated on the display by an "F" followed by a number. In addition, the "crossed-out flame" symbol is displayed. Fault with No. "F.." Description 0 Open circuit in flow sensor 1 Open circuit in return sensor Possible cause 10 Short circuit, flow sensor 11 Short circuit, return sensor 13 Short circuit, cylinder sensor 20 Safety temperature limiter has triggered 22 Water pressure too low, lack of water Water pressure less than 0.
9 Troubleshooting 9.4 Resetting the interlock after switch-off by the safety temperature limiter (STL) h Note! If a bridge is applied between terminals 3 and 4 and the ecoCRAFT starts up, the external controller must be checked. 1 Boiler does not respond to a request for hot water • Check the settings of the regulator unit. • Check the charging pump. • Check the setting of the cylinder target value adjuster on the boiler controller. 9.
Factory customer service/manufacturer's guarantee 10 Recycling and disposal 12 10 Factory customer service/ manufacturer's guarantee 10.1 Vaillant Service To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details. 10.2 Vaillant warranty Vaillant provide a full parts and labour warranty for this appliance.
12 Technical data 12 Technical data Term Rated heat output range for heating max. rated heat loading min. rated heat loading Units VKK GB VKK GB VKK GB VKK GB VKK GB VKK GB 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 kW 13.6 -78.2 21.3 -113.4 26.2 -156.5 43.1 -196.8 60/40 kW 14.1 - 80.4 40/30 kW 14.7 - 84.1 47.0 -236.2 51.0 - 275.5 22.1 - 116.5 27.1 - 160.8 44.2 - 201.0 48.2 - 241.2 52.3 - 281.4 23.1 - 121.8 28.4 - 168.2 46.2 - 210.2 50.4 - 252.2 54.
Technical data 12 Term Units VKK GB VKK GB VKK GB VKK GB VKK GB VKK GB 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 max. elec. power consumption W elec.
0020055744_03 GB 112008
