Vaillant ecoCRAFT VKK GB SERIES User manual

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
GB

Installation and maintenance instructions ecoCRAFT - 0020055744_032
Contents
1 Notes on the documentation...............................3
1.1 Storage of the documents.......................................... 3
1.2 Symbols used ................................................................. 3
1.3 Applicability of the manual......................................... 3
2 Description of the appliance .............................. 4
2.1 Model description..........................................................4
2.2 Identification plate........................................................4
2.3 CE label............................................................................4
2.4 Construction and function..........................................5
3 Safety instructions and regulations ................. 8
3.1 Safety instructions .......................................................8
3.2 Regulations.....................................................................9
4 Assembly .............................................................10
4.1 Scope of delivery ........................................................ 10
4.2 Accessories................................................................... 10
4.3 Installation location......................................................11
4.3.1 Regulations pertaining to the installation
location............................................................................11
4.3.2 Recommended minimum distances for
installation ......................................................................11
4.3.3 Aligning the boiler ........................................................11
4.4 Dimensions......................................................................11
5 Installation........................................................... 13
5.1 General information on the heating system .........13
5.2 Removing the casing...................................................13
5.3 Gas connection .............................................................14
5.4 Heating side connection.............................................14
5.5 Connecting the DHW cylinder...................................15
5.6 Air/flue gas installation..............................................16
5.6.1 Flue gas connection, room-sealed...........................16
5.6.2 Flue gas connection, open flued ..............................16
5.7 Connecting the boiler to the flue gas pipe............16
5.8 Condensate discharge ................................................16
5.9 Electrical connection...................................................17
5.9.1 Connecting the mains cable......................................18
5.9.2 Connecting a controller..............................................18
5.9.3 Connecting electrical accessories and internal
wiring...............................................................................19
6 Start-up...............................................................22
6.1 Entering the service code.........................................22
6.2 Start-up checklist........................................................22
6.3 Function menu (for maintenance and service
work) ............................................................................. 24
6.4 Filling the system........................................................26
6.4.1 Filling the heating side ..............................................26
6.4.2 Filling the siphon.........................................................26
6.5 Checking the gas setting...........................................26
6.5.1 Checking the connection pressure (Gas flow pres-
sure) ...............................................................................27
6.5.2 Checking the CO2content.........................................27
6.5.3 Setting the CO2content ........................................... 28
6.6 Checking the appliance function............................ 30
6.7 Instructing the user................................................... 30
7 Adapting the unit to the heating system........ 31
7.1 Setting the maximum boiler flow temperature...32
7.2 Setting pump overrun time ......................................32
7.3 Blocking time and heating partial load..................32
8 Maintenance ....................................................... 32
8.1 General notes...............................................................32
8.2 Safety instructions .....................................................32
8.3 Operating hours indication.......................................32
8.4 Chimney sweeper operation ....................................32
8.5 Maintenance checklist ...............................................32
8.6 Cleaning the condensate collector.........................33
8.7 Cleaning the siphon....................................................34
8.8 Checking the flue gas pressure monitor...............34
8.9 Checking the combustion air pressure monitor ...34
8.10 Cleaning the burner....................................................35
8.11 Checking the safety temperature limiter .............36
8.12 Functional check .........................................................36
9 Troubleshooting ................................................. 36
9.1 Status messages .........................................................36
9.2 Diagnostic mode..........................................................37
9.3 Error messages............................................................39
9.4 Resetting the interlock after switch-off by the
safety temperature limiter (STL)........................... 40
9.5 General notes ............................................................. 40
9.6 Measurements on the components....................... 40
10 Factory customer service/manufacturer's
guarantee.............................................................41
10.1 Vaillant Service.............................................................41
10.2 Vaillant warranty..........................................................41
11 Recycling and disposal.......................................41
11.1 Appliance........................................................................41
11.2 Packaging.......................................................................41
12 Technical data....................................................42

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 owner of the system:
Operating manual No. 00200587171
Short-form instructions No. 0020063363
Auxiliary service equipment:
The following test and measuring equipment are re-
quired for inspection and maintenance:
– CO2measuring instrument
– Pressure gauge
– flue gas analyser
– Torque wrench
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
Please observe the following when operating the unit:
Safety instructions in this installation manual!
dDanger!
Immediate risk of serious injury or death!
eDanger!
Danger of death from electric shock!
HDanger!
Danger of burning and scalding!
aCaution!
Potentially dangerous situation for the product
and the environment!
hNote
Useful information and instructions.
• Symbol for a necessary task
1.3 Applicability of the manual
These installation instructions apply exclusively to appli-
ances with the following part numbers:
Appliance type Part 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 2.3 Overview of the part numbers
The part number of the appliance can be found on the
identification plate (see Section 2.2).
3Installation and maintenance instructions ecoCRAFT - 0020055744_03
Notes on the documentation 1

2 Description of the appliance
2.1 Model description
Appliance type Designated country (designation
in accordance with ISO 3166)
Category
of permit Type of gas Nominal heat output range P (kW)
VKK GB 806/3-E-H
GB (Great Britain)
IE (Ireland) I2H G20 (natural gas E)
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 – 168.2 (40/30 °C)
VKK GB 2006/3-E-H
43.1 – 196.8 (80/60 °C)
44.2 – 201 (60/40 °C)
46.2 – 210.2 (40/30 °C)
VKK GB 2406/3-E-H
47.0 – 236.2 (80/60 °C)
48.2 – 241.2 (60/40 °C)
50.4 – 252.2 (40/30 °C)
VKK GB 2806/3-E-H
51.0 – 275.5 (80/60 °C)
52.3 – 281.4 (60/40 °C)
54.7 – 294.3 (40/30 °C)
Table 2.1 Overview of types of unit
2.2 Identification plate
The identification plate is mounted on the front of the
boiler under the front casing. It becomes visible after
the front section of the casing is removed.
1
2
3
4
Serial-Nr. 21080400100054150006000000N0
Typ B23, B23P, C33, C43, C53, C63, C83
GB, IE, cat. I2H
P(40/30°C) = 54,7 - 294,3 kW
P(60/40°C) = 52,3 - 281,4 kW
P(80/60°C) = 51,0 - 275,5 kW
Q = 52,0 - 280,0 kW NCV (Hi)
Q = 57,7 - 310,8 kW GCV (Hs)
NOx class 5
Tmax. = 85 °C
PMS = 6 bar
V = 17,37 I BED 92/42 ****
VKK GB 2806/3-E-H
ecoCRAFT
2H, G20 - 20 mbar
Read the instructions fully before 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!
Vaillant GmbH Remscheid / Germany
230 V ~ 50 Hz 320 W IP 20
EAN-CODE
0063 08
CE-0063BS3986
Fig. 2.1 Identification plate
Key
1 Serial No.
2 Model designation
3 Type approval designation
4 Technical Data
Explanation of the model designation
The following table explains the model designation,
using the VKK GB 2806/3-E-H as an example.
VKK GB 2806/3-E-H Equipment
VKK Vaillant gas-fired condensing
boiler
GB Great Britain
280 Unit size (output in kW)
6 Gas-fired condensing boiler
3 Boiler production series
H Gas category I2H
Table 2.2 Explanation of the model designation
2.3 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 (2004/108/EEC)
– Low voltage directive (2006/95/EEC)
The appliances meet the basic requirements of the effi-
ciency requirements directive
(Council Directive 92/42/EEC) as condensing boilers.
Installation and maintenance instructions ecoCRAFT - 0020055744_034
2 Description of the appliance

2.3 Intended use
Vaillant gas-fired condensing boilers
VKKGB 806/3 -2806/3-E-H are constructed in accord-
ance 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.
This unit is not intended for use by persons (including
children) having limited physical, sensory or mental ca-
pacities or who have inadequate experience and/or
knowledge, unless they are supervised by a person re-
sponsible for their safety or have been given instruc-
tions by him regarding the operation of the unit.
Children must be supervised to ensure that they do not
play with the unit.
The boiler is suitable for connection to sealed central
heating installations.
Any other or additional use is considered to be improp-
er. The manufacturer or supplier is not liable for any re-
sulting damage. The user alone bears the risk.
Use includes observance of the operating and installa-
tion manuals and all other applicable documents, as well
as adherence to the maintenance and inspection condi-
tions.
aCaution!
Any improper use is forbidden.
2.4 Construction and function
The ecoCRAFT is a gas-fired condensing boiler which is
used as a heat producer for hot water central heating
installations up to 85 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 heating control
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. The boiler is suitable for connection to room
sealed flues „Type C“.
Equipment
- Modulation range, see Table 2.3
- Reduced environmental impact as a result of the
extremely low emission of toxic substances:
NOx <60 mg/kWh and CO < 20mg/kWh
- Compact high efficiency heat exchanger with NTC
sensor
- Modulating multi-port burner
- Class A gas valve
- Gas - air mixture regulation
- Electronically controlled fan
- Flow manifold with NTC sensor
- Return manifold with NTC sensor
- Safety temperature limiter (STL)
- Operating panel with multi-function display
- Flue gas temperature max. 80 °C
- Condensate collector
- Polypropylene siphon
- Internal frost protection function
- Interface for control of a modulating pump
- Internal cylinder temperature regulation
- Interface for temperature-based activation
- Adjustable boiler feet
Regulation range
Appliance type Minimum Load Maximum Load
kW % kW %
VKK GB 806/3-E-H 14.0 17.5 80.0 100
VKK GB 1206/3-E-H 22.0 19.0 115.9 100
VKK GB 1606/3-E-H 27.0 17.0 160.0 100
VKK GB 2006/3-E-H 44.0 22.0 200.0 100
VKK GB 2406/3-E-H 48.0 20.0 240.0 100
VKK GB 2806/3-E-H 52.0 19.0 280.0 100
Table 2.3 Regulation ranges
5Installation and maintenance instructions ecoCRAFT - 0020055744_03
Description of the appliance 2

Overview of the operating controls
1
9
8
7
6
5
2
3
4
Fig. 2.2 ecoCRAFT operating controls
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. 4.1):
1Display indicating the current heating flow tem-
perature, the pressure of the heating system, the
operating mode and other additional information
2Button "i" for displaying information
3Controller (accessory)
4On and Off switch
5"+" button for navigating forwards through the
display view (used by expert technician to speci-
fy settings and for troubleshooting) or displaying
the storage temperature (VC with cylinder sen-
sor)
6"–" button for navigating backwards through the
display view (used by expert technician to speci-
fy settings and for troubleshooting) and for dis-
playing the filling pressure of the heating system
7"Reset" button for resetting the system in the
case of specific faults
8Rotary knob to adjust the heating flow tempera-
ture.
9Rotary knob to adjust the hot water temperaure
Overview of the functional controls
hNote
When using Vaillant controls both dials must be
turned to maximum position.
6
7
8
9
10
5
1
2
4
3
Fig. 2.3 View from the right hand side
Key
1 Flow
2 Gas pipe
3 Air inlet box with dust filter
4 Condensate pan
5 Supply air hose
6 Drain point
7 Return
8 Return NTC
9 Water pressure sensor
10 Venturi
Installation and maintenance instructions ecoCRAFT - 0020055744_036
2 Description of the appliance

14
1
2
3
4
65
13
12
11
10
9
8
7
15 16
Fig. 2.4 View from the left hand side
Key
1 Fan
2 Gas valve
3 Supply air silencer
4 Inspection opening for heat exchanger
5 Supply air hose
6 Siphon
7 Condensate discharge
8 Condensate trap/siphon connection
9 Flue gas STL (optional)
10 Flue gas silencer
11 Condensate trap
12 Supply air box with dust filter
13 Gas pipe
14 Boiler NTC and STL sensor
15 Safety temperature limiter (STL) reset button
16 VR35 0-10 V pump module
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 NTC
5 Ignition and monitoring electrode
6 Flue gas pressure monitor
7 Air pressure monitor
2
3
5
6
1
4
Fig. 2.6 Front view
Key
1 Control panel
2 Supply air silencer
3 Supply air filter
4 Neutralisation box (optional)
5 Condensate discharge
6 Inspection opening for condensate pan
7Installation and maintenance instructions ecoCRAFT - 0020055744_03
Description of the appliance 2

3 Safety instructions and regulations
The appliance may only be installed by a competent
qualified person registered with Corgi.
3.1 Safety instructions
The combustion air fed to the unit must be free of
chemicals e.g. fluorine, chlorine or sulphur. Sprays,
solvents or cleaning agents, paints and adhesives can
contain such materials which can, in certain circum-
stances, lead to corrosion when operating the unit,
including the flue gas installation.
aCaution!
Malfunction!
The combustion air must be free of particles or
the burner can be contaminated with dirt.
Take particular care that no building dust or
fibres of insulating material are present in the
combustion air.
In business premises such as hairdressing salons, paint-
ing or carpentry workshops, cleaning businesses etc.,
when installed as an open flued appliance. It is desirable
that the boiler is installed in a purpose made boiler
room conforming to the guidance within BS 6644.
The boiler shall only be sited on floors and adjacent to
walls capeable of withstanding at least 65 degrees C.
(However, the recommended minimum distance in
section 4.3.2 must be observed).
A safety valve must be fitted to the boiler as defined in
BS 6644 for both single or modular cascades of boilers.
hNote concerning flue design:
Modulation of the boiler together with
combustion air matching produces high values
of combustion efficiency. This requires
technical evidence of the suitability of the flue
in according with the relevant standards.
Installation
• Flush the heating system thoroughly before connect-
ing 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.
aCaution!
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!
aCaution!
Damage to the screwed connections!
To tighten or loosen bolts, only use suitable
open-ended spanners (do not use pliers or ex-
tensions etc.) Improper use or unsuitable tools
can cause damage, such as gas or water leaks!
Always tighten the couplings fixing the flow distributor
and the return collector to the heat exchanger block
with a torque wrench set to 12 Nm.
On sealed heating installations, a type-approved safety
valve corresponding to the heat capacity must be fitted.
aCaution!
Damage to the gas valve!
The gas regulating block may be tested for
leakage only with a maximum pressure of 110
mbar! The operating pressure must not exceed
60 mbar! If these pressures are exceeded, the
gas valve may be damaged.
The electrical installation must only be made by a quali-
fied electrician in accordance with BS 7671 and the Elec-
tricity at Work Regulations.
eDanger!
Danger of death from electric shock!
The supply terminals in the terminal box of the
device are under voltage even if the mains
switch is off. Before working on the appliance,
turn off the power supply and secure it against
being switched on again!
Installation and maintenance instructions ecoCRAFT - 0020055744_038
3 Safety instructions and regulations

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 alu-
minium. Always seek the advice of a professional water
treatment company. Advice may be sought from:
Fernox
Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey
GU21 5RZ
Sentinel Performance Solutions Ltd
The Heath Business & Technical Park
Runcorn
Cheshire
WA7 4QX.
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.
• Inform the user of the procedure for frost protection.
The boiler is suitable for installation to artificially sof-
tened water supplies.
Only for natural gas:
The inlet gas working pressure must not be less than 17
mbar whilst operating at maximum output.
Inspection and maintenance
Inspection, maintenance and repair work should only be
undertaken by an approved heating installation compa-
ny. Inspections/Maintenance work not carried out can
result in damage to property and personal injury.
The electrical installation must only be made by a quali-
fied electrician in accordance with BS 7671 and the Elec-
tricity at Work Regulations.
eDanger!
Danger of death from electric shock!
The supply terminals in the terminal box of the
device are under voltage even if the mains
switch is off. Before working on the appliance,
turn off the power supply and secure it against
being switched on again!
• Protect the switch box from water spray.
dDanger!
Danger of explosion through gas leakage! When
installing, maintaining and repairing the unit,
always check the gas carrying components, in-
cluding the burner seals, for gas leaks. We rec-
ommend the use of an electronic gas sensor in-
strument.
HDanger!
Danger of burning and scalding!
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
work. Close the gas valve and the maintenance valves.
• Drain the appliance if you want to replace water-car-
rying components within.
eDanger!
Danger of death from electric shock!
The supply terminals in the terminal box of the
device are under voltage even if the mains
switch is off. Before working on the appliance,
turn off the power supply and secure it against
being switched on again!
• Make sure that no water falls on live components
(e.g. electronic box etc.).
• Use only new gaskets and O-rings.
• Perform a functional test after you have finished this
work.
3.2 Regulations
To ensure the safe installation of your appliance, the
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 tested accordingly.
The Clean Air Act 1993 and the 3rd Edition of the 1956
Clean Air Act.
The Building Regulations, England and Wales, The Build-
ing Standards, Scotland, and any requirements deter-
mined by the local authorities within.
Water supply (water fittings) regulations 1999.
Detailed recommendations are also contained in the fol-
lowing documents:
9Installation and maintenance instructions ecoCRAFT - 0020055744_03
Safety instructions and regulations 3

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 gas-
fired hot water boilers with rated inputs
between 70kW (net) and 1.8MW (net)
(2nd and 3rd family gases).
BS 6880 Code of practice for low temperature
heating systems with outputs greater
than 45kW.
Part 1 Fundamental and design consid-
erations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and
maintenance.
BS 6981 Installation of low pressure gas pipe-
work of up to 28mm in domestic
premises.
BS 7074 Application, selection and installation of
expansion vessels and ancillary equip-
ment for sealed water systems.
Part 1 Code of practice for domestic
heating and hot water.
Part 2 Code of practice for low and me-
dium temperature hot water systems.
BS 6700 Specification for the design, installa-
tion, testing and maintenance of servic-
es supplying water for domestic use
within buildings and their curtilages.
Institute of Gas Engineers Publications
IGE/UP/1
Soundness testing and purging of in-
dustrial and commercial gas installa-
tions.
IGE/UP/1A
Soundness testing and purging of small
low pressure industrial and commercial
natural gas installations.
IGE/UP/10
Installation of gas appliances in indus-
trial and commercial premises.
Part 1 Flued appliances
4 Assembly
The boilers are supplied ready for connection in a pack-
aging unit with the casing fitted.
4.1 Scope of delivery
• Check the delivery for completeness and potential
damage using the following overview.
1
2
Fig. 4.1 Scope of delivery
Item Quantity Name
1 1 Unit (casing fitted)
25
Operating manual,
Short operating manual,
Installation manual,
Guarantee card
Table 4.1 Scope of delivery
4.2 Accessories
The following accessories are required for the installa-
tion in addition to the necessary safety and isolating de-
vices:
– Heating controller (e.g. VRC 430 or 630),
– Low loss header (optional),
– Boiler circulating pump (with fixed or variable speed),
– Neutralisation box, if required.
Installation and maintenance instructions ecoCRAFT - 0020055744_0310
3 Safety instructions and regulations
4 Assembly

4.3 Installation location
• The unit should be installed in a frost-protected room.
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" table (Chapter 12), must be taken
into account.
A heating boiler pedestal (sound-deadening) or similar
installation can be used to provide noise deadening; we
recommend installing the unit on a boiler 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 flue gas handling systems of the installation room.
The combustion air fed to the appliance must be physi-
cally free of chemical substances that contain,
e.g. fluorine, chlorine and sulphur. Sprays, paints, sol-
vents and cleaning materials and adhesives contain
such substances, which can, during operation of the
unit, lead to corrosion under unfavourable conditions,
including in the flue gas installation.
aCaution!
Malfunction!
The combustion air must be free of particles or
the burner can be contaminated with dirt.
Take particular care that no building dust or
fibres of insulating material are present in the
combustion air.
For this reason, the boiler is factory-fitted with a dust
filter. During a construction phase the boiler must only
be operated with this filter.
• Replace the filter after 10 weeks at the most, and
even sooner if there is heavy contamination.
• Remove the filter after the completion of the con-
struction phase.
• Clean the supply air hose.
4.3.2 Recommended minimum distances for
installation
500
50
500
300
Fig. 4.2 Recommended distances during installation
• Keep to the recommended minimum distances in
order to be able to carry out assembly and mainten-
ace work with as little impediment as possible.
4.3.3 Aligning the boiler
• The boiler should be levelled using the height-adjust-
able feet to prevent water condensate from flowing
out of the condensate collector.
4.4 Dimensions
152,5
214,5 695
495
819
1285
1305
90
981,5
678
R2‘‘
1 1/2“
R2‘‘
Fig. 4.3 Pipe connection dimensions
11Installation and maintenance instructions ecoCRAFT - 0020055744_03
Assembly 4

A
B
C
D
E
F
G
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
D50 50
A 1168 1478
F 1240 1550
G22 22
Table 4.2 Appliance dimensions
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
2806/
3-E-H
Flue pipe 150 150 150 200 200 200
Supply
air pipe 130 130 130 130 130 130
Table 4.3 Dimensions of supply air and flue pipes
Installation and maintenance instructions ecoCRAFT - 0020055744_0312
4 Assembly

5 Installation
5.1 General information on the heating system
aCaution!
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 de-
scribed in BS 6644.
• The system shall be vented at high points to prevent
air locks.
• The system shall be filled and drained in accordance
with guidance in BS 6644 and the current Water Reg-
ulations.
The safety temperature limiter fitted to the boiler
serves, in addition to the water pressure switch, as a
low water level safety device.
The fault-induced shut-down temperature of the boiler
is approx. 110 °C (nominal shut-down temperature 110 °C,
tolerance - 6 K).
• If plastic pipes are used in the heating system, you
must fit a suitable pipe thermostat on this section of
the heating system. This is required to protect the
heating installation from temperature-related damage.
The thermostat can be wired to the plug for the con-
tact thermostat (blue ProE plug).
• When using non-oxygen barrier plastic pipes in the
heating system, you must install to plate to plate heat
exchanger downstream for system separation, to pre-
vent corrosion in the boiler.
5.2 Removing the casing
1
Fig. 5.1 Opening the front flap
To remove the casing, proceed as follows:
• Open the front flap by lifting the silver handle strip (1).
2
Fig. 5.2 Removing the front casing
• Unscrew the screw (1) above the multi-function oper-
ating panel.
• Pull the front panel in the upper section towards you.
• Lift the front panel in order to remove it.
• You can now remove the remaining casing sections as
required.
13Installation and maintenance instructions ecoCRAFT - 0020055744_03
Installation 5

5.3 Gas 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.
aCaution!
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!
• The cross-sections of the gas pipes should be selected
to suit the nominal boiler load.
aCaution!
Damage to the gas valve!
The gas valve may be tested for leakage only
with a maximum pressure of 110 mbar! The op-
erating pressure must not exceed 60 mbar! If
these pressures are exceeded, the gas valve
may be damaged.
1
Fig. 5.3 Gas connection (rear of boiler)
• Connect the gas line to the gas connection (1) 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).
• Connect the heating return to the heating return con-
nection (2).
• Fit the required isolation valves between the heating
installation and the boiler and fit the relevant safety
devices and a pressure gauge.
aCaution!
If the volume of water circulating falls below
the nominal value, the temperature difference
will be too great and the burner will start to
cycle.
For this reason it is necessary to ensure the
water circulation quantities specified in
Table 5.1.
The boiler circulation pump is not integrated into the
boiler and thus must be fitted within the system.
Installation and maintenance instructions ecoCRAFT - 0020055744_0314
5 Installation

The following pumps and low loss headers are recom-
mended 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. 309 442 WH 160 (Item No. 306 726)
VKK GB 2006/3-E-H 8.60 Item no. 0020022254 Item no. 309 443 WH 280 (Item No. 306 725)
VKK GB 2406/3-E-H 10.33 Item no. 0020022254 Item no. 309 443 WH 280 (Item No. 306 725)
VKK GB 2806/3-E-H 12.05 Item no. 0020022255 Item no. 0020016930 WH 280 (Item No. 306 725)
Table 5.1 Application of pumps and low loss headers
5.5 Connecting the DHW cylinder
16a
230 V~
230 V~
2
3
3
10
2
30
3
3
3
2
3
3
2
5
31
15
52
ϑ
42b
32
ϑ
47
1
27
30 43
46
30
5
24
4
BUS2
17a
45
17b
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 (modulated)
2b Heating circuit pump (mixer circuit 1)
2c Heating circuit 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
17aFlow temperature sensor (heating circuit 1)
17bFlow temperature sensor (heating circuit 2, mixer circuit)
19 Maximum temperature thermostat
21aRemote control unit VR 80 or VR 90 (radiator circuit)
21bRemote control unit VR 80 or VR 90 (underfloor circuit)
24 Cylinder temperature sensor
27 Cylinder charging pump
30 Non-return valve
31 Regulator valve
32 Cap valve
33 Sludge separator
42aExpansion relief valve
42bExpansion vessel
43 Safety group
45 Low loss header
46 Circulation pump
47 Air separator
52 Room temperature controlled valve
15Installation and maintenance instructions ecoCRAFT - 0020055744_03
Installation 5

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 en-
closed 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). The flue gas duct must be labelled
with the CE conformity mark or, if necessary, be certi-
fied according to national standards. The instructions of
the manufacturer of the flue gas ducts must be ob-
served.
The dimensioning of the flue gas system must be car-
ried out according to EN 13384-1 (EN 13384-1 - Chimneys
- Thermal and fluid dynamic calculation methods -
Part 2: Chimneys serving one heating appliance). The
required device parameters are listed in table 12.1.
aCaution!
The diameter of the flue gas pipe must at least
be equal to the diameter of the flue gas spigot
of the boiler. A reduction is not permitted.
Furthermore the valid type standards concerning flue
gas systems must be observed. The respective type
standard determines conditions and safety-related re-
quirements concerning the planning, erection and start-
up as well as concerning the maintenance of flue gas
systems.
5.6.1 Flue gas connection, room-sealed
The combustion air is fed to the boiler via ducting from
the outside. The boiler room must be constructed as
stated in BS 6644.
5.6.2 Flue gas connection, open flued
hNote!
Ensure that the horizontal section of the flue
gas pipe is run with a downward slope towards
the boiler!
The combustion 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 connecting condensate secure and over-
pressure leak-tight flue gas pipes.
• For adjusting purposes, the flue pipe must be fitted
with a cleaning opening having a diameter of at least
100 mm. It may be necessary to have openings of larg-
er diameter for cleaning the flue pipe, depending upon
the diameter of the pipe.
hNote!
The user must provide a measurement opening
on the customer side of the flue pipe, externally
to the boiler casing.
Note!
A condensate trap is fitted to the flue gas con-
nection on the boiler to prevent contaminated
condensate from getting into the boiler. The
drain of this condensate trap is connected to
the siphon on the boiler.
• If required, fit the flue gas line with the flue gas safety
temperature limiter which is provided as an accessory.
The flue pipe must be approved for use at a tempera-
ture of at least 120 °C.
5.8 Condensate discharge
The pH value of the flue gas condensate, which is pro-
duced at a rate of max. 1 kg/m3, is between 3.5 and 4.5.
The condensate does not contain any prohibited heavy
metal ions.
The boiler is fitted with a condensate collector and a
condensate discharge with siphon. The condensate aris-
ing from the combustion is either fed directly via the si-
phon into the drain channel or first neutralised and then
fed into the drain.
• Before starting up the boiler, the condensate water
syphon should be filled with water.
Installation and maintenance instructions ecoCRAFT - 0020055744_0316
5 Installation

17Installation and maintenance instructions ecoCRAFT - 0020055744_03
1
2
3
Fig. 5.6 Siphon
Key
1 Siphon
2 Drain hose to the neutralisation box (optional) or to the drain
3 Hose from the condensate trap to the siphon
dDanger!
Risk of poisoning from leaking flue gas!
If the device is operated with an empty
condensate siphon, there is a risk of poisoning
from the escaping flue gases. Be absolutely
certain, therefore, to fill the siphon before
starting up.
Connecting the condensate drain
The chimney drainage line is run on a slope using suita-
ble plastic or stainless steel piping with a minimum
cross-section of DN 20. The condensate water piping to
the waste outlet is also installed at an angle using a
DN 25 pipe (plastic or stainless steel) and must go to
the nearest waste water outlet. The take-off from the
boiler is effected by means of a ø 21 mm plastic pipe.
The discharge point must remain visible.
hNote!
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.
5.9 Electrical connection
eDanger!
Risk of fatal electric shock from live connec-
tions!
The electrical installation must be carried out
by an electrical specialist, who is responsible
for complying with the existing standards and
guidelines. All electrical work must be in ac-
cordance with 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. Continuous voltage is
present on the L and N terminals, even when
the main switch is turned off.
Danger!
Risk of fatal electric shock from live connec-
tions!
Mains and low-voltage cables (e.g. sensor wir-
ing) must be run separately from each other.
Use the divided cable channel on the left hand
side section for this.
aCaution!
Access to the main switch (4) (see Fig. 2.2)
must be guaranteed at all times and must not
be covered or blocked, so that the appliance
can be switched off in the event of a malfunc-
tion.
To simplify the wiring, the appliance is equipped with
System ProE connectors and is ready for connecting.
The mains cable and all the other connecting cables
(e.g. from the room thermostat) can be connected to
the System ProE plugs that have been provided in each
case.
Installation 5

Installation and maintenance instructions ecoCRAFT - 0020055744_0318
eDanger!
Danger of death from electric shock!
The fan is connected to a 230 V/50 Hz supply.
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.
• 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 unit.
aCaution!
Risk of malfunction!
Do not use the same strain relief for the extra
low voltage cable as for the mains cable!
• Take care to ensure spatial separation of the mains
and extra low voltage cables.
• Secure the cables with the strain reliefs.
• Carefully strip the insulation from the cable ends.
• Then close the rear cover of the electronics box and
press it down until it audibly engages.
• Hinge the electronics box up.
• Fasten the front casing.
• Screw the screw above the multi-function operating
panel in again.
• Close the front cover.
5.9.1 Connecting the mains cable
The nominal voltage of the mains must be 230 V; if the
mains voltage is more than 253 V or below 190 V, func-
tional impairment is possible. The mains feed must be
connected via a fixed connection and an isolating device
having a minimum contact opening of 3 mm (e.g. fuses,
power switches).
• Connect the mains cable to the terminals provided, N,
L and PE, in the plug.
hNote
Ensure that the boiler room complies wit the
requirements of BS 664 and IGE UP10.
5.9.2 Connecting a controller
The Vaillant VRC 630 controller or an externally mount-
ed Vaillant VRC 430 controller must be connected via
the "Bus" connection (red plug) in accordance with Fig.
5.8 or Fig. 5.9. The bridge between the terminals 3 and
4 should remain intact (lilac plug).
The sensors and the system components that are not
listed in Section 5.10.3 are connected to the controller.
The electrical connection to the Vaillant heating control
unit is shown in Fig. 5.7.
Further information can be obtained from the regulator
instructions.
5 Installation

19Installation and maintenance instructions ecoCRAFT - 0020055744_03
5.9.3 Connecting electrical accessories and internal
wiring
Mains voltage Edge connector
Option - ext. controller/ room thermostat 7-8-9 (analogue)
Option - ext. controller/ room thermostat 3-4 (contact)
Bus connection (controller/room
thermostat, digital)
Water pressure sensor
Pump
module
0-10V output
24V Supply
PWM input.
Remote control – Circulation pump
Contact thermostat
Edge connector
X41
1
DCF connection
Earth
Earth
External sensor
Flow line sensor (Option)
X1
Heating water pump
Mains input
Charging pump
Mains voltage
230 V~
24 V
Extra-low voltage
X22
X14 Equipment earth
Ignition
unit Ignition electrode
6
Pump PWM signal
X18
X11
X13
Extra-low voltages - plug
14
12
13
7
8
X20
4
15
9
5
6
18
10
17
3
Gas valve
+
Earth
PWM signal
Hall signal
+ 24 V
N
L
Accessory module signals
X29
X40
17
9
6
19
20
5
18
8
22
X12
Accessory module VR40
24 V
2
16
24 V
230 V~
0 .. 10V Pump signal
5
1
4
2
9
7
1
2
8
L
N
3
5
4
purpleturquoise
whiteSSblue
FB
AF
RF
DCF
0
0
-
+
red
blue
LL
NN
L
L
L
N
green
N
N
grey
1
6
Plug for VCR 4xx
controller accessory
or ZP single start
J
STB
Return sensor (R25=10k)
Flue gas pressure
sensor
J
J
AT only, otherwise bridged
Flue gas temperature limiter
Flow sensor (R25=10k)
Air pressure switch
black J
Fan
Cylinder sensor
(accessory)
(R25=2k7)
Cylinder contact
"C1-C2"
1
4
2
white
white J
red JBoiler block sensor (R25=2k7)
Coding resistor
4320 Ù
white
green
clear
AT
DE
P
P
P
black
black
black
black
black
black
blue
blue
green
red
red
blue
red
red
black
grey
black
green
red
black
orange
black
brown
black
red
black
white
black
black
Fig. 5.7 Connecting electrical accessories and internal wiring
Installation 5

Installation and maintenance instructions ecoCRAFT - 0020055744_0320
Boiler circulation pump, fixed speed
• Connect the boiler circulation pump to the green ProE
plug connector on the connection rail.
Boiler circulation pump, modulating
• Connect the boiler circulation pump additionally to the
0-10V adapter box in the unit.
External flow thermostat
A flow thermostat can be electrically incorporated in the
safety chain by connecting it to the "contact thermo-
stat" 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.
Connecting a VRC 430 control unit (controller out-
side the electronics box)
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
Network
tur-
quoise
white purple
Pump
2
grey red
Bus
VRC 430
Fig. 5.8 Connecting a VRC 430 control unit
Condensate feed pump
• Connect the alarm output of a condensate feed pump
to the "Contact thermostat" plug.
VRC 430, 630 control units
• Connect the 2 wires of the "Bus" connections (red
plug) to the connections of the same name in the con-
troller on the VRC 630, or on the VRC 430 if it is
mounted externally.
• Alternatively, plug the VRC 430 controller into the
boiler operating panel (internal mounting).
hNote!
If several contacts are to be connected to the
"Contact thermostat" connection, They must
be connected in series, not in parallel!
5 Installation