Vaillant ecoCRAFT VKK GB SERIES User manual

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
GB

Installation and maintenance instructions ecoCRAFT 0020055744_082
Contents
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 Intended use...................................................................5
2.5 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.................................................... 10
4.3.1 Regulations pertaining to the installation
location.......................................................................... 10
4.3.2 Recommended minimum distances for
installation ......................................................................11
4.3.3 Levelling the boiler.......................................................11
4.4 Dimensions......................................................................11
5 Installation...........................................................12
5.1 General information on the heating system.........12
5.2 Removing the casing...................................................12
5.3 Gas connection .............................................................13
5.4 Heating side connection.............................................13
5.5 Connecting the DHW cylinder...................................14
5.6 Air/flue gas installation..............................................15
5.6.1 Flue gas connection, room-sealed...........................15
5.6.2 Flue gas connection, open flued ..............................15
5.7 Connecting the boiler to the flue gas pipe............15
5.8 Condensate discharge ................................................15
5.9 Electrical connection...................................................16
5.9.1 Connecting the mains cable......................................17
5.9.2 Connecting a contro ller.............................................17
5.9.3 Connecting electrical accessories and
internal wiring...............................................................18
5.9.4 Connecting a controller............................................ 20
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 ............................................. 28
6.4.2 Filling the siphon........................................................ 28
6.5 Checking the gas setting.......................................... 28
6.5.1 Checking for tightness of the flue gas system
Caution! ........................................................................ 28
6.5.2 Checking the gas inlet working pressure ...............29
6.5.3 Checking the gas flow rate.........................................29
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 Pump operating modes .............................................32
7.3.1 "Overrun mode" ("Comfort Mode") .......................32
7.3.2 "Intermittent" mode ("Eco mode") ........................32
7.4 Blocking time and heating partial load..................32
8 Inspection and maintenance ............................ 33
8.1 Inspection and maintenance intervals...................33
8.2 General inspection and maintenance
instructions...................................................................33
8.3 Checking the CO/CO2ratio.......................................34
8.4 Adjusting the CO/CO2ratio ......................................34
8.7 Cleaning the siphon....................................................36
8.8 Checking the flue gas pressure monitor...............37
8.9 Checking the combustion air pressure
monitor ..........................................................................37
8.10 Cleaning the burner................................................... 38
8.11 Changing the ignition and ionisation/
monitoring electrodes ..............................................39
8.12 Checking the safety thermostat..............................39
8.13 Check the dust filter...................................................39
8.14 Functional check .........................................................39
9 Troubleshooting .................................................40
9.1 Status messages ........................................................ 40
9.2 Diagnostic mode...........................................................41
9.3 Error messages............................................................43
9.4 Test programs............................................................. 44
9.5 Resetting the interlock after switch-off by
the safety temperature limiter (STL) ................... 44
9.6 General notes ............................................................. 44
9.7 Measurements on the components....................... 44
10 Customer service and warranty ......................45
10.1 Vaillant Service........................................................... 45
10.2 Vaillant warranty........................................................ 45
11 Recycling and disposal......................................45
11.1 Appliance...................................................................... 45
11.2 Packaging..................................................................... 45
12 Technical data....................................................46

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 plant operator:
Operating manual No. 0020058717
Short-form instructions No. 0020063363
For the expert technician:
Installation instructions for the
Flue pipe No. 0020058722
Auxiliary service equipment:
The following test and measuring equipment are re-
quired for inspection and maintenance:
– Flue Gas analyser CO/ CO2/ ratio
– Pressure gauge
– Gas sensing equipment
– Torque wrench
System logbook:
• Maintain a logbook for the system.
• Keep the logbook and all the technical data for the
system in the service folder by the ecoCRAFT.
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
When installing the unit, please observe the safety in-
structions in this installation and maintenance 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
This installation and maintenance manual applies exclu-
sively to units with the following article numbers:
Unit type Article 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 1.1 Overview of the article numbers
The 10-digit part number for the equipment can be
found on the identification plate (see Fig. 2.1, read from
the 7th digit onwards).
3Installation and maintenance instructions ecoCRAFT 0020055744_08
Notes on the documentation 1

2 Description of the appliance
2.1 Model description
Unit type
Designated coun-
try (designation
in accordance
with ISO 3166)
Approval category 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)
14.7 – 84.1 (40/30 °C)
13.6 – 78.2 (80/60 °C)
VKK GB 1206/3-E-H 23.1 - 121.8 (40/30 °C)
21.3 - 113.4 (80/60 °C)
VKK GB 1606/3-E-H 28.4 - 168.2 (40/30 °C)
26.2 - 156.5 (80/60 °C)
VKK GB 2006/3-E-H 46.2 - 210.2 (40/30 °C)
43.1 - 196.8 (80/60 °C)
VKK GB 2406/3-E-H 50.4 - 252.2 (40/30 °C)
47.0 - 236.2 (80/60 °C)
VKK GB 2806/3-E-H 54.7 - 294.3 (40/30 °C)
51.0 - 275.5 (80/60 °C)
Table 2.1 Overview of types of unit
2.2 Identification plate
The identification plate is mounted on the front of the
appliance under the front casing. It becomes visible
after the front section of the casing is removed.
Serial-Nr. 21400400100054100006000000N0
Typ B23, B23P, C33, C43, C53, C63, C83, C93
GB, IE, cat. I2H
2H, G20 - 20 mbar
P(40/30°C) = 14,7 - 84,1 kW
P(60/40°C) = 14,1 - 80,4 kW
P(80/60°C) = 13,6 - 78,2 kW
Q = 15,5 - 88,8 kW GCV (Hs)
Q = 14,0 - 80,0 kW NCV (Hi
NOx class 5
Tmax = 85°C
PMS = 6 bar
V = 5,74 BED 92/42
****
CE-0063BS3986
VKK GB 806/3-E-H
ecoCRAFT
230 V~ 50 Hz 260 W IP 20
EAN-CODE
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!
0063 08
Vaillant GmbH Remscheid / Germany
1
2
3
5
4
Fig. 2.1 Identification plate
Key
1 Serial-No.
2 Model designation
3 Permitted flue pipes
4 Designated countries, permitted gas category
5 Technical Data
Explanation of the model designation
The following table explains the model designation,
using the VKK GB/3-E-H as an example.
VKK GB 1206/3-E-H Equipment
VKK Vaillant gas-fired condensing
boiler
GB Great Britain
120 Unit size (power in kW)
6 Gas-fired condensing boiler
3 Boiler production series
E Exclusiv
H Gas category I2H
Table 2.2 Explanation of the model designation
2.3 CE label
CE labelling shows that, based on the model overview,
the appliances comply with the basic requirements of
the following directives:
- Gas equipment 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
efficiency requirements directive (Council Directive
92/42/EEC) as condensing boilers.
Installation and maintenance instructions ecoCRAFT 0020055744_084
2 Description of the appliance

2.4 Intended use
Vaillant VKK GB 806/3 — 2806/3-E-H gas-fired condens-
ing boilers 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.
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 unit is a heat producer for closed hot water 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.
2.5 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 heat-
ing control systems, Vaillant controls and BEMS sys-
tems. 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
- Regulation range, see Table 2.3
- Reduced environmental impact as a result of the
extremely low emission of toxic substances:
see table 12.1
- Compact high efficiency heat exchanger
with NTC sensor
- Modulating multi-port burner
- Class A gas fitting
- Gas - air mixture regulation
- Electronically controlled fan
- Flow manifold with NTC sensor
- Return manifold with NTC sensor
- Safety thermostat (STL)
- Operating field with multi-function display
- Flue gas temperature max. 80 °C
- Condensate collector
- Siphon
- Internal frost protection function
- Interface for control of a speed-regulated pump
- Internal cylinder temperature regulation
- Interface for temperature-based activation
- Adjustable boiler feet
Regulation range
Unit type Minimum Loading Maximum Loading
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_08
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
Open the front flap by lifting the silver handle and fold-
ing it out. You can now see the controls, which have the
following functions (Fig. 2.2):
1Display indicating the current heating flow tem-
perature, the filling pressure of the heating sys-
tem, the operating mode and other additional in-
formation
2"i" button for calling up information
3Controller (accessory)
4Button for switching the unit on and off
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 specific faults
8Rotary knob for setting the heating flow
temperature. When operating with the VRC 430,
VRC 630, or VRS 620, turn to the clockwise end
stop so that the maximum flow temperature for
the controller will not be limited.
9Rotary 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.
- anticlockwise end stop: frost protection 15 °C
- clockwise end stop: max. 65 °C
Depending on the setting at d.20, adjustable
from 50 °C to 70 °C (default setting: 65 °C)
Overview of the functional controls
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 Incoming air 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_086
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 fitting
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 Incoming air box with dust filter
13 Gas pipe
14 Safety temperature limiter (STL) and block temperature sensor
15 Safety temperature limiter (STL) reset button
16 0 — 10 V pump module VR35
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 temperature sensor
5 Ignition and monitoring electrodes
6 Air pressure monitor
7 Flue gas pressure monitor
2
3
5
6
1
4
Fig. 2.6 Front view
Key
1 Control panel
2 Supply air silencer
3 Supply air pipe
4 Neutralisation box (optional)
5 Condensate discharge
6 Inspection opening for condensate pan
7Installation and maintenance instructions ecoCRAFT 0020055744_08
Description of the appliance 2

3 Safety instructions and regulations
The appliance may only be installed by a competent per-
son approved at the time by the Health and Safety Ex-
ecutive.
3.1 Safety instructions
The combustion air fed to the unit must be free of
chemicals containing e.g. fluorine, chlorine or sulphur.
Sprays, solvents or cleaning agents, paints and adhe-
sives can contain such materials which can, in certain
circumstances, lead to corrosion when operating the
unit, including the exhaust 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, fi-
bres of insulating material or pollen is 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
capable of withstanding at least 65 degrees C. (Howev-
er, 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 gas-fired condensing boiler
together with combustion air matching produc-
es a high level of combustion efficiency. This
requires technical evidence of the suitability of
the flue in according with the relevant stand-
ards.
Installation
aCaution!
Malfunction!
Flush the heating system thoroughly before
connecting the appliance!
In this way you will remove residues such as
welding beads, cinders, hemp, mastic, rust,
coarse dirt and the like from the pipes. Other-
wise 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.
Caution!
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.
aCaution!
Damage to the gas fitting!
The gas regulating block may be tested for
leakage only with a maximum pressure of
110 mbar! The operating pressure must not ex-
ceed 60 mbar! If these pressures are exceeded,
the gas fitting may be damaged.
The electrical installation may only be carried out by a
qualified electrician complying with the BS 7671 stand-
ard and the regulations concerning electricity in the
workplace.
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!
Start-up
aCaution!
Risk of material damage if the heating water is
treated with unsuitable frost or corrosion pro-
tection agents!
Frost and corrosion protection agents can
cause changes in the seals, noises during heat-
ing and possibly subsequent damage.
Do not use any unsuitable frost or corrosion
protection agents.
Only for natural gas:
The operating pressure of the gas at the intake must
not be less than 17 mbar when the unit is running at
maximum output.
Installation and maintenance instructions ecoCRAFT 0020055744_088
3 Safety instructions and regulations

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
Electricity 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!
dDanger!
Danger of explosion caused by gas leaks!
When installing, maintaining and repairing the
unit, always check the gas-carrying compo-
nents, including the burner seals, for gas leaks.
We recommend the use of an electronic gas
sensor instrument.
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 compo-
nents 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:
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 70 kW (net) and 1.8 MW (net)
(2nd and 3rd family gases).
BS 6880 Code of practice for low temperature
heating systems with outputs greater
than 45 kW.
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 28 mm 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.
9Installation and maintenance instructions ecoCRAFT 0020055744_08
Safety instructions and regulations 3

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 boiler is delivered in a packing unit, ready for con-
nection and 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 instructions,
Installation instructions for air/flue gas ac-
cessory,
Guarantee card
Table 4.1 Scope of delivery
4.2 Accessories
The following accessories are available 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.
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 approx. 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 exhaust 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 exhaust gas installation.
aCaution!
Malfunction!
The combustion air must be free of particles as
it can otherwise result in contamination of the
burner and malfunctions.
The ecoCRAFT gas-fired condensing boiler is
factory fitted with a dust filter. The ecoCRAFT
gas-fired condensing boiler may only be in-
stalled and operated with the dust filter.
Take care that no building dust, fibres of insu-
lating material or pollen is present in the com-
bustion air.
• Replace or clean the dust filter, particularly after the
building phase is complete, as the filter can become
blocked with building dust.
• Check the dust filter annually for contamination.
• Clean the dust filter or replace it with a new one.
Especially with boilers >= 200 kW, a saturated dust filter
can cause a reduction in output.
Installation and maintenance instructions ecoCRAFT 0020055744_0810
3 Safety instructions and regulations
4 Assembly

4.3.2 Recommended minimum distances for
installation
500
500
300 50
Fig. 4.2 Recommended distances during installation (in mm)
• Keep to the recommended minimum distances in
order to be able to carry out assembly and mainte-
nance work with as little impediment as possible.
4.3.3 Levelling the boiler
• The boiler should be levelled using the height-adjusta-
ble feet to ensure that the condensate water flows
out of the condensate basin.
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 (in mm)
A
B
C
D
E
F
G
Fig. 4.4 Appliance dimensions
VKK GB 806-1606/3-E-H VKK GB 2006-2806/3-E-H
A 165 165
B 326 326
C 369 369
D50 50
E 1168 1478
F 1240 1550
G22 22
Table 4.2 Appliance dimensions (in mm)
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 for supply air and flue pipe (Ø in mm)
11Installation and maintenance instructions ecoCRAFT 0020055744_08
Safety instructions and regulations 3

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 res-
idues, coarse dirt and similar substances are
removed from the pipes. Otherwise such sub-
stances 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 installation, you
must fit a suitable thermostat to the heating flow line
on site. This is required to protect the heating installa-
tion from temperature-related damage. The thermo-
stat can be wired to the plug for the contact thermo-
stat (blue ProE plug).
• When using non diffusion resistant plastic pipes in the
heating system, you must install a 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, Fig. 5.1).
2
Fig. 5.2 Removing the front casing
• Unscrew the screw (2, Fig. 5.2) above the multi-func-
tion operating panel.
• Pull the front casing in the upper section towards you.
• Lift the front casing in order to remove it.
• You can now remove the remaining casing sections as
required.
Installation and maintenance instructions ecoCRAFT 0020055744_0812
5 Installation

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 heating load.
aCaution!
Damage to the gas fitting!
The gas regulating block may be tested for
leakage only with a maximum pressure of
110 mbar! The operating pressure must not ex-
ceed 60 mbar! If these pressures are exceeded,
the gas fitting may be damaged.
1
Fig. 5.3 Gas connection (rear of boiler)
• Connect the gas pipe to the gas connection
(1, Fig. 5.3) 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, Fig. 5.4).
• Connect the heating return to the heating return con-
nection (2, Fig. 5.4).
• Fit the required isolation devices 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, the circulating water volumes
specified in Table 5.1 must be ensured.
The boiler circulation pump is not integrated into the
boiler and thus must be installed on-site.
13Installation and maintenance instructions ecoCRAFT 0020055744_08
Installation 5

The following pumps and low loss headers are recom-
mended for use with the respective boilers:
Gas-fired condensing boiler Nominal water circulation volume
for 20 K difference Speed regulated high-effi- ciency pump Low loss header
VKK GB 806/3-E-H 3.44 Item no. 0020022253 WH 95 (Item No. 306721)
VKK GB 1206/3-E-H 4.99 Item no. 0020022253 WH 160 (Item No. 306726)
VKK GB 1606/3-E-H 6.88 Item no. 0020022253 WH 160 (Item No. 306726)
VKK GB 2006/3-E-H 8.60 Item no. 0020022254 WH 280 (Item No. 306725)
VKK GB 2406/3-E-H 10.33 Item no. 0020022254 WH 280 (Item No. 306725)
VKK GB 2806/3-E-H 12.05 Item no. 0020022255 WH 280 (Item No. 306725)
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
3
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 (electronically regulated)
2b Heating pump (mixer circuit 1)
2c Heating 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
17a Flow temperature sensor
17b Flow temperature sensor (heating circuit 2, mixer circuit)
19 Maximum temperature thermostat
21a Remote control unit VR 80 or VR 90 (radiator circuit)
ł2 Two-wire
ł3 Three-wire
ł4 Four-wire
21b VR 80 or VR 90 remote control unit (underfloor circuit)
24 Cylinder sensor
27 Cylinder charging pump
30 Non-return valve
31 Flow limiter
32 Cap valve
33 Sludge separator
42a Expansion relief valve
42b Expansion vessel
43 Safety group
45 Low loss header
46 Circulation pump
47 Air separator
52 Room temperature controlled valve
Installation and maintenance instructions ecoCRAFT 0020055744_0814
5 Installation

5.6 Air/flue gas installation
Should you use air/flue gas pipes which are licensed to
be used together with the boiler, please observe the en-
closed installation instructions 0020058722.
Should you use conventional air/flue gas pipes, please
note the following:
The flue gas system must be suitable for the flue gas
duct of the boiler (e.g. temperature, pressure and leak-
tightness classification). The flue gas duct must be la-
belled with the CE conformity mark or, if necessary, be
certified according to national standards. The instruc-
tions of the manufacturer of the flue gas ducts must be
observed.
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 re-
quired 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 requirements concerning the planning,
erection and start-up as well as concerning the mainte-
nance 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 adjustment 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
larger diameter for cleaning the flue pipe, depending
upon the diameter of the pipe.
hNote
The user must provide a measurement opening
in the flue pipe on site, external to the boiler
casing.
Note
There is a condensate trap installed at the flue
connection of the boiler which prevents con-
taminated condensed water 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 lies 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 the boiler up, the condensate water si-
phon should be filled with water.
15Installation and maintenance instructions ecoCRAFT 0020055744_08
Installation 5

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 conden-
sate 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) 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 gas-fired condensing boilers up to 200 kW:
If required, a neutralisation device with conden-
sate feed pump from the Vaillant range of ac-
cessories can be connected.
For gas-fired condensing boilers above 200 kW:
If required, an in-line neutralisation device from
the Vaillant range of accessories can be con-
nected.
5.9 Electrical connection
eDanger!
Risk of fatal electric shock from live connec-
tions!
The electrical installation must be carried out
by an authorised qualified electrician, who is re-
sponsible for complying with the existing
standards and guidelines. All electrical work
must be in accordance 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. Voltage is continuously
present on the L and N terminals of the tur-
quoise coloured plug, 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, Fig. 2.2) must be
guaranteed at all times and must not be cov-
ered or blocked, so that the appliance can be
switched off in the event of a malfunction.
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.
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.
• Unhitch 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.
Installation and maintenance instructions ecoCRAFT 0020055744_0816
5 Installation

17Installation and maintenance instructions ecoCRAFT 0020055744_08
• 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.
• Remove the insulation from the ends of the wires and
connect them in accordance with Sections 5.10.1 to
5.10.2.
• 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).
hNote
Ensure that the boiler room complies with the
requirements of BS 6644 and IGE UP10.
The connection should be wired as follows:
• Open the front flap by lifting the silver handle strip.
• Unfasten the screw above the multifunction control
panel.
• Pull the front casing in the upper section towards you
and lift it in order to remove it.
• Hinge the electronics box forwards.
• Unhitch 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.
• Connect the mains cable to the terminals provided, N,
L and PE, in the plug.
• Take care to ensure spatial separation of the mains
and extra low voltage cables.
• Secure the cables with the strain reliefs.
• Remove the insulation from the ends of the wires and
connect them in accordance with Sections 5.10.1 to
5.10.2.
• 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.
• Fasten the screw above the multifunction control
panel.
• Close the front cover.
• Switch on at the mains and check the functionality of
the unit.
5.9.2 Connecting a contro ller
The Vaillant VRC 430, 630 or VRS 620 controllers must
be connected via the "Bus" connection (red plug) in ac-
cordance 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.
Installation 5

Installation and maintenance instructions ecoCRAFT 0020055744_0818
5.9.3 Connecting electrical accessories and internal
wiring
Ionisation electrode
4A slow-blow
blue
Option - ext. controller/room thermostat
3-4 (contact)
Charging pump
Heating circuit pump/
Boiler circulation pump
Option - ext. controller/room thermostat
7-8-9 (analogue)
Bus connection (controller/room
thermostat, digital)
Contact thermostat
0 .. 10 V
Signal
PWM Input
Pump
module
Pump PWM signal
Accessory module signals VR40
1 +24 V
2 Hallsignal
4 PWM-Signal
5 Earth
Air pressure switch
Gas valve
VR 32, vrDIALOG,
vrnetDIALOG Boiler heat exchanger sensor
(R25=2k7)
Flow sensor (R25=10k)
Return sensor (R25=10k)
Cylinder contact
"C1-C2"
Water pressure sensor
Coding resistor 4320 Ω
X14
X29
X20
X40
X22
X41
X1
X6
X30
P
P
STB
P
Cylinder sensor
(R25=2k7) (accessory)
Fan
Mains input
X11 X18
X13
F4
Accessory
pink
230 V~
24 V
230 V~
24 V
Mains voltage
Extra-low voltage
Edge connector
X12
blue
blue
red white
white
24 V
Supply
0-10V
Output
black
Extra-low voltages - plug
turquoise violet
green grey
red
black
grey
blue
red
green
blue
red
red red
black
red
black black
green
transparent
black
blue
black
black white
white
white
braun
black
orange
black
black
red
green
black
black
white
black
black
blue
red
N
NL
L
N
L
N
L
N
L
5
4
3
9
4
7
2
1
6
6
1
1
+
-
FB
AF
RF
DCF
0
0
17
3
4
15
10
6
18
9
2
16
5
7
8
12
13
14
22
5
8
18
17
19
20
9
6
Remote control – Circulation pump
DCF connection
Earth
Earth
External sensor
Flow line sensor (Option) Plug for VCR 4xx
controller accessory
or ZP single start
If not available, bridge contact
Flue gas temperature limiter
Flue gas pressure
sensor
Equipment earth
Ignition electrode
Ignition
unit
Mains voltage Edge connector Accessory module VR40
Fig. 5.7 Connecting electrical accessories and internal wiring
5 Installation

19Installation and maintenance instructions ecoCRAFT 0020055744_08
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. Pay attention to the polarity when doing this, as
the pump will only run at minimum speed if incorrectly
connected.
External flow thermostat
A flow thermostat can be electrically incorporated in the
safety chain by connecting it to the "contact
thermostat"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.
Gas pressure monitor
• A gas pressure monitor can be electrically integrated
into the safety chain at the contact thermostat termi-
nals.
Condensate feed pump
• Connect the alarm output of a condensate feed pump
to the "Contact thermostat" plug.
hNote
If several contacts are to be connected to the
contact thermostat connection, they must be
connected in series, not in parallel!
Installation 5

Installation and maintenance instructions ecoCRAFT 0020055744_0820
5.9.4 Connecting a controller
Connecting a VRC 430 control unit (controller out-
side the electronics box)
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).
The sensors and the system components that are not
listed in Section 5.10.2 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.
Before opening the electronics box, switch off the sup-
ply to the unit and secure it against unintentional
switching on.
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
VRC 430, VRC 630, VRS 620 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, VRS 620 or on the VRC 430 if
it is mounted externally.
• Alternatively, plug the VRC 430 controller into the op-
erating screen on the boiler (internal mounting).
5 Installation