Vaillant ecoMAX 824/2 E Instructions For Installation Manual Download Page 2

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Supplied By www.heating spares.co Tel. 0161 620 6677

Table of Contents

Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1

Page

1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Contents included with boiler (turboMAX plus)

1.2

Contents included with boiler (thermoCOMPACT) 4

2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

General Information . . . . . . . . . . . . . . . .

2.2

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

EC designation . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Boiler Specification . . . . . . . . . . . . . . . . . . . . . .

3.1

Technical data . . . . . . . . . . . . . . . . . . . .

3.2

Boiler connections (turboMAX plus) . . . . . . . .

3.3

Boiler connections (thermoCOMPACT) . . . . . .

3.4

Functional diagram (turboMAX plus) . . . . . . . .

3.5

Functional diagram (thermoCOMPACT) . . . . . .

4 General Requirements . . . . . . . . . . . . . . . . . . . .

4.1

Related documents . . . . . . . . . . . . . . . . . . . . . .

4.2

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1

Top outlet flue system . . . . . . . . . . . . . . . . . . . .

4.4.2 Rear outlet flue system . . . . . . . . . . . . . . . . . . .

4.4.3 Extended top outlet flue system . . . . . . . . . . .

4.4.4 Flue termination . . . . . . . . . . . . . . . . . . . . . . . .

4.5

Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6

Cupboard or compartment ventilation . . . . . .

4.7

Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . .

4.8

Guide to system requirements . . . . . . . . . . . . .

4.8.1

Water circulation system . . . . . . . . . . . . . . . . . .

4.8.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . .

4.8.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . .

4.8.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . .

4.8.6 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . .

4.8.7 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.8 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Boiler Installation Sequence . . . . . . . . . . . . . . .

5.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Using boiler template . . . . . . . . . . . . . . . . . . . .

5.3

Fitting the boiler hanging bracket . . . . . . . . . .

5.4

Install the flue system . . . . . . . . . . . . . . . . . . . .

5.5

Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . .

5.6

Removing boiler casing . . . . . . . . . . . . . . . . . . .

5.7

Gas supply (turboMAX plus) . . . . . . . . . . . . . . .

5.8

Cold water mains inlet and hot water outlet
(turboMAX plus) . . . . . . . . . . . . . . . . . . . . . . . . .

5.9

Central heating flow and return pipework
(turboMAX plus) . . . . . . . . . . . . . . . . . . . . . . . . .

5.10

Gas supply (thermoCOMPACT) . . . . . . . . . . . . .

5.11

Central heating flow and return pipework
(thermoCOMPACT) . . . . . . . . . . . . . . . . . . . . . .

5.12

Connection to a Vantage unvented cylinder .
(thermoCOMPACT) . . . . . . . . . . . . . . . . . . . . . . 20

Page

5.13

Connect the flue system to the boiler . . . . . . . 20

5.14

Electrical installation . . . . . . . . . . . . . . . . . . . . . 20

5.15

Connection to the main supply . . . . . . . . . . . . 20

5.16

Electronic board layout . . . . . . . . . . . . . . . . . . .

5.17

Controls (turboMAX plus boiler) . . . . . . . . . . . .

5.18

Controls (thermoCOMPACT boiler) . . . . . . . . .

5.19

Thermostatic radiator valves . . . . . . . . . . . . . .

5.20

Frost protection . . . . . . . . . . . . . . . . . . . . . . . . .

5.21

Circulating pump . . . . . . . . . . . . . . . . . . . . . . . .

5.22

Anti-cycling ‘economiser’ control . . . . . . . . . . .

6 Commissioning Part I . . . . . . . . . . . . . . . . . . . . 25

6.1

Preliminary electrical checks . . . . . . . . . . . . . .

6.2

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.3

Cold water supply (turboMAX plus only) . . . . .

6.4

Filling the heating system (turboMAX plus) . .

6.5

Filling the heating system (thermoCOMPACT)

6.6

Initial system flush ("cold“) . . . . . . . . . . . . . . . .

7 Gas supply adjustments (Commissioning Part II) 26

7.1

Gas inlet working pressure . . . . . . . . . . . . . . . .

7.2

Main burner pressure . . . . . . . . . . . . . . . . . . . .

7.3

Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4

Adjusting to the maximum heat load
(nominal load) . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.5

Adjusting the ignition rate . . . . . . . . . . . . . . . . 29

7.6

Checking and adjusting to the operating point
(turboMAX plus 837E and
thermoCOMPACT 637E only) . . . . . . . . . . . . . . 30

7.7

Setting or adjusting the mid-setting point . . .

7.8

Fit combustion chamber cover . . . . . . . . . . . . .

7.9

Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . .

8 Functional checks (Commissioning Part III)

8.1

Functional checks . . . . . . . . . . . . . . . . . . . . . . .

8.2

Functional check of operation
(turboMAX plus only) . . . . . . . . . . . . . . . . . . . . .

8.3

Functional check of operation
(thermoCOMPACT only) . . . . . . . . . . . . . . . . . . 34

8.4

Adjusting pump speed . . . . . . . . . . . . . . . . . . . . 34

8.5

Handing over to the user . . . . . . . . . . . . . . . . .

9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.1

Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . .

9.2

Cleaning the burner and primary heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for ecoMAX 824/2 E

Page 1: ...l 0161 620 6677 For the installer 824 2 E 828 2 E 837 E 615 2 E 620 2 E 624 2 E 628 2 E 637 E GB Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT Wall hung room sealed fan assisted combination and system boilers ...

Page 2: ...18 5 9 Central heating flow and return pipework turboMAX plus 18 5 10 Gas supply thermoCOMPACT 19 5 11 Central heating flow and return pipework thermoCOMPACT 19 5 12 Connection to a Vantage unvented cylinder thermoCOMPACT 20 Page 5 13 Connect the flue system to the boiler 20 5 14 Electrical installation 20 5 15 Connection to the main supply 20 5 16 Electronic board layout 21 5 17 Controls turboMAX...

Page 3: ... 10 Fault Finding 37 10 1 Introduction 37 10 2 Indicator lights turboMAX plus only 37 10 3 Indicator lights thermoCOMPACT only 37 10 4 Logical fault finding procedure 36 10 5 Status Modes 38 10 6 Diagnostic Mode 39 10 7 Fault codes 40 10 8 Fault memory 40 10 9 Fault finding charts 41 11 Diagrams 48 11 1 Functional flow diagrams 48 12 2 Wiring diagrams 50 ...

Page 4: ... Quantity Description 1 1 Boiler 2 1 Flue restriction ring 3 1 Controls cover door 4 1 Lower cover plate packed in bottom packaging 5 1 Cold water inlet valve 6 3 Flow and return service value gas service valve 7 5 Copper tails for gas and water pipework 8 1 Template 9 2 Guarantee Card and Benchmark log book 10 1 Installation and connection accessories and PRV packages incl DHW outlet union nut 11...

Page 5: ...are also available in LPG 2 2 General Notes The boilers have been designed for use with a sealed central heating system and come fully tested and assembled with a built in circulating pump expansion vessel and diverter valve turboMAX plus only The boilers are not suitable for use on open vented systems The boilers are easily sited on any internal wall and can be installed with either a horizontal ...

Page 6: ...low rate 0 5 0 5 0 5 bar Minimum water flow rate 1 5 1 5 1 5 l min Mains water pressure required for min flow rate 0 15 0 15 0 15 bar Maximum inlet water pressure 10 10 10 bar Inlet gas working pressure required natural gas 20 20 20 mbar Gas supply G20 Gross CV s t 37 8 37 8 37 8 MJ m3 Gas burner pressure max rate 9 8 10 5 12 0 mbar Gas burner pressure ignition rate 1 9 1 8 1 2 mbar Gas rate max D...

Page 7: ...7 79 8 79 8 Inlet gas working pressure required natural gas 20 20 20 20 20 mbar Gas supply G20 37 8 37 8 37 8 37 8 37 8 MJ m3 Gross CV s t Gas burner pressure 9 9 9 0 9 8 10 5 12 0 mbar max rate Gas burner pressure 2 2 1 5 1 9 1 8 1 2 mbar ignition rate CH temperature 35 82 35 82 35 82 35 82 35 82 C flow range Minimum CH water flow for 20 C rise 650 860 1032 1203 1587 l h Pump pressure available 0...

Page 8: ...ypass valve 13 CH flow service valve 14 Hot water outlet 15 Gas service valve 16 Cold water service valve 17 CH return service valve 18 Pressure relief valve 19 Aqua sensor DHW flow switch 20 Temperature sensor NTC III 21 Main on off control u C C i 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3 2 Boiler connections turboMAX plus Fig 3 1 Connection diameters ...

Page 9: ... duct 2 Fan 3 Main heat exchanger 4 Temperature sensor NTC I 5 Flame sensing electrodes 6 Modulating burner 7 Fully modulating automatic gas value 8 This control has no function on this boiler 9 Maximum radiator temperature control 10 Automatic bypass valve 11 CH flow service valve 12 Gas service valve 13 CH return service valve 14 Pressure relief valve 15 Main on off control 16 Pressure gauge 17 ...

Page 10: ...f an adequate size Do not use pipes of a smaller size than the boiler gas connection 15 mm 22 mm for 837 637 The complete installation must be tested for soundness and purged as described in BS 6891 Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 10 4 General Requirements 4 1 Related Documents The installation of the boiler must be in accordance with the relevant req...

Page 11: ...etails Fig 4 4 Art No 303 609 70 1103 70 15 750 4 4 Flue system Note The boilers are delivered ready for installation utilising a top outlet flue assembly For installation with a rear outlet flue assembly refer to the boiler flue outlet adaptation in the flue instructions 4 4 1 Top outlet flue system 100 mm outside diameter The top outlet horizontal flue system Art No 303 807 is suitable for insta...

Page 12: ...ed socket outlet both complying with the Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 12 4 4 4 Flue termination The following details refer to both flue systems a The terminal must be positioned such that the pro ducts of combustion can disperse freely at all times b In certain weather conditions a plume of water vapour may be visible from the flue terminal Positi...

Page 13: ...h with a 3 mm contact separation on both poles may be used Important This appliance must be earthed 4 8 Guide to system requirements 4 8 1 Water circulation system Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449 Part 1 for small bore and micro bore central heating systems Pipework not forming part of the useful heating surface should be insulated to help ...

Page 14: ...uctions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 14 4 8 6 Circulating pump The circulating pump is included in the boiler The pump head available for the heating system is shown in fig 4 6 Fig 4 6 Pump specifications 12 28 kW 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Volume flow l hr Lift mbar Pump...

Page 15: ...the casing use the optional top connection accessory Art No 306 251 5 Boiler Installation Sequence 5 1 General Preparation of boiler location Clearances required Mount the boiler on a flat and vertical area of wall of sufficient area for the boiler plus the required clearances for installation and servicing The clearances are as detailed below and are shown on the installation template supplied wi...

Page 16: ...lternative fixings to ensure adequate support Fig 5 4 Free space required for installation Note If the boiler is to be fitted in a timber framed building ensure that the bracket is secured to a substantial part of the timber frame capable of taking the weight of the boiler 3 402 171 174 5 12 5 1 1 2 Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 16 5 2 Using boiler ...

Page 17: ...s connection turboMAX plus I 0 3 1 2 5 4 Install the flue system Fit the flue restrictor to the boiler if required and install the flue system refer to separate air flue duct installation instructions for further information 5 5 Fitting the boiler Lift the boiler 3 up to the wall so that it is slightly above the hanging bracket 1 Note Lift the boiler from either side at the bottom edge Lower the b...

Page 18: ...res that any discharge of water or steam from the valve cannot create a hazard to persons in or about the premises or cause damage to any electrical components or external wiring and the point of discharge should be clearly visible see diagram in plastic bag Fig 5 8 Central heating flow and return pipework turboMAX plus 9 I 0 4 1 2 3 8 7 6 Instructions for Installation and Servicing turboMAX plus ...

Page 19: ...s than 15 mm diameter to the outlet of this valve The discharge pipework should be as short as possible and installed with a continuous fall away from the boiler The pipe should terminate in a position which ensures that any discharge of water or steam from the valve cannot create a hazard to persons in or about the premises or cause damage to any electrical components or external wiring and the p...

Page 20: ...1 IEE Regulations The boiler is supplied for connection to 230 V 50 Hz supply fused at 3 A rating Connection to the mains supply shall be made via a fused 3 pin plug to an unswitched shuttered socket both complying to the requirements of BS1363 Alternatively connection may be made via a 3 A fused double pole isolator having a contact separation of at least 3 mm in all poles and supplying the boile...

Page 21: ... 8 7 F3 5 4 3 24V 230V F1 5 16 Electronic board layout Socket X2 for internal unit components Socket X4 for diverter valve Socket X7 for accessory box connection Socket X8 for VRC VC connection Room thermostat 230 V connections 3 4 and 5 Mains power supply connections L N and earth Socket X12 pump connection Socket X14 gas valve connection Socket X13 fan connection Do not use Socket for fan contro...

Page 22: ...L N 3 4 1 L N 2 3 4 L N 3 4 1 L N 2 3 4 L N 3 4 1 N E 2 3 4 N E 1 L L 3 5 6 4 N E 2 3 4 N E 1 L L 3 4 L N 2 3 4 L N 3 4 1 L N 2 3 4 L N 3 4 1 A B D L N L N C N E 3 1 2 4 3 4 5 E 1 2 4 4 3 2 L 1 N 3 6 5 mains supply L N E E Landis Staefa RWB7 RWB30 5 17 Controls turboMAX plus boiler External electrical controls The boiler terminals 3 4 and 5 are for connecting external electrical controls such as a...

Page 23: ... 4 5 E N L X Y Z 3 amp fused main supply THERMOcompact terminal strip Programmer for programmer connections see fig 16 b L N L N 3 4 5 E 5 3 6 7 8 External wiring centre junction box 3 4 5 6 7 8 9 10 N N L L Do not use pre wired printed circuit board type not used EARTH BLUE BROWN OR WHITE GREY ORANGE 3 Port mid position motorised valve 4 E 5 8 9 E C A N 4 N 4 2 4 4 3 3 3 3 3 2 2 2 2 1 1 L 2 1 L 1...

Page 24: ...rboMAX only once in a 24 hour period This control helps to prevent seizure when the boiler is not operated for a period of time This control is not active when the power supply to the appliance is turned off Fig 5 19 Key X Central heating on Y Hot water on Z Hot water off Connection details for control systems utilising 2 x 2 port motorised valves via external wiring centre junction box Diagram on...

Page 25: ...t water taps supplied by the boiler turn on the mains water supply to the boiler and open the mains water isolating valve below the boiler Water will now flow through the boiler to the hot taps Starting with the lowest tap supplied turn the hot taps off one at a time until the hot water pipework is purged of air Check all hot and cold water pipework for leaks 6 4 Filling the heating system turboMA...

Page 26: ...mmissioning and Service Log Book Fig 7 1 Gas inlet working pressure 1 1 2 6 5 Filling the heating system thermoCOMPACT The boiler and the heating system should be filled using a filling method as described on page 13 Ensure that the boiler CH service valves are open Partially open the filling valve and allow water to enter the system Starting with the lowest radiator open the radiator air release ...

Page 27: ...pressure is correct as shown in table 7 1 for the appropriate boiler To cancel selected P1 or P2 mode press the i and buttons simultaneously turboMAX plus only Measure the domestic hot water burner operating pressure mbar the heat input kW the inlet outlet domestic hot water temperatures C and flow rate l min by fully opening a hot water tap and record details in the boiler logbook thermoCOMPACT o...

Page 28: ...e restarting again at d 0 1 Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 28 Press the i button and a value between 1 and 15 will be displayed Use the or buttons to increase or decrease the value Observe the U gauge as the button is pushed and stop pushing when the required main burner pressure has been achieved After setting press and hold the i button for five se...

Page 29: ...l selected P1 or P2 mode press the i and buttons simultaneously Fig 7 4 Adjusting the ignition rate 1 2 7 5 Adjusting the ignition rate Undo screw and remove the cap 1 turcoMAX only Disconnect the modulating coil wires from the gas valve set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap thermoCOMPACT only Turn off the boiler at the main ON...

Page 30: ...le below 7 7 Setting or adjusting the mid setting point Turn off the boiler at the main ON OFF control Press and hold the button while pressing the button turn the main ON OFF control to the I ON position Continue holding button until display starts to alternate between the P numbers P1 P2 P3 P11 P12 and P13 Release button Press button until P11 for natural gas or P 13 for LPG is shown in display ...

Page 31: ...or G31 4 3 4 3 4 5 71 10 1 13 7 17 6 22 0 26 9 Burner Pressure thermoCOMPACT 624 2 E turboMAX plus 824 2 E Output kW Gas type Ignition rate 8 9 10 0 12 0 14 0 16 0 18 0 20 0 22 0 24 0 Natural gas 2H Burner pressure1 mbar Main burner jet mark2 for G20 1 9 1 9 2 1 2 9 3 7 4 7 5 8 6 7 8 4 9 8 7 120 LPG 3 B P Burner pressure1 mbar Main burner jet mark2 for G30 3 9 3 9 4 8 6 8 9 0 11 6 14 3 17 4 20 6 2...

Page 32: ...atural gas 2H Gas Rate1 m3 h Main burner jet mark2 per G20 1 3 1 5 1 7 1 9 2 1 2 4 2 6 2 8 3 1 3 3 7 120 Gas Rate thermoCOMPACT 637E turboMAX plus 837 E Output kW Gas type 10 5 12 0 16 0 18 0 20 0 24 0 28 0 30 0 33 0 36 9 Natural gas 2H Gas Rate1 m3 h Main burner jet mark2 per G20 1 3 1 5 1 9 2 2 2 4 2 8 3 3 3 5 3 9 4 3 7 120 Burner Pressure thermoCOMPACT 637 turboMAX plus 837 E Output kW Gas type...

Page 33: ...erate the system to ensure that it is working correctly Operate the system following the operating instructions supplied with the boiler Check the system for water leaks and escaping gas Check that the flue has been correctly installed according to the fitting instructions supplied with the flue assembly Check the burner for correct ignition and flame picture t tu ur rb bo oM MA AX X p pl lu us s ...

Page 34: ...Adjusting pump speed The unit is fitted with a two speed pump The pump is delivered with the switch 1 set to position III Fig 8 4 Attention Important note The boiler should only be operated at pump setting III because the heating capacity for hot water is reduced when operated at pump setting II It is possible however to change the pump setting from Level III to Level II manually when there is noi...

Page 35: ...aw that all servic ing work is carried out by a competent person Corgi registered Improtant Before starting any maintenance work Isolate the mains electricity supply by disconnecting the plug at the socket outlet if there is only an isolating switch remove the fuse from the switch Turn OFF the gas supply at the gas service valve fitted to the boiler Always test for gas soundness and always carry o...

Page 36: ...heck the burner 9 and heat exchanger fins 10 and remove any loose deposits with a soft brush Reassemble in reverse order Check central heating expansion vessel Note It is not necessary to carry out this check every year a check every three years should be sufficient Release the system water pressure from the boiler Remove valve cap from expansion vessel charge point Check that the internal charge ...

Page 37: ...to do so by the fault finding guide turboMAX only 1 If a fault code is showing in the boiler display follow the fault finding charts referring also to the fault code and diagnostic mode tables 2 If the boiler is not functioning correctly and a fault code is not showing in the boiler display follow the fault finding charts referring also to the status mode table Note If the boiler display is comple...

Page 38: ... Fan and pump over run 837 637 only x x S 07 Pump over run heating operation x x S 08 Anti cycling mode heating operation x x S 10 Hot water demand hot water operation x S 11 Fan running hot water operation x S 13 Ignition sequence hot water operation x S 14 Burner ignited hot water operation x S 16 Fan over run hot water operation x S 17 Pump over run hot water operation x S 20 Warmstart demand w...

Page 39: ...i cycling period min d 68 Number of unsuccessful attempted 1st ignitions d 69 Number of unsuccessful attempted 2st ignitions d 71 Maximum target value for heating system flow temperature 0 82 C 1 87 C factory setting 82 C d 72 Pump over run for loading warmstart 0 1 2 250 s factory adjusted to 80 s d 73 Offset warmstart temperature value 15 14 5 K factory adjusted 5 K d 75 Maximum hot water priori...

Page 40: ...pump return NTC s too large blocked or defective pump output too low F 24 Dry fire protection temperature gradient of flow NTC too steep Air in boiler system pump blocked or defective pump output too low F 27 No demand to gas valve Electronic board defective Gas valve defective F 28 Boiler goes to lock out No gas Isufficient gas Incorrect gas valve adjustment Electrode defective Ignition lead defe...

Page 41: ...t across terminals 8 and 9 Yes Is 5 VDC present between 5V and GND test points on electronic board Replace LCD display Yes No Repair external fault Is the continuity across fuse F1 Go to sheet B Does ON OFF knob operate switch on electronic board Boiler ON OFF control defective change electronic board Replace switch mechanism No No No Yes Yes Note 1 For test purposes disconnect external controls f...

Page 42: ...he boiler Go to sheet A Is there a display on the LCD panel Check transformer 230 VAC primary black red and approx 17 VDC secondary blue brown Check replace pump Replace fuse F1 If fan commences operation exchange gas valve After approx 20 secs Does fuse F1 blow Produce central heating demand Does fuse blow immediately Turn the main ON OFF control to the 1 position Is t here a display on the LCD p...

Page 43: ...tion and that any internal timer if fitted is calling for heat Check diagnostic code D 08 see page 53 Is heating demand present No Is 230 VAC present across terminals 4 and 5 No External fault Check all external controls are calling for heat replace or repair as necessary see also note 1 sheet A Yes Yes Does failure code show on LCD display Disconnect built in timer if fitted No Go to sheet D Does...

Page 44: ...or replace air pressure switch 837 637 Check 4 pin connector for fan speed control Does the fan run now Is 230 VAC present across fan terminals Replace electronic board Yes No No Yes No Yes Yes Check replace fan Does the boiler commence ignition Check status code see page 52 is S 33 Check air flue gas system is correctly fitted and not obstructed Yes No Replace electronic board No Yes Are electrod...

Page 45: ...ngs are correct Yes No Reset boiler No Check replace gas valve as necessary Does burner light No Replace electronic board Yes Is burner indicator illuminated No Check flame rectification lead and electrode Is burner indicator illuminated No Yes Does burner shut down after approx 15 secs No Go to sheet F Yes Does status code see page 52 show S 53 Check water pressure in central heating system refil...

Page 46: ...nsure flow and return service valves are open No No No Replace electronic board No Check operation of boiler in DHW mode does flame increase in size to full rate TURBOmax Plus only Yes Check partial load setting No Check diagnostic code D 22 see page 53 equals 1 TURBOmax Plus only No Go to sheet G Yes Check connections and modulator replace gas valve if burner still fails to increase to full rate ...

Page 47: ...er filter Normal operation carry out electrical safety checks No Check cold water inlet pressure is sufficient and that cold water inlet filter is clear Check cold water inlet is fully open and adjustment is at maximum flow rate Does green warmstart indicator flash now Check Clear impeller in Aquasensor replace if necessary Check replace hall sensor Replace electronic board Does hot water indicato...

Page 48: ... TEMPERATURE SENSOR FLAME SENSOR GAS VALVE DHW Aqua Sensor F1 25A NTC RETURN TEMPERATURE SENSOR Burner lock out indicator red Hot water warmstart demand indicator Ignition indicator MAIN SWITCHBOARD IGNITION ELECTRODES Legend b blue br brown y g yellow green r red p pink or orange t transparent bl black gr grey w white gr b r bl b gr br y g b br y g br t w p t br br r b br y g gr p p r CONTROL BOX...

Page 49: ...SWITCH MAIN TRANSFORMER 230V 20V AIR PRESSURE SWITCH FAN PUMP NTC FLOW TEMPERATURE SENSOR FLAME SENSOR GAS VALVE F1 25A NTC RETURN TEMPERATURE SENSOR Burner lock out indicator red Ignition indicator MAIN SWITCHBOARD IGNITION ELECTRODES Legend b blue br brown y g yellow green r red p pink or orange t transparent bl black gr grey w white gr b br y g b br y g br t w t br br r b br y g gr r CONTROL BO...

Page 50: ... 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 4 3 2 1 X2 NTC NTC Warmstart earth Ionisation electrode NTC flow NTC return Lifting magnet 24 23 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 Fan unit Ignition electrodes Gas valve Diverter valve Air pressure switch NTC Warmstart Ionisation electrode Pump NTC return 1 2 EV1 EV2 3 4 X8 X4 VUV X12 X14 X13 7 9 L 4 8 N 3 5 X7 Access...

Page 51: ...00 X3 T 2 F1 T 1 25 F3 X2 X2 X1 24 23 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 X2 Pressure sensor NTC earth Ionisation electrode Coding resistor NTC flow NTC return Lifting magnet 24 23 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 Fan unit Ignition electrodes Gas valve Air pressure switch Ionisation electrode Pump NTC flow NTC return X8 X4 VUV X12 X14 X13 7 9 L 4 8 N 3 ...

Page 52: ...20 6677 83 37 86_30 GB R2 04 2003 Mü Printed on 100 recycled paper Subject to alteration Head Office Vaillant Ltd Service Solutions 0870 6060 777 Vaillant House Trident Close Medway City Estate Rochester Kent ME2 4EZ Technical Advice 01634 292392 ...

Page 53: ...Supplied By www heating spares co Tel 0161 620 6677 824 E 828 E 837 E 615 E 620 E 624 E 628 E 637 E GB Instructions for use turboMAX plus thermoCOMPACT ...

Page 54: ...e contact either your installer or Vaillant Technical Department Key to symbols Important Note This symbol is used to indicate important instructions This symbol is used to indicate a required step Liability We can accept no liability whatsoever for damage or injury resulting from failure to obser ve these instructions Specified use Vaillant turboMAX plus and thermoCOMPACT boilers are made to fulf...

Page 55: ...e in the quality of craftmanship and per formance of our products is demonstrated by the Vaillant two year guarantee During the first year from installation the guarantee covers your boiler against manufacturing defects for both parts and labour In order to extend this guarantee to the second year from installation all you have to do is ensure that your boiler receives a service when it is a year ...

Page 56: ...rols For access to the controls press the upper middle of the lower front panel and drop it down The following can be seen 1 Maximum radiator temperature control 2 The and buttons for the display panel 3 Main ON OFF control 4 Built in control timer module if fitted 5 The i information button 6 Boiler display 7 Indicator lights to display the current operating mode 8 Reset button 9 Pressure gauge d...

Page 57: ... of the system on the pressu re gauge 1 The needle on the pressure gauge should be within the green band between 1 and 1 5 bar If the needle displays a value below 0 8 bar when the appliance is cold follow the instructions left by your installer to refill the system Alternatively your installer should be called to refill the system Fig B 4 Checking the water level Domestic hot water operation turb...

Page 58: ...or a short time The green indicator light will now illuminate Reset the hot water temperature control knob to the desired setting The boiler will now provide instantaneous delivery of hot water directly when a hot water tap is turned on The warmstart system is switched off by turning the hot water temperature control knob 1 all the way to the very left for a short time The green indicator light is...

Page 59: ...l as well as improved comfort Ask your installer Fig B 9 Setting the external controller The boiler will now operate automatically to provide central heating for the conditions selected on the external con trols turboMAX plus will also provide domestic hot water on demand Whilst the boiler is operating the boiler display fig B 2 indicates the temperature of the water within the boiler circuit Afte...

Page 60: ...y other fault developing which prevents the boiler from operating the display will also show other fault codes If a fault code is displayed please contact your installer or Vaillant Service Solutions Note If contacting Vaillant Service Solutions please remember to quote the fault code as this will help to pinpoint the fault Turning the boiler OFF turboMAX plus only To turn OFF the central heating ...

Page 61: ...ther details please contact Vaillant Service Solutions 0870 6060777 Frost protection Your boiler is equipped with a frost protection function If the heating water temperature drops below 5 C when the main switch is ON then the boiler goes into operati on and heats the boiler circuit to approx 30 C It cannot be guaranteed that water will circulate throughout the entire heating system If the boiler ...

Page 62: ...t operate then please consult your installer or Vaillant Service Solutions 0870 6060 777 Status display For maintenance and service work performed by your installer or service agent The status displays are activated by pressing the i button 1 The current status code e g S 34 for the frost protection mode is shown on the display 2 Pressing the i button again will switch you back to the normal mode ...

Page 63: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 64: ...co Tel 0161 620 6677 83 36 90 _22 GB_R1 03 2003 Mü Subject to alteration Head Office Vaillant Ltd Service Solutions 0870 6060 777 Vaillant House Trident Close Medway City Estate Rochester Kent ME2 4EZ Technical Advice 01634 29 23 92 ...

Page 65: ...828 E VUW 242 242 2 5 H B VUW 282 282 2 5 H B THERMOcompact 615 628 E VU 152 152 2 5 H VU 202 202 2 5 H B VU 242 242 2 5 H VU 282 282 2 5 H B This catalogue covers original TURBOmax Pro and Plus and THERMOcompact models Also the later 2 versions are covered e g VUW 242 3 and VUW 242 2 3 Refer to the appliance data badge for identification 802762 04 GB 05 01 ...

Page 66: ...VU 282 282 2 5 H B General view of sheets TURBOmax Pro Plus THERMOcompact Main component 04 burner Main component 05 gas section Main component 06 heat exchanger Main component 07a casing parts Main component 07b air pressure chamber fan Main component 08a hydraulic parts TURBOmax Pro Plus THERMOcompact Main component 08b connecting accessories Main component 12 switch box In order to maintain the...

Page 67: ... By www heating spares co Tel 0161 620 6677 General view sheet TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 ...

Page 68: ...www heating spares co Tel 0161 620 6677 Main component 04 Burner TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 1 ...

Page 69: ... cpl 28kW H Gas 2 4 5 x x x 126755 distributor tube cpl 24kW PB Gas 2 4 5 x 126756 distributor tube cpl 28kW PB Gas 2 4 5 x x 126777 distributor tube cpl 12 15kW H gas 2 4 5 x 126778 distributor tube cpl 20kW H gas 2 4 5 x 126779 distributor tube cpl 20kW B gas 2 4 5 x 126780 distributor tube cpl 24kW H gas 2 4 5 x x x 126781 distributor tube cpl 24kW B gas 2 4 5 x x x 126782 distributor tube cpl ...

Page 70: ... heating spares co Tel 0161 620 6677 Main component 05 Gas section TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 3 ...

Page 71: ...ube cpl supply for all types 5 6 7 x x x x x x 123467 gas tube cpl supply for all VU types 5 6 7 x x x x x x 05 982319 packing ring 21 0x2 5 rubber x x x x x x x x x x x x 06 981140 washer 17 0x24 0x2 0 set of 10 x x x x x x x x x x x x 07 219622 clip set of 10 x x x x x x x x x x x x 08 123423 gas tube cpl Turbo 9 10 x x x x x x x x x x x x 09 981142 washer 13 0x18 3x1 5 set of 10 x x x x x x x x...

Page 72: ...heating spares co Tel 0161 620 6677 Main component 06 Heat exchanger TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 5 ...

Page 73: ...heat exchanger cpl 28kW Euro Plus 3 4 x x x x 02 252805 ntc resistor cpl x x x x x x x x x x x x 03 981151 packing ring 19 0x3 15 set of 10 x x x x x x x x x x x x 04 219621 clip primary heat ex Set of 6 x x x x x x x x x x x x 05 235715 sheet metal screw ST4 8x9 5 x x x x x x x x x x x x 06 065088 secondary heat exchanger cpl 12 7 8 9 x x x x x x 065107 secondary heat exchanger cpl 12 7 8 9 x x x...

Page 74: ...heating spares co Tel 0161 620 6677 Main component 07a Casing parts TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 7 ...

Page 75: ...s 824 E B Plus 828 E H Plus 828 E B 615 E H 620 E H 620 E B 624 E H 628 E H 628 E B 02 07 056 01 067314 cowling cpl 4 5 x x x x x x x x x x x x 02 079533 cover plate x x x x x x x x x x 03 209714 control box cover x x x x x x x x x x 04 219620 clip set of 10 x x x x x x x x x x x x 05 219619 clip set of 10 x x x x x x x x x x x x THERMOcompact with parts TURBOmax Pos No Article No Part Subject to ...

Page 76: ...g spares co Tel 0161 620 6677 Main component 07b Air pressure chamber fan TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 9 ...

Page 77: ...50577 fan proving switch cpl Huba 6 x x x x x x x x x x x x 06 084139 flexible tube cpl x x x x x x x x x x x x 07 256097 cable tree cpl x x x x x x 256116 cable tree cpl x x x x x x 08 981048 packing ring set for cover x x x x x x x x x x x x 09 139472 plug set of 2 x x x x x x x x x x x x 10 161255 inspection glas cpl x x x x x x x x x x x x 11 980766 packing ring red small x x x x x x x x x x x...

Page 78: ...Supplied By www heating spares co Tel 0161 620 6677 Main component 08a Hydraulic parts TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 11 ...

Page 79: ... 42 x x x x x x 15 081162 connection tube W W cpl 35 37 x x x x x x 022776 connection tube w w cpl 35 37 x x x x x x 16 194819 impeller cpl aqua sensor 33 35 42 43 x x x x x x 17 014692 pressure relief valve 38 x x x x 18 711933 sensor cpl hall sensor x x x x x x 19 014675 valve cpl filling without non return valve 20 33 38 43 x x x x 19a 139471 plug 43 x x x x x x 20 125151 handle fill in valve x...

Page 80: ...Supplied By www heating spares co Tel 0161 620 6677 Main component 08a Hydraulic parts TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 13 ...

Page 81: ... ex set of 6 x x x x x x 35 219622 clip set of 10 x x x x x x 36 219623 clip set of 10 x x x x x x 37 981142 washer 13 0x18 3x1 5 set of 10 x x x x x x 38 981146 washer 5 5x11 0x1 5 set of 10 x x x x x x 39 981140 washer 17 0x24 0x2 0 set of 10 x x x x x x 40 981149 washer 10 0x14 9x1 5 set of 10 x x x x x x 41 981165 packing ring 12 0x2 0 set of 10 x x x x x x 42 981163 packing ring 15 0x2 0 set ...

Page 82: ...Supplied By www heating spares co Tel 0161 620 6677 Main component 08a Hydraulic parts THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 15 ...

Page 83: ... x x 23 019377 connection tube cpl 33 35 43 44 x x x x x x 24 190732 safety valve cpl 35 42 x x x x x x 26 101271 manometer 27 45 x x x x x x 27 085751 support x x x x x x 28 019372 connection tube cpl 36 40 41 x x x x x x 29 181057 expansion vessel cpl 10 ltr x x x x x x 32 118937 oval head screw M5x12 x x x x x x 33 154150 bow x x x x x x 34 219621 clip primary heat ex set of 6 x x x x x x 35 21...

Page 84: ...ng spares co Tel 0161 620 6677 Main component 08b Connecting accessories TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 17 ...

Page 85: ...r warm water system 07 014714 valve cpl 08 not for GB 09 not for GB 10 not for GB 11 081447 connection tube cpl GB 23 12 not for GB 13 not for GB 14 not for GB accessories for gas system 15 082782 gas shut off valve cpl 16 not for GB 17 not for GB 18 not for GB 19 not for GB 20 not for GB 21 not for GB 22 not for GB seals 23 981511 packing ring 24 not for GB 25 not for GB 26 not for GB 27 not for ...

Page 86: ... heating spares co Tel 0161 620 6677 Main component 12 Switch box TURBOmax Pro Plus VUW 242 3 282 3 242 5 282 5 H B inc 2 THERMOcompact VU 152 5 202 5 242 5 282 5 H B inc 2 Subject to alteration 802762 04 GB 05 01 19 ...

Page 87: ...r x x x x x x x x x x x x 06 077954 cover cpl display x x x x x x x x x x 07 257957 control switch x x 08 132925 plug set of 10 x x x x x x x x x x x x 09 101271 manometer x x x x x x x x x x x x 10 287450 transformer cpl x x x x x x x x x x x x 11 130473 printed circuit cpl x x 130474 printed circuit cpl x x x x x x x x x x 12 256097 cable tree cpl x x x x x x 256116 cable tree cpl x x x x x x 13...

Page 88: ...e contact either your installer or Vaillant Technical Department Key to symbols Important Note This symbol is used to indicate important instructions This symbol is used to indicate a required step Liability We can accept no liability whatsoever for damage or injury resulting from failure to obser ve these instructions Specified use Vaillant turboMAX plus and thermoCOMPACT boilers are made to fulf...

Page 89: ...e in the quality of craftmanship and per formance of our products is demonstrated by the Vaillant two year guarantee During the first year from installation the guarantee covers your boiler against manufacturing defects for both parts and labour In order to extend this guarantee to the second year from installation all you have to do is ensure that your boiler receives a service when it is a year ...

Page 90: ...rols For access to the controls press the upper middle of the lower front panel and drop it down The following can be seen 1 Maximum radiator temperature control 2 The and buttons for the display panel 3 Main ON OFF control 4 Built in control timer module if fitted 5 The i information button 6 Boiler display 7 Indicator lights to display the current operating mode 8 Reset button 9 Pressure gauge d...

Page 91: ... of the system on the pressu re gauge 1 The needle on the pressure gauge should be within the green band between 1 and 1 5 bar If the needle displays a value below 0 8 bar when the appliance is cold follow the instructions left by your installer to refill the system Alternatively your installer should be called to refill the system Fig B 4 Checking the water level Domestic hot water operation turb...

Page 92: ...or a short time The green indicator light will now illuminate Reset the hot water temperature control knob to the desired setting The boiler will now provide instantaneous delivery of hot water directly when a hot water tap is turned on The warmstart system is switched off by turning the hot water temperature control knob 1 all the way to the very left for a short time The green indicator light is...

Page 93: ...l as well as improved comfort Ask your installer Fig B 9 Setting the external controller The boiler will now operate automatically to provide central heating for the conditions selected on the external con trols turboMAX plus will also provide domestic hot water on demand Whilst the boiler is operating the boiler display fig B 2 indicates the temperature of the water within the boiler circuit Afte...

Page 94: ...y other fault developing which prevents the boiler from operating the display will also show other fault codes If a fault code is displayed please contact your installer or Vaillant Service Solutions Note If contacting Vaillant Service Solutions please remember to quote the fault code as this will help to pinpoint the fault Turning the boiler OFF turboMAX plus only To turn OFF the central heating ...

Page 95: ...ther details please contact Vaillant Service Solutions 0870 6060777 Frost protection Your boiler is equipped with a frost protection function If the heating water temperature drops below 5 C when the main switch is ON then the boiler goes into operati on and heats the boiler circuit to approx 30 C It cannot be guaranteed that water will circulate throughout the entire heating system If the boiler ...

Page 96: ...t operate then please consult your installer or Vaillant Service Solutions 0870 6060 777 Status display For maintenance and service work performed by your installer or service agent The status displays are activated by pressing the i button 1 The current status code e g S 34 for the frost protection mode is shown on the display 2 Pressing the i button again will switch you back to the normal mode ...

Page 97: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 98: ...co Tel 0161 620 6677 83 36 90 _22 GB_R1 03 2003 Mü Subject to alteration Head Office Vaillant Ltd Service Solutions 0870 6060 777 Vaillant House Trident Close Medway City Estate Rochester Kent ME2 4EZ Technical Advice 01634 29 23 92 ...

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