Vaillant THERMOcompac SERIES Instructions For Installation And Servicing Download Page 43 | Manualshive

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43

COMMISSIONING PART I

THERMOcompact

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Summary of Contents for THERMOcompac SERIES

Page 1: ...24 2 E 828 2 E Wall hung room sealed fan assisted combination boilers THERMOcompact 615 2 E 620 2 E 624 2 E 628 2 E Wall hung room sealed fan assisted system boilers The code of practice for the insta...

Page 2: ...uirements 16 Water circulation system 16 Filling and make up 16 Pressure relief valve 16 Pressure gauge 16 Expansion vessel 17 Circulating pump 18 System by pass 18 Venting 18 DHW expansion vessel acc...

Page 3: ...pressure switch 66 Automatic bypass 67 Pressure gauge 67 Diverter valve TURBOmax Plus only 68 Aqua sensor TURBOmax Plus only 68 DHW heat exchanger TURBOmax Plus only 69 Pressure relief valve 69 Checki...

Page 4: ...ms supplied with unit TURBOmax Plus Table L 1 Items supplied with unit TURBOmax Plus Euro B S 086 0GB_Plus Item Quantity Description 1 1 Boiler 2 1 Flue restriction ring 3 1 Controls cover door 5 1 Co...

Page 5: ...unit THERMOcompact for THERMOcompact 624 628 only Euro B S_VC_025 0 DO NOT remove the boiler from the polystrene base at this stage Item Quantity Description 1 1 Boiler 2 1 Flue restriction ring 3 1 C...

Page 6: ...ithin the information pack you will find a Benchmark Log Book It is very important that this is completed correctly at the time of installation commissioning and handover to the user Note This boiler...

Page 7: ...ange 35 82 C Minimum CH water flow for 20 C rise 650 l h Pump pressure available 0 25 25 bar KPa Expansion vessel pre charge pressure 0 75 bar Maximum CH system pressure 3 bar Electrical supply 230 50...

Page 8: ...nnections TURBOmax Plus 7 5 4 3 2 1 148 6 8 310 592 145 6 5 100 100 35 35 4 3 2 130 180 1 Fig B 1 Connection diameters TURBOmax Plus Euro B S 090 2 Key 1 Heating system return 22 mm tail 2 Gas connect...

Page 9: ...Diverter valve 11 DHW heat exchanger 12 Automatic bypass 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 rel...

Page 10: ...unction 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...

Page 11: ...forced circulation hot water for domestic premises BS 5546 Specification for gas hot water supplies for domestic premises BS 6700 Services supplying water for domestic use within buildings and their...

Page 12: ...t of the installation of a boiler in a room containing a bath or shower Where the installation of the boiler will be in an unusual location special procedures may be necessary and BS 5546 and BS 6798...

Page 13: ...kness Extended top outlet flue system 125 mm outside diameter A top outlet horizontal flue system of 125 mm outside diameter is also available Art No 303 609 and can be used to achieve flue lengths of...

Page 14: ...drain pipes and soil pipes 25 F From internal or external corners 25 G Above ground or balcony level 300 I From a terminal facing a terminal 1200 K Vertically from a terminal on the same wall 1500 L H...

Page 15: ...nal space in which the boiler is installed Electrical supply A 230 V 50 Hz single phase electricity supply fused to 3 Amp must be provided in accordance with the latest edition of BS7671 IEE Wiring Re...

Page 16: ...dance with BS 7593 For advice on the application of system cleansers contact either Sentinel Betz Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 495 1861 or Fernox Alpha Fry Technologies Tandem House M...

Page 17: ...heating system for instance in case of modernization of old open systems an additional expansion vessel can be installed external to the boiler It should be fitted in the return pipe as close as possi...

Page 18: ...is included within the boiler The boiler is suitable for use in systems with thermostatic radiator valves and no additional by pass is required Venting The boiler is fitted with an automatic air vent...

Page 19: ...service and maintenance The boiler can be correctly flued i e the flue terminal position is sited in accordance with the flue termination section see page 14 and the air flue duct can be installed in...

Page 20: ...he position of the hanging bracket fixing holes 1 Drill 2 holes 8 mm for the hanging bracket Identify correct flue exit Mark the centre of the selected air flue duct and its circumference e g by drill...

Page 21: ...g bracket Note Lift the boiler from either side at the bottom edge Install the flue system Install the flue system refer to separate air flue duct installation instructions Fitting the boiler hanging...

Page 22: ...ckwise by 90 to release control panel 2 Pull the case 3 forward at the bottom to disengage from the securing clips Lift the case slightly to clear the top locations and pull forward to remove VRC VC 3...

Page 23: ...the appliance 2 and tighten Connect a gas supply pipe of not less than 15 mm diameter to the copper tail Tighten all connections Ensure the gas supply pipework is adequately sized such that a 20 mbar...

Page 24: ...e 15 mm cold water inlet pipe copper tail 4 to the cold water service valve 1 and tighten Connect the 15 mm hot water outlet copper tail 6 to the hot water outlet connection of the appliance 8 with th...

Page 25: ...the illustration and tighten the nuts Connect the central heating pipework to the flow 9 and return 4 tails Pressure Relief Valve Connect a discharge pipe not less than 15 mm diameter to the outlet of...

Page 26: ...the appliance and tighten Connect a gas supply pipe of not less than 15 mm diameter to the copper tail Tighten all connections Ensure the gas supply pipework is adequately sized such that a 20 mbar g...

Page 27: ...the illustration and tighten the nuts Connect the central heating pipework to the flow 9 and return 4 tails Pressure Relief Valve Connect a discharge pipe not less than 15 mm diameter to the outlet o...

Page 28: ...er THERMOcompact For connecting a Vaillant Vantage unvented cylinder please refer to the Vantage installation instructions provided with the cylinder Connect the flue system to the boiler Refer to sep...

Page 29: ...29 BOILER INSTALLATION SEQUENCE...

Page 30: ...mains supply must allow complete electrical isolation of the boiler and its ancillary controls It should be readily accessible and adjacent to the boiler A 3 core flexible cord according to BS6500 tab...

Page 31: ...l and secure in place Connection to the main supply Lower the control panel Unclip the terminal box cover 1 from the control panel 2 Feed the power supply cord in to the appliance as shown fig I 11 Us...

Page 32: ...ority reversing 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 co...

Page 33: ...ime switch with built in room thermostat is used to control the boiler Important The arrowed numbers indicate connection into the relevant terminal in the boiler terminal strip Connection details for...

Page 34: ...locking clips L N 2 3 4 L N 3 4 1 ACL Drayton Tempus 1 Tempus 2 Lyfestyle LP111 LP711 ACL Drayton Switchmaster SM300 ACL Drayton Switchmaster 980 Danfoss Randall 103 Series Danfoss Randall Set 1E TS97...

Page 35: ...neywell ST699B ST799A Note Link L 5 8 Honeywell ST6200 ST6300 ST6400 Horstmann Channel Plus H21 H27 Note Earth not required Link L 2 5 Siemens Landis Staefa RWB2 RWB9 Potterton Myson EP 2002 EP 3002 E...

Page 36: ...C 1 1 3 ACL Drayton HTS3 Danfoss Randall ATC Tower CS1 Honeywell L641 Horstmann HTC1 Siemens Landis Staefa RAM 1 Sunvic SA 2452 10 7 E Cylinder thermostat 3 E 2 E E EARTH BLUE BROWN GREY ORANGE Centra...

Page 37: ...ny external heating controls Circulating pump The boiler incorporates a built in circulating pump that is fully prewired no additional wiring is necessary The pump incorporates an automatic overrun pe...

Page 38: ...points either side at the top of the boiler engage Push the casing onto the securing clips at the bottom of the boiler Close control panel 2 Secure control panel by turning both securing fasteners 3...

Page 39: ...n extinguish all naked flames and do not smoke whilst purging After purging the gas service valve connection must be retightened and tested for soundness The boiler itself does not require purging as...

Page 40: ...40 COMMISSIONING PART I TURBOmax Plus 2 1 90 Fig Com 1 Filling TURBOmax Plus boiler Eor B S 054 0...

Page 41: ...Now check the water pressure in the unit again and add more water if necessary Close the filling valve 1 and disconnect the temporary connection Filling the heating system TURBOmax Plus Proceed as fol...

Page 42: ...system THERMOcompact The boiler and the heating system should be filled using a filling method as described on page 16 Ensure that the boiler CH service valves are open Partially open the filling valv...

Page 43: ...43 COMMISSIONING PART I THERMOcompact...

Page 44: ...tinue holding button until display alternates between P1 and P2 Release button Press button until P1 full gas rate is shown in display Press i button to operate boiler at full gas rate Check that the...

Page 45: ...on while pressing the button turn the main ON OFF control to the 1 ON position Continue holding button until display alternates between P1 and P2 Release button Press button until P1 is shown in the d...

Page 46: ...hile carrying out this procedure TURBOmax Plus only Check that the U gauge reading corresponds to the maximum burner pressure as detailed on the table on page 48 Identify required range rating setting...

Page 47: ...flashing The new setting value is now memorised The new main burner pressure can now be checked If the new output is not correct repeat steps 3 to 5 6 To return to normal mode press the i and buttons...

Page 48: ...tton until display alternates between P1 and P2 Release button Press button until P2 igniti on rate is shown in display Press i button to operate boiler at full gas rate Using a 9 mm spanner turn the...

Page 49: ...operate boiler at full gas rate Using a 7 mm spanner turn the inner hexagonal nut 1 to adjust the burner operating pressure Turn the nut 1 clockwise to increase the nominal load Turn the nut 1 anticl...

Page 50: ...nozzles are stamped with the mark shown in this table The marking corresponds to the nozzle hole diameter multiplied by 100 3 Ignition rate Ignition rate 4 1 5 4 1 8 Burner Pressure THERMOcompact 624...

Page 51: ...13 mbar dry 2 The nozzles are stamped with the mark shown in this table The marking corresponds to the nozzle hole diameter multiplied by 100 Table G 4 Gas flow rate Gas Rate THERMOcompact 624 2 E TUR...

Page 52: ...erating 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...

Page 53: ...er is operating correctly the status of the indicators will be as follows Red lock out indicator 1 OFF Yellow flame indicator 2 ON Flame indicator Green warmstart indicator 3 FLASHING hot water is bei...

Page 54: ...indicator 1 OFF Yellow flame indicator 2 OFF Green indicator 3 has no function Central Heating hot water opera tion Operate the heating hot water system If boiler is operating correctly the status of...

Page 55: ...tem until the system design pressure of 1 0 bar is attained The actual reading on the pressure gauge should ideally be 0 5 bar plus an additional pressure corresponding to the highest point of the sys...

Page 56: ...rtance of having the boiler regularly serviced by a competent servicing company To ensure regular servicing it is strongly recommended that arrangements are made for a Maintenance Agreement Please con...

Page 57: ...efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions...

Page 58: ...combustion chamber 8 Check 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 Release the syste...

Page 59: ...exchanging any gas carrying component Always check earth continuity polarity and resistance to earth with a multimeter after any service work and after exchanging any electrical component Initial pre...

Page 60: ...acket supporting screw 1 and then remove the electrodes 2 Remove two screws 3 and pull burner 4 forwards to remove Reassemble in reverse order Electrodes Refer to the important information and initial...

Page 61: ...the fan outlet when the boiler is installed with a rear outlet flue system push the flue connector 4 towards the rear of the boiler until it clears the fan outlet Disconnect the electrical connections...

Page 62: ...e outlet connection Undo compression nut on the outlet of the gas service valve Pull off the locating spring 8 Remove complete gas valve assembly and inlet pipe from the boiler Remove both inlet pipe...

Page 63: ...ant information and initial preparation on page 59 Release central heating water pressure Remove combustion chamber cover by unclipping the three clamps Remove four screws 4 and pull off combustion ch...

Page 64: ...from the wall as follows Refer to important information and initial preparation on page 57 Release central heating water pressure Disconnect external wiring from boiler wiring terminal box Disconnect...

Page 65: ...y by releasing the retaining clips Carefully insert the new electronic board into the control box Insert the electronic display by carefully lining up the pins and push until the display locks in to p...

Page 66: ...mp connections Re assemble in reverse order Air pressure switch Refer to the important information and initial preparation on page 59 Remove clips 6 and lift out pressure switch 7 Disconnect electrica...

Page 67: ...se order 3 2 1 Fig E 14 Automatic Bypass Euro B S 169 0 picture shows a TURBOmax Plus boiler 2 2 1 Fig E 15 Pressure gauge Euro B S171 0 Pressure gauge Refer to the important information and initial p...

Page 68: ...a sensor Remove the spring clip 3 Pull the aqua sensor forward and release cable Remove aqua sensor Remove the spring clip 6 and disconnect filling loop valve Re assemble in reverse order Diverter val...

Page 69: ...union 2 Push the heat exchanger 5 backwards to disconnect Re assemble in reverse order Pressure relief valve Refer to the important information and initial preparation on page 59 Release central heat...

Page 70: ...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 separate fl...

Page 71: ...erature this indicates that the boiler is operating correctly after an internal self check Status Mode The status display is helpful in diagnosing faults where a fault code is not displayed Diagnostic...

Page 72: ...hed ON Not illuminated Warmstart is switched OFF and there is no demand for hot water Flashing There is either a demand for hot water or warmstart Indicator lights THERMOcompact only The boiler contro...

Page 73: ...re attempting to use the fault fin ding guide 1 Carry out electrical safety checks See Section Preliminary Electrical Checks 2 Check that the external electricity supply to the boiler is on and a supp...

Page 74: ...nti cycling mode warm start S 07 Pump over run heating operation S 30 S 08 Anti cycling mode heating operation No heating demand from external controls S 10 Hot water demand hot water operation S 34 S...

Page 75: ...rature Display Indication Displayed values adjustment values d 00 Part load setting 0 1 2 15 factory adjusted to 15 max rating d 01 Water pump over run 1 2 3 60 min factory adjusted setting 5 min d 02...

Page 76: ...72 Pump over run for loading warmstart or Vantage cylinders 0 1 2 250 s factory adjusted to 80 s d 74 Not applicable d 75 Maximum hot water priority operation time Vantage only 20 21 22 90 min factory...

Page 77: ...TC faulty F 01 Return NTC NTC broken NTC cable broken Defective connection at NTC Defective connection at electronics Return NTC cable defective broken NTC faulty F 11 Short circuit return NTC 130 C N...

Page 78: ...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 cha...

Page 79: ...ansformer 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 Produ...

Page 80: ...de 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...

Page 81: ...ssure switch 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 pa...

Page 82: ...urner 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...

Page 83: ...ronic 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 TURBO...

Page 84: ...ld 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 Che...

Page 85: ...nition 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 p t br br r b br...

Page 86: ...ition 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...

Page 87: ...C 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 Pressure sensor Water sensor Ionisation electrode...

Page 88: ...lectrode Bridge 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 Pressure sensor Ionisation electrode Pump NTC f...

Page 89: ...ensing electrode 090724 Er 2 Fan 190215 Er 3 Gas valve LPG 053499 Natural gas 053473 Er 4 Flow NTC Return NTC Warmstart NTC 252805 Er 5 Main heat exchanger 615E 065098 620E 065098 624E 824E 065086 628...

Page 90: ...5 Er 6 Er 7 Er 8 Er 9 Er 10 Er 11 Er 12 Euro B S 143 0 Euro B S 148 0 Euro B S 147 0 Euro B S 142 1 Euro B S 177 1 Euro B S 146 0 Euro B S 156 0 Euro B S 152 0 Euro B S 154 0 Euro B S 144 0 Euro B S...

Page 91: ...91 SHORT PARTS LIST Er 13 Er 14 Er 16 Er 17 Er 15 Euro B S 149 0 Euro B S 155 1 Euro B S 145 0 Euro B S 178 0 Euro B S 150 0 TURBOmax Plus only...

Page 92: ...2001 M Printed on 100 recycled paper Subject to alteration Head Office Vaillant Ltd Vaillant House Medway City Estate Trident Close Rochester Kent ME2 4EZ Service Solutions 0870 6060 777 Technical Ad...

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