Vaillant TURBOmax Plus SERIES Instructions For Installation And Servicing Download Page 86

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DIAGRAMS

POWER SUPPLY

F2A

MAIN 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

blue

brown

y/g

yellow/green

red

pink

orange

transparent

black

grey

white

y/g

b
br

y/g

CONTROL BOX

plug in

connector

display

plus / minus buttons

reset button

info button

Fig. D.2: Functional Flow diagram VU

Euro B/S_VC_019/0

Functional Flow diagram: THERMOcompact 615/2 E, 620/2 E, 624/2 E, 628/2 E

THERMOcompact

Summary of Contents for TURBOmax Plus SERIES

Page 1: ...824 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 installation commissioning servicing of central heating systems ...

Page 2: ...quirements 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 accessory 18 General 19 Preparation of boiler location 19 Selecting position of boiler 19 Using boiler template 20 Fitting the boiler hanging bracket 21 Install the flue system 21 Fitting the boiler 21 ...

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 Checking functions 70 Functional checks Commissioning Part III Functional checks 52 Functional check of operation 53 54 Adjusting pump speed 55 Final system flush hot 55 Handing over to the user 56 Gas inl...

Page 4: ...ems 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 Cold water inlet valve 6 3 Flow and return service value gas service valve 4 1 Lower cover plate packed in bottom packaging 7 5 Copper tails for gas and water pipework 8 1 Template 9 2 Guarantee Card a...

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 Controls cover door 6 3 Copper tails for gas and water pipework 4 1 Lower cover plate packed in bottom packaging 7 1 Template 8 2 Guarantee Card and Benchmark log book 9 1 Installation and connection ...

Page 6: ...Within 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 must be installed and serviced by a competent person in accordance with the Gas Safety Installation and Use Regulations 1998 In the UK CORGI registered installers undertake the work to a safe and sat...

Page 7: ...range 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 V Hz External fuse 3 A Power input 150 W Maximum DHW heat input net kW Btu h THERMOcompact 628 2 E VU GB 282 2 5 TURBOmax Plus 828 2 E VUW GB 282 2 5 10 4 28 35500 95500 28 11 5 9 5 0 5 37 8 10 10 8...

Page 8: ...onnections 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 connection 15 mm tail 3 Heating system flow 22 mm tail 4 Flue outlet 100 mm flue with turret 5 Hanging bracket 6 Rear flue outlet Boiler connections THERMOcompact 5 3 2 1 148 4 6 310 592 145 4 3 100 100 2 1...

Page 9: ...0 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 relief valve 19 Aqua sensor DHW flow switch 20 Temperature sensor NTC III 21 Main on off control 22 Pressure gauge 23 Display 24 Expansion vessel 25 Expansion vessel charging valve 26 Circulating pump 2...

Page 10: ...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 Display 18 Expansion vessel 19 Expansion vessel charging valve 20 Circulating pump 21 Automatic air vent 22 Ignition electrode 23 Temperature sensor NTC II 24 Air pressu...

Page 11: ...r 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 curtilages BS 6798 Specification for installation of gas fired boilers not exceeding 60 kW input BS 6891 Specification for installation of low pressure gas pipework up to 28 mm R1 in domestic premise...

Page 12: ...ct 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 give detailed guidance on this aspect The boiler must be mounted on a flat vertical wall which must be sufficiently robust to take the weight of the boiler The boiler may be installed on a combustibl...

Page 13: ...ckness 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 up to 12 9 m for 15 20 24 kW 10 m for 28 kW Both 45 and 90 bends and elbows are also available to increase siting flexibility A vertical 125 mm concentric flue system is also available Art No 303 60...

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 Horizontally from a terminal on the same wall 300 M Distance from adjacent wall for vertical Flue 500 GW 595 2 Where a terminal is fitted less than 1 m below a plastic gutter or less than 0 5 m below ...

Page 15: ...rnal 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 Regulations and any other local regulations that may apply The method of connection to the mains electricity supply must provide a means of completely isolating the boiler and its ancillary controls Is...

Page 16: ...rdance 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 Marlow Way Beddington Farm Road Croydon CRO 4xS Tel 0870 601 5000 Fernox technical help line 01799 550811 Filling and make up The system can be filled using the built in filling loop TURBOmax Plus onl...

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 possible to the boiler in accordance with BS 5449 Part 1 Guidance on the sizing of an additional expansion vessel is given in Table R 2 Table R 2 Sizing of additional expansion vessel Vessel Volume L Init...

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 Additional provision should be made to enable the heating system to be vented during filling and commissioning either by automatic air vents or manually DHW expansion vessel accessory TURBOmax Plus o...

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 accordance with the flue installation instructions supplied All necessary pipework can be connected including the pressure relief valve yyyyyyyyyy yyyyyyyyyy yyyyyyyyyy yyyyyyyyyy yyyyyyyyyy yyyyyyyy...

Page 20: ...he position of the hanging bracket fixing holes 1 Drill 2 holes Ø 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 drilling through the template For installation of a rear exit outlet please refer to the installation instructions of the rear exit outlet kit Art No 303 817 Other flue options Flue instructions for othe...

Page 21: ...ng 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 bracket Fix the hanging bracket 2 to the wall using the screws supplied it may be necessary to use additional or alternative fixings to ensure adequate support Note If the boiler is to be fitted in a...

Page 22: ...ockwise 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 I 0 2 I 0 90 90 1 Fig I 5 Remove of boiler casing Euro B S 087 1 picture shows TURBOmax Plus ...

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 gas pressure is available at the boiler inlet at full flow rate I 0 3 1 2 Euro B S 046 0GB Fig I 6 Fitting the gas connection TURBOmax Plus TURBOmax Plus ...

Page 24: ...he 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 the washer provided 7 and tighten Note The hot water outlet union nut is packed in with the PRV fitting pack Connect the cold water service pipe and hot water outlet pipework to the copper tails 1 2 3 ...

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 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...

Page 26: ...h 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 gas pressure is available at the boiler inlet at full flow rate I 0 3 1 2 Euro B S_VC_027 0 Fig I 9 Fitting the gas connection THERMOcompact THERMOcompact ...

Page 27: ...n 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 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 o...

Page 28: ...der 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 separate air flue duct installation instructions included with the boiler ...

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 tables 6 8 or 16 3 x 0 75 to 3 x 1 5 mm2 should be used Warning This appliance must be earthed Important Ensure that all cords pass through the cable clamps in the rear of the control box and are secure...

Page 31: ...el 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 Use cable clamps Connect the power supply cord as follows Fig I 13 on page 32 Green yellow earth wire boiler terminal Earth sign Blue neutral wire boiler terminal N Brown live wire boiler terminal L No...

Page 32: ...nority 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 connection Socket X14 gas valve connection Socket X13 fan unit connection Do not use Electronic board layout Fig I 13 Connection wiring ...

Page 33: ...time 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 programmable thermostats L N 2 3 4 L N 3 4 1 ACL Drayton Lyfestyle PT271 PT371 ACL Drayton Digistat 2 3 4 ACL Drayton Digistat RF SCR Receiver Danfoss Randall TP4 TP5 TP5E Danfoss Randall TP5E RF wit...

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 TS975 Danfoss Randall TS715 Grässlin Towerchron QE1 QM1 Honeywell ST610A ST6100C Horstmann Channel Plus H11 H17 425 Coronet Horstmann Centaur Plus C11 C17 L N 2 3 4 L N 4 3 1 Potterton Myson EP 4002 EP 5...

Page 35: ...oneywell 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 EP 6002 Note Link L 5 Sunvic Select 207 N L 2 3 4 5 3 8 7 6 1 E N L 2 3 4 5 3 8 7 6 1 E N L 2 3 4 5 3 7 8 6 1 E 5 6 N L 2 3 4 5 3 8 7 6 1 N 3 5 6 7 5 6 7 8 4 L 3 8 N L 2 3 4 5 3 8 7 6 1 N L 2 3 4 5 3 ...

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 Central heating 2 port motorised valve 4 E 5 3 9 N L 2 3 4 5 3 not used 7 6 1 not used Lifestyle LP241 LP 522 LP 722 Tempus 6 Tempus 7 Danfoss Randall CP 715 FP715 Note Earth not required Danfoss Randall S...

Page 37: ...any 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 period after the boiler switches off Automatic pump spin control APS The boiler incorporates a built in control which will spin the built in circulating pump and operate the diverter valve TURBOmax onl...

Page 38: ...g 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 clockwise by 90 Fit and close front door 4 Fit lower cover plate 5 using the screws supplied Fig I 21 Fit boiler casing Euro B S 098 1 ...

Page 39: ...on 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 this will be done by the automatic burner sequence control Cold water supply TURBOmax Plus only Open all domestic hot water taps supplied by the boiler turn on the mains water supply to the boiler an...

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 follows to fill the system Open all radiator valves on the system Check flexible filling loop is connected Locate the filling valve handle 1 on the valve as shown Open the valve slowly and fill the unit...

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 valve and allow water to enter the system Starting with the lowest radiator open the radiator air release until water clear of bubbles is emitted Repeat this at all radiators until the complete system is...

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

Page 44: ...ntinue 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 U gauge is reading in the range between 18 and 20 mbar If the pressure is not within this range this should be investigated before continuing with the commissioning procedure Lower pressures than thi...

Page 45: ...ton 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 display P1 indicates the maximum gas rate and P2 indicates the ignition rate Press i button to operate boiler at maximum gas rate Check that the burner pressure is correct as shown in table G3 for the...

Page 46: ...while 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 and note main burner pressure in mbar for that output Adjust central heating output range as shown on page 47 Record central heating operating pressure in the Benchmark Log Book along with the heat ...

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 simultaneously The adjustment mode is also cancelled if no button is pushed for a period of four minutes 4 Use the or buttons to increase or decrease the value Observe the U gauge as the button is pu...

Page 48: ...utton 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 outer hexagonal nut 3 to adjust the ignition rate Turn the nut 3 clockwise to increase the ignation rate Turn the nut 3 anticlockwise to decrease the ignation rate Adjust the burner pressure until it...

Page 49: ...o 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 anticlockwise to decrease the nominal load Adjust the burner pressure until it matsches the maximum output as detailed on page 22 Now turn the 7 mm hexagonal nut 1 anticlockwise until the burner pressure d...

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 2 E TURBOmax Plus 824 2 E Natural gas 2H Main burner jet mark2 7 120 Burner pressure1 mbar Delivered gas for G20 Output kW 10 0 12 0 14 0 16 0 18 0 20 0 22 0 24 0 LPG 3 Main burner jet mark2 7 072 2 ...

Page 51: ...013 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 TURBOmax Plus 824 2 E Natural gas 2H Main burner jet mark2 7 120 Gas Rate1 m3 h Delivered gas for G20 Output kW 10 0 12 0 14 0 16 0 18 0 20 0 22 0 24 0 1 2 1 4 1 7 1 9 2 1 2 4 2 6 2 8 Gas Rate THERMOcom...

Page 52: ...perating 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 TURBOmax Plus only Check the hot water system for correct operation Check the heating system for correct operation Fig F 1 Test ...

Page 53: ...ler 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 being drawn from the system Central Heating operation Operate the heating system If boiler is operating correctly the status of the indicators will be as follows Red lock out indicator 1 OFF Yellow flam...

Page 54: ...t 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 the indicators will be as follows Red lock out indicator 1 OFF Yellow flame indicator 2 ON burner active Green indicator 3 OFF The LCD display indicates the flow temperature in C of the boiler in no...

Page 55: ...stem 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 system above the base of the boiler 10 m head equals an additional 1 bar reading on the pressure gauge The minimum pressure should not be less than 1 bar in any installation If the system is to be treat...

Page 56: ...ortance 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 contact Vaillant Service Solutions 0870 6060 777 for further details Ensure the boiler log book is fully completed and leave with the end user Failure to install and commission this appliance to the man...

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 and usage but in general once per year should be adequate It is the law that all servic ing work is carried out by a compe tent person Corgi registered Important Before starting any maintenance work...

Page 58: ...e 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 system water pressure from the boiler Remove valve cap from expansion vessel charge point Check that the internal charge pressure of expansion vessel is between 0 7 0 9 bar If pressure is lower than this ...

Page 59: ...r 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 preparation Turn off the boiler Isolate the electrical supply to the boiler Remove boiler bottom cover by undoing the four retaining screws Turn off the gas service valve Turn off the boiler CH service ...

Page 60: ...racket 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 preparation on page 59 Remove combustion chamber cover by unclipping the three clamps Unclip the terminal box cover Disconnect both HT leads 3 4 from the electronic board Pull off flame sensor HT le...

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 5 and the air tubes 6 and 7 from the fan Note the respective connection points for each tube Remove two screws 8 and remove the fan 9 Reassemble in reverse order ensuring that the air tubes are reco...

Page 62: ...ve 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 12 and outlet 14 connection from the gas valve by removing the eight secu ring screws 11 and 13 and refit to new gas valve using new seals provided Reassemble in reverse order and test all joints for...

Page 63: ...tant 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 chamber front panel Remove the fan the locating spring and the fan hood Pull off the flow clamp 5 and disconnect the return connection Remove the main heat exchanger 6 disconnect the return connection ...

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 flow and return connections at union nuts between service valves and boiler Disconnect gas connection at compression joint on gas valve outlet Disconnect domestic hot and cold water connections at un...

Page 65: ...ay 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 position Re assemble in reverse order Main transformer Refer to the important information and initial preparation on page 59 Lower control box Unclip the terminal box cover by releasing the cover reta...

Page 66: ...ump 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 electrical connections 4 Disconnect air tubes 5 Re assemble in reverse order Note Air tubes should be reconnected P1 marked on air pressure switch to white tube P2 marked on air pressure switch to blue tube 3...

Page 67: ...rse 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 preparation on page 59 Release central heating water pressure Pull out the four retaining clips and remove the pressure gauge from fascia Remove retaining clip and disconnect pressure gauge capillary ...

Page 68: ...ua 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 valve TURBOmax Plus only Refer to the important information and initial preparation on page 59 Release central heating water pressure Disconnect the plug 4 from the diverter valve Remove the spring clip...

Page 69: ...d 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 heating water pressure Remove the spring clip 5 Disconnect the discharge pipe from the pressure relief valve Remove pressure relief valve Re assemble in reverse order 5 1 2 3 4 Fig E 18 DHW heat exchange...

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 flue instructions Check the burner for correct ignition and flame picture TURBOmax Plus only Check the hot water system for correct operation Check the heating system for correct operation ...

Page 71: ...perature 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 Mode In order to assist with the pinpointing of a particular fault it is possible to use the boiler display in a diagnostic mode to interrogate the boiler about the status of certain components Faul...

Page 72: ...ched 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 control panel also contains three indicator lights whose function is as follows Red lock out indicator 1 when illuminated boiler is at lock out Yellow flame indicator 2 when illuminated main burner is igni...

Page 73: ...ore 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 supply of 230 V is present between boiler terminals L and N 3 Check that the gas supply to the boiler is on that it has been correctly purged and that an inlet pressure of 20 mbar is available at the gas...

Page 74: ...Anti 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 11 Fan running hot water operation Frost protection mode S 13 Ignition sequence hot water operation S 31 S 14 Burner ignited hot water operation Summer mode heating control knob in off position S 36...

Page 75: ...erature 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 Maximum burner anti cycling period at 20 C flow temperature 8 60 min predelivery setting 15 min d 04 Not applicable d 05 Flow temperature setting C d 06 Not applicable d 07 1 Vantage hot water tempe...

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 adjusted to 30 min d 71 Maximum target value for heating system flow temperature 0 82 C 1 87 C factory setting 82 C d 80 Number of heating system operating hours Total h d 81 Number of hot water sys...

Page 77: ...NTC 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 NTC plug shorted to casing NTC defective F 10 Short circuit flow NTC 130 C NTC plug shorted to casing NTC defective F 42 Faulty cable loom Faulty or incorrect loom fitted F 43 Faulty cable loom Faulty...

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 change electronic board Replace switch mechanism No No No Yes Yes Note 1 For test purposes disconnect external controls from terminal 3 4 and replace with a bridge between these terminals It appliance t...

Page 79: ...ransformer 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 panel Yes No No No Yes Check replace fan Replace electronic board No...

Page 80: ...ode 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 ignition commence No Yes Replace defective timer Sheet C FAULT FINDING ...

Page 81: ...essure 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 page 52 is S 33 Check air flue gas system is correctly fitted and not obstructed Yes No Replace electronic board No Yes Are electrodes sparking at the burner Yes Go to sheet E No Check electrodes and e...

Page 82: ...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 refill and vent as necessary Check pump is running Yes Yes Replace pump No Is 230 VAC ...

Page 83: ...tronic 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 Turn main ON OFF control to the 0 position TURBOmax Plus only Yes I...

Page 84: ...old 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 indicator glow flash now Does green warmstart indicator flash now No No Yes Yes ...

Page 85: ...gnition 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 y g gr p p r CONTROL BOX DIVERTER VALVE bl bl bl bl NTC WARMSTART TEMPERATURE SENSOR or plug in connector display plus minus buttons reset button info button Fig D 1 Functional Flow diagram VUW Euro...

Page 86: ...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 t br br r b br y g gr r CONTROL BOX plug in connector display plus minus buttons reset button info button Fig D 2 Functional Flow diagram VU Euro B S_VC_019 0 Functional Flow diagram THERMOcompact 615 2 E 620 2 E 624...

Page 87: ...TC 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 Pump Aqua sensor NTC flow NTC return X8 X4 VUV X12 X14 X13 7 9 L 4 8 N 3 5 X7 Accessories 1 2 EV1 EV2 3 4 Fig D 3 Wiring diagram VUW Euro B S 029 1_GB Wiring diagram TURBOmax Plus 824 2 E 828 2 E TUR...

Page 88: ...electrode 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 flow NTC return X8 X4 VUV X12 X14 X13 7 9 L 4 8 N 3 5 X7 Accessories 1 2 EV1 EV2 3 4 Fig D 4 Wiring diagram VU Wiring diagram THERMOcompact 615 2 E 620 2 E 624 2 E 628 2 E THERMOcompact ...

Page 89: ...sensing 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 628E 828E 065087 Er 6 Expansion vessel 10 l 181057 Er 7 Switch and control board 130474 Er 8 Main transformer 287450 Er 9 Pump 160928 Er 10 Air pressure switch 050577 Er 11 Automatic bypass 150240 Er 12...

Page 90: ...r 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 151 0 TURBOmax Plus only Euro B S VC 057 0 ...

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 Mü 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 Advice 01634 292392 ...

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Vaillant TURBOmax Plus SERIES, Instructions For Installation And Servicing

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