Vaillant TURBOmax Pro 2 E Instructions For Installation And Servicing Download Page 1

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INSTRUCTIONS FOR

INSTALLATION AND SERVICING

TURBOmax Pro 28/2 E

Wall hung room sealed fan assisted combination boilers

The code of practice for the installation,

commissioning & servicing of central heating systems

Summary of Contents for TURBOmax Pro 2 E

Page 1: ...IONS FOR INSTALLATION AND SERVICING TURBOmax Pro 28 2 E Wall hung room sealed fan assisted combination boilers The code of practice for the installation commissioning servicing of central heating syst...

Page 2: ...e relief valve 14 Pressure gauge 14 Expansion vessel 15 Circulating pump 16 System by pass 16 Venting 16 DHW expansion vessel accessory 16 General 17 Preparation of boiler location 17 Selecting positi...

Page 3: ...odes 46 Fan 47 Gas valve 48 Temperature sensors NTCs 49 Main heat exchanger 49 Expansion vessel 50 Electronic control board 51 Main transformer 51 Pump 52 Air pressure switch 52 System bypass 53 Diver...

Page 4: ...4 I 0 3 Fig L 1 Items supplied with unit Table L 1 Items supplied with unit Euro B S 021 1 GB_Pro Item Quantity Description 1 1 Boiler 2 1 Flue restriction rings 3 1 Cold water inlet valve 5 1 Copper...

Page 5: ...e heat exchanger is limited by the boiler control system and it is not necessary to install a scale reducer on the cold mains to the boiler However in exceptionally hard water areas to prevent scale f...

Page 6: ...nlet gas working pressure required natural gas 20 mbar Gas burner pressure ignition rate 1 8 mbar Gas rate max DHW 3 3 m3 h Weight 45 kg Primary water content 2 0 l Maximum CH heat input net 31 1 106...

Page 7: ...ction diameters Euro B S 024 2 Key 1 Heating system return 22 mm compression 2 Cold water connection with shut off valve 15 mm compression 3 Gas connection 15 mm compression 4 Hot water connection 15...

Page 8: ...or temperature control 10 Diverter valve 11 DHW heat exchanger 12 Automatic bypass valve 13 CH flow service valve 14 Hot water outlet 15 Gas service valve 16 Service valve 17 Service valve 18 Pressure...

Page 9: ...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 10: ...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 11: ...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 10 m Bo...

Page 12: ...ion for fan assisted flue minimum distance mm A1 300 B Below gutters soil pipes or drain pipes 25 C Below eaves 25 D Below balconies below car port roof 25 E From vertical drain pipes and soil pipes 2...

Page 13: ...om or internal 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 IE...

Page 14: ...the new boiler and be in accordance 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 F...

Page 15: ...le 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 Initia...

Page 16: ...he 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...

Page 17: ...Boiler location for information regarding siting the appliance In general the boiler must be positioned such that There is adequate space around the boiler for service and maintenance The boiler can b...

Page 18: ...Mark the 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 b...

Page 19: ...s onto the hanging 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 th...

Page 20: ...ION SEQUENCE Removing boiler casing Turn both securing fasteners 1 anti clockwise by 90 to release control panel Lower control panel 2 Pull the case 3 forward at the bottom to disengage from the secur...

Page 21: ...hten Connect a gas supply pipe of not less than 15 mm diameter to the inlet of the gas service cock Tighten all connections Ensure the gas supply pipework is adequately sized such that a 20 mbar gas p...

Page 22: ...r 2 provided and tigh ten Connect cold water service pipe to the cold water service valve and tighten Connect the 15 mm hot water outlet copper tail 4 to the hot water outlet connection of the applian...

Page 23: ...e valves 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 f...

Page 24: ...onnection to the 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 accord...

Page 25: ...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 9 Use...

Page 26: ...valve Socket X7 for accessory box connection Socket X8 for VRC VC connection Room thermostat 230 V connections 3 4 and 5 Socket X12 pump connection Socket X14 gas valve connection Socket X13 fan unit...

Page 27: ...t is to be connected in addition to a time switch the wire between the time switch ON terminal and boiler terminal 4 should be broken by the contacts of the room thermostat see schematic layout Fig I...

Page 28: ...ater can be drawn at any time 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 once in a 24 hour...

Page 29: ...hat the locating 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 secur...

Page 30: ...e ventilation 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...

Page 31: ...31 COMMISSIONING PART I...

Page 32: ...32 COMMISSIONING PART I 2 5 3 4 Fig Com 1 Draining the heating system Eor B S 207 0GB_Pro...

Page 33: ...alve by rotating the knob on the valve Filling the heating system Proceed as follows to fill the system Open all radiator valves on the system Fill the system via the seperate filling point Open the v...

Page 34: ...t water tap Ensure that the hot water outlet temperature adjustment control is set to maximum Check that the U gauge is reading in the range of 18 to 20 mbar If the pressure is not within this range t...

Page 35: ...int on the burner inlet gas pipe and attach one arm of a U gauge 2a to the test point Remove plastic sealing plug and connect the other arm to the combustion chamber sensing tube 3a Set the DHW temper...

Page 36: ...ad The central heating output can now be altered by inserting an electricans screwdriver into the potentiometer 3 Turn the potentiometer fully anticlockwise Slowly turn the potentiometer clockwise whi...

Page 37: ...w rate Table G 2 Burner pressure Burner Pressure Natural gas 2H Main burner jet mark2 7 120 Burner pressure1 mbar Delivered gas for G20 Output kW 14 0 16 0 18 0 20 0 22 0 24 0 26 0 28 0 LPG 3 Main bur...

Page 38: ...ing 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 supplie...

Page 39: ...operation indicator 4 will light The gas valve will open and sparking will commence at the burner The ignition indicator 5 will illuminate As soon as the burner has ignited and the flame has been sens...

Page 40: ...ation indicator 4 will light The gas valve will open and sparking will commence at the burner The ignition indicator 5 will illuminate As soon as the burner has ignited and the flame has been sensed t...

Page 41: ...se water from the system 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 hig...

Page 42: ...rly 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 08...

Page 43: ...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 44: ...th 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...

Page 45: ...out functional checks after any service work and after exchanging any gas carrying component Always check earth continuity polarity and resistance to earth with a multimeter after any service work and...

Page 46: ...removing support screw 1 Reassemble by following these instructions in reverse order PARTS REPLACEMENT 3 2 1 2 4 Fig E 2 Burner Euro B S 157 0 Fig E 3 Electrodes Burner Refer to the important informat...

Page 47: ...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 48: ...m gas valve Undo nut 1 on the gas valve 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 f...

Page 49: ...t information and initial preparation on page 45 Release central heating water pressure Remove combustion chamber cover by unclipping the three clamps Remove four screws 4 and pull off combustion cham...

Page 50: ...Remove the boiler from the wall as follows Refer to important information and initial preparation on page 45 Release central heating water pressure Disconnect external wiring from boiler wiring termi...

Page 51: ...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...

Page 52: ...tch to blue tube 4 7 5 6 Euro B S 168 0 Pump Refer to the important information and initial preparation on page 45 Release central heating water pressure Unclip the terminal box cover by releasing the...

Page 53: ...ng pipe Re assemble in reverse order Diverter valve Refer to the important information and initial preparation on page 45 Release central heating water pressure Disconnect the plug 4 from the diverter...

Page 54: ...from fascia Remove retaining clip and disconnect pressure gauge capillary tube Re assemble in reverse order Aqua sensor Refer to the important information and initial preparation on page 45 Release c...

Page 55: ...bottom left hand 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 45 Rele...

Page 56: ...em 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 instr...

Page 57: ...the external controls are not calling for heat i e the room thermostat has reached temperature this indicator will go out This is perfectly normal Fan operation indicator yellow Illuminates to indicat...

Page 58: ...ce 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 R...

Page 59: ...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...

Page 60: ...eat 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 Disconnect built in...

Page 61: ...resent across fan terminals Replace electronic board Yes No No Yes No Yes Yes Check replace fan Does the boiler commence ignition Check air flue gas system is correctly fitted and not obstructed Yes N...

Page 62: ...ecessary 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...

Page 63: ...re open No No No Replace electronic board No Check operation of boiler in DHW mode does flame increase in size to full rate Yes Check partial load setting No No Go to sheet G Yes Check connections and...

Page 64: ...re is sufficient and that cold water inlet filter is clear Check cold water inlet is fully open and adjustment is at maximum flow rate Check Clear impeller in Aquasensor replace if necessary Check rep...

Page 65: ...65 FAULT FINDING...

Page 66: ...r Central heating demand indicator Fan operation indicator Ignition indicator Flame indicator Power on indicator green MAIN SWITCHBOARD IGNITION ELECTRODES Legend b blue br brown y g yellow green r re...

Page 67: ...n electrode Bridge NTC flow NTC flow 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 fitting Diverter valve Aqua sensor Ionisation electr...

Page 68: ...atural gas 053462 Er 4 Flow NTC Return NTC 252805 Er 5 Main heat exchanger 065087 Er 6 Expansion vessel 10 l 181057 Er 7 Switch and control board 130473 Er 8 Main transformer 287450 Er 9 Pump 160928 E...

Page 69: ...r 4 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 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 Euro B S 153 0 Er 2 Er...

Page 70: ...70 SHORT PARTS LIST Er 13 Er 14 Er 17 Er 15 Euro B S 149 0 Euro B S 145 0 Euro B S 178 0 Euro B S 150 0 Er 16 Euro B S 155 1...

Page 71: ...71...

Page 72: ...2002 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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Vaillant TURBOmax Pro 2 E, Instructions For Installation And Servicing

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