Vaillant TURBOmax Pro 28/2 E Instructions For Installation And Servicing Download Page 1

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

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 28/2 E

Page 1: ...Tel 0161 620 6677 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 servici...

Page 2: ...ing and make up 14 Pressure 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 lo...

Page 3: ...ration 45 Burner 46 Electrodes 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...

Page 4: ...ions for Use 7 10 6 1 2 5 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 wat...

Page 5: ...nger The temperature in the 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 wate...

Page 6: ...et water pressure 10 bar Inlet 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 C...

Page 7: ...8 5 4 3 2 1 Fig B 1 Connection 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...

Page 8: ...e control 9 Maximum radiator 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...

Page 9: ...BS 5449 Specification for 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 w...

Page 10: ...land Regulations in respect 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 necessar...

Page 11: ...mm wall thickness 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 flu...

Page 12: ...termination Terminal position 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 dr...

Page 13: ...have an air vent in the room 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 l...

Page 14: ...e prior to the fitting of 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...

Page 15: ...rn 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 ves...

Page 16: ...pass 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...

Page 17: ...sition of boiler Refer to 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 ma...

Page 18: ...ting directly through wall 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 a...

Page 19: ...of the boiler fully engages 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 installati...

Page 20: ...casing 20 BOILER INSTALLATION 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 t...

Page 21: ...ied with appliance and tighten 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...

Page 22: ...e appliance with the washer 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...

Page 23: ...flow 4 and return 1 service 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 ins...

Page 24: ...ntrols only The point of connection 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...

Page 25: ...ion Raise the control panel 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 appl...

Page 26: ...X4 for minority reversing 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 conn...

Page 27: ...strip If a room thermostat 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 s...

Page 28: ...by this control and hot water 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 diverte...

Page 29: ...e 1 onto the boiler such that 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 p...

Page 30: ...sure that there is adequate 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 boil...

Page 31: ...Supplied By www heating spares co Tel 0161 620 6677 31 COMMISSIONING PART I...

Page 32: ...Supplied By www heating spares co Tel 0161 620 6677 32 COMMISSIONING PART I 2 5 3 4 Fig Com 1 Draining the heating system Eor B S 207 0GB_Pro...

Page 33: ...n of the pressure relief valve 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 seperat...

Page 34: ...full rate by opening a hot 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...

Page 35: ...ealing screw 1a at test point 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...

Page 36: ...essure switches to full load 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 p...

Page 37: ...Gas rate Table G 3 Gas flow 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...

Page 38: ...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 fi...

Page 39: ...has proved itself the fan 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 a...

Page 40: ...ory operation the fan 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 t...

Page 41: ...and release all air Release 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 pressur...

Page 42: ...f 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 Vai...

Page 43: ...re the continued safe and 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 particul...

Page 44: ...move 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 ch...

Page 45: ...oundness and always carry 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...

Page 46: ...5 Remove electrodes 2 by 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...

Page 47: ...4 upwards until it clears 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...

Page 48: ...es Disconnect air tube from 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...

Page 49: ...nger Refer to the important 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 an...

Page 50: ...ts above the boiler EITHER 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 wirin...

Page 51: ...emove the electronic display 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 unti...

Page 52: ...marked on air pressure switch 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...

Page 53: ...apart bypass and connecting 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 th...

Page 54: ...remove the pressure gauge 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 prepar...

Page 55: ...ng clips 3 and 4 Undo the 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 p...

Page 56: ...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...

Page 57: ...calling for heat Note If 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 yel...

Page 58: ...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...

Page 59: ...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 centra...

Page 60: ...if fitted is calling for heat 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 Y...

Page 61: ...e 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 air flue gas system is correctly fitte...

Page 62: ...eck 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...

Page 63: ...nd 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 Yes Check partial load setting No No Go to sheet G...

Page 64: ...ck 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 Check Clear impeller in Aquasensor repl...

Page 65: ...Supplied By www heating spares co Tel 0161 620 6677 65 FAULT FINDING...

Page 66: ...Hot water demand indicator Central heating demand indicator Fan operation indicator Ignition indicator Flame indicator Power on indicator green MAIN SWITCHBOARD IGNITION ELECTRODES Legend b blue br b...

Page 67: ...return NTC earth Ionisation 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 Aqu...

Page 68: ...r 3 Gas valve LPG 053463 Natural 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...

Page 69: ...ORT PARTS LIST Er 1 Er 3 Er 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...

Page 70: ...Supplied By www heating spares co Tel 0161 620 6677 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: ...Supplied By www heating spares co Tel 0161 620 6677 71...

Page 72: ...620 6677 83 41 11 GB 11 02 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...

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