Vaillant TURBOmax VUW 282/1 E Instructions For Installation And Servicing Download

Page: 54 / 60

9 Electrical diagrams

9.1 Functional Flow diagram: VUW 242/1 E, 282/1 E

GW 651/1

MAIN SWITCH

CONTROL BOX

MAIN SWITCHBOARD

MAIN
TRANSFORMER

230V

20V

POWER SUPPLY

CONTROL BOARD

WATER-PUMP

SELECTOR

OVERHEAT
THERMOSTAT

FAN-
CONTROL

AIR
PRESSURE
SWITCH

FAN

PUMP

DHW
MICRO
SWITCH

FLAME
SENSOR

GAS
VALVE

GAS BURNER CONTROL

LEGEND

NOTE
ALL UNCODED
WIRES ARE BLACK

blue

brown

red

transparent

NTC
TEMPERATURE
SENSOR

PRESSSURE
DIFFERENTIAL
SWITCH

IGNITION ELECTRODES

IGNITION
TRANSFORMER

F2A

plug in connector

fig. 78

Summary of Contents for TURBOmax VUW 282/1 E

Page 1: ...TURBOmax VUW 242 1 E TURBOmax VUW 282 1 E Wall hung room sealed fan assisted combination boilers INSTRUCTIONS FOR INSTALLATION AND SERVICING HEATING CONTROLS HOT WATER...

Page 2: ...cks 27 5 11 Checking flame supervision device 28 5 12 Final system flush hot 28 5 13 Fitting case 28 5 14 Handing over to user 29 Page 6 Servicing 29 6 1 Initial inspection 29 6 2 Routine maintenance...

Page 3: ...nt The Boiler Effi ciency Regulations 1993 and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous...

Page 4: ...ss C V s t 37 8 37 8 MJ m3 Gas burner pressure max rate 10 0 10 6 mbar Gas burner pressure ignition rate 2 0 2 0 mbar Gas rate max DHW 2 79 3 26 m3 h Main burner jet size 16 x 7 120 18 x 7 120 no x si...

Page 5: ...off valve 7 Service valve return of heating system 8 Compression union return of heating system 9 Pressure relief valve 200 124 50 35 70 25 1 2 3 4 5 6 7 8 9 GW 546 1 fig 2 2 2 Dimensions All dimensi...

Page 6: ...ts LED s 11 Maximum radiator temperature control 12 Maximum hot water temperature control 13 Central heating control and lockout reset 14 Main on off control 15 CH flow service valve 16 Gas service va...

Page 7: ...hosen for the boiler must permit the provision of a satisfactory flue termination The location must also provide adequate space for servicing and air circulation around the boiler The boiler may be in...

Page 8: ...nstallation must be tested for soundness and purged as described in BS 6891 3 4 Flue system The standard horizontal flue system Art No 300 807 is suitable for installations up to 995 mm measured from...

Page 9: ...pes or drain pipes 25 C Below eaves 25 D Below balconies 25 below car port roof 200 E From vertical drain pipes and soil pipes 25 F From internal or external corners 25 G Above ground or balcony level...

Page 10: ...le pole switch with a 3mm contact separation on both poles may be used 3 7 Guide to system requirements 3 7 1 Water circulation system Detailed recommendations for the water circulation system are giv...

Page 11: ...pump with break tank must be used The heating system will not be filled automatically from the domestic hot water side Alternative methods of filling sealed systems are given in BS 5449 3 7 3 Pressure...

Page 12: ...d 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 2 3 7 6 Circulating pump The circul...

Page 13: ...e installation connecting group Art no 8015 is used This clearance is only required to enable easier access to the boiler for servicing and may be provided by an openable door etc Note If the boiler i...

Page 14: ...ble for the TURBOmax combination boilers 4 2 2 Unpack the boiler fig 11 Open the boiler carton and remove a protective cardboard sheet b top and bottom decorative panels c polystyrene packaging Note C...

Page 15: ...xisting connecting group Refer to the instructions supplied separately with these accessories 4 3 2 3 Mark on the wall the positions of the hanging bracket fixing holes 2 Drill two holes 10 mm for the...

Page 16: ...heating and water pipework to above the boiler the purpose provided voids in the left and right sides of the boiler casing may be used see fig 16 Note To allow fitting of the bottom boiler cover the...

Page 17: ...izontal flue is more than 1 m in length Vertical flues Where a vertical flue less than 1 m e g 1 m between the top of the boiler and the bottom of the vertical air flue duct assemly is used DO NOT fit...

Page 18: ...are not to penetrate the inner flue duct Screw the clamps to the air ducts using the self tapping screws provided 4 6 2 Vertical Flue Remove the two half rings 2 fig 18 and if necessary fit the flue r...

Page 19: ...w 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 3x0 75 t...

Page 20: ...boiler terminal 4 should be broken by the contacts of the room thermostat see Schematic layout fig 30 If a frost thermostat is to be fitted it should be connected in parallel across terminals 3 and 4...

Page 21: ...cycling economiser control The boiler incorporates a built in anti cycling control to ensure that energy wasteful short cycling of the boiler cannot occur This control prevents the boiler from re ign...

Page 22: ...here is adequate ventilation extinguish naked flames and do not smoke whilst purging After purging the gas service valve connection must be re tightened and tested for soundness The boiler itself does...

Page 23: ...release valve To allow this to vent the boiler the cap on top 2 fig 32 must be slackened by 1 2 turns This cap must be left slackened during boiler operation to ensure any residual air or system gase...

Page 24: ...e Heating and Hot Water position The boiler will now operate for central heating Allow the boiler to run for a few minutes to clear any air remaining in the primary circuit If the boiler should fail t...

Page 25: ...the desired level Turn off the hot tap after completion of adjustment 5 7 Gas inlet working pressure Check the gas inlet working pressure by slackening the sealing screw and attaching a U gauge to the...

Page 26: ...Remove screw 1 fig 39 and remove terminal box cover to access the range rating potentiometer 1 fig 40 beneath Operate the central heating by turning the central heating control to the Heating and Hot...

Page 27: ...d Set the boiler central heating control to the Hot Water only position Turn on a hot tap and draw water at a high rate The hot water demand indicator will illuminate The appliance will start its ligh...

Page 28: ...he minimum pressure should not be less than 1 Bar in any installation If the system is to be treated with an inhibitor it should be applied at this stage Sentinel X 100 is suitable for this purpose an...

Page 29: ...is law that all servicing work is carried out by a competent person CORGI registered IMPORTANT Before starting any maintenance work Isolate the mains electricity supply by disconnecting the plug at th...

Page 30: ...urn off boiler CH service valves 1 and 5 Turn off DHW cold water service valve 4 6 2 3 Remove combustion chamber front cover 5 fig 44 Remove four screws 2 fig 54 securing combustion chamber front cove...

Page 31: ...l is between 0 7 0 9 Bar If pressure is lower than this the vessel should be re pressurised using an air pump Refit valve cap 2 fig 49 Open central heating service valves and re pressurised the boiler...

Page 32: ...er any service work and after exchanging any electrical component 7 1 Initial preparation These initial preparation procedures need only be carried out where specifically mentioned in the individual c...

Page 33: ...bustion chamber cover fig 54 Remove front casing as in section 7 1 3 Remove four screws 2 securing combustion chamber front cover Lift combustion chamber cover clear of top retaining lugs and pull for...

Page 34: ...casing Carry out electrical checks see section 5 1 7 3 Replacement of air pressure switch fig 56 Isolate the boiler from the electrical supply Remove front casing as in section 7 1 3 Disconnect electr...

Page 35: ...7 5 Replacement of electrodes Isolate the boiler from the electrical supply Remove front casing as in section 7 1 3 and remove combustion chamber cover as in section 7 1 5 Remove heat exchanger front...

Page 36: ...al supply Remove the front casing as in section 7 1 3 Lower front control panel as in section 7 1 6 Turn off the gas service valve 1 fig 50 Loosen screw 1 fig 59 and pull off rectifier plug 2 fig 59 f...

Page 37: ...Carry out electrical checks see section 5 1 and test all gas joints for soundness 1 4 2 3 fig 61 GW 644 1 7 8 Replacement of main heat exchanger Turn off the boiler as in section 7 1 1 Remove front ca...

Page 38: ...as in section 7 1 1 Release CH water pressure and drain boiler as in section 7 1 2 Lower front control panel as in section 7 1 6 Disconnect external wiring from boiler wiring terminal box Disconnect...

Page 39: ...7 1 6 Pull wires off overheat thermostat 2 fig 66 Unscrew overheat thermostat to remove Reassemble in reverse order Carry out electrical checks see section 5 1 7 12 Replacement of pump Remove front ca...

Page 40: ...move bypass connecting pipe Undo union 1 fig 69 to remove bypass Reassemble in reverse order using sealing washers supplied Refill and repressurise the boiler see section 5 4 7 15 Replacement of diver...

Page 41: ...on 7 1 6 Undo union 2 fig 71 on diverter valve to release pressure gauge tube Remove temperature gauge phial from pocket on primary flow pipe Press spring clips on side of gauge to remove from front p...

Page 42: ...s see section 5 1 7 19 Replacement of DHW heat exchanger Turn off boiler as in section 7 1 1 Remove front casing as in section 7 1 3 Release CH water pressure and drain boiler as in section 7 1 2 Lowe...

Page 43: ...e from control board 2 fig 75 Unplug all leads from the both boards 1 fig 75 Pull off switchboard board support Pull switchboard carefully out of control box Push four spring retaining clips 5 fig 76...

Page 44: ...n operation indicator yellow Illuminates to indicate that the fan is operating and has been checked by the fan pressure switch A flashing indicator shows that the air pressure switch has not made Igni...

Page 45: ...with appliance If fuse is defective suspect wiring fault on external controls see note 1 Does green power on indicator glow now Go to sheet B Go to sheet C Check continuity of overheat thermostat repl...

Page 46: ...k replace 1 25 A fuse next to the transformer plug spare fuse provided with the appliance Does green indicator glow now Check main on off control overheat thermostat and anti surge fuse Sheet B Check...

Page 47: ...tral Heating control and external controls Sheet C If the central heating demand indicator still does not glow replace electronic boards Yes Yes No No Go to sheet D Is 230 V AC present across boiler t...

Page 48: ...fter 30s Turn boiler on off control switch off then on again Check maximum radiator temperature control is set high enough e g 9 Does the pump run now Is 230 V present at the pump plug connection X10...

Page 49: ...o heat demand Go to sheet C Check replace fan Yes No Yes Yes No No No No Yes Switch main on off control off and on again Yes Check NTC Disconnect NTC lead at plug 3 fig 37 Does fan run now Check conne...

Page 50: ...th water Is solenoid activated Is differential pressure switch activated Check for dirt or damage to the differential switch supply tubes and diaphragm Go to sheet G Yes Yes No Yes No No No Yes Fill a...

Page 51: ...sion device defective replace electronic boards Check gas supply Reset lockout turn central heating control to position and release Does sparking commence at burner Go to sheet H No Yes No Yes Go to s...

Page 52: ...onnections to modulating solenoid Replace modulating regulator of gas valve if burner still fails to increase to full rate Yes No No No Replace electronic boards Go to sheet J Yes Is flame extinguishe...

Page 53: ...ctrical checks Check D H W operation Sheet J Does actuating lever operate D H W microswitch on diverter valve water section assembly Check cold water inlet pressure is sufficient Check filter in cold...

Page 54: ...TER PUMP SELECTOR OVERHEAT THERMOSTAT FAN CONTROL AIR PRESSURE SWITCH FAN PUMP DHW MICRO SWITCH FLAME SENSOR GAS VALVE GAS BURNER CONTROL LEGEND NOTE ALL UNCODED WIRES ARE BLACK b blue br brown r red...

Page 55: ...0 Combustion chamber Control box Flame sensing electrode Ignition electrode NTC sensor Fan Water switch Pressure differential switch Overheat thermostat Air pressure switch Gas valve Pump Main transfo...

Page 56: ...TION ELECTRODES GAS VALVE PUMP PRESSURE DIFFERENTIAL SWITCH OVERHEAT THERMOSTAT MAIN SWITCHBOARD CONTROL BOARD CONTROL BOX DHW MICRO SWITCH 9 IGNITION TRANSFORMER grey orange green 8 MAIN TRANSFORMER...

Page 57: ...ode 09 0562 10 Flame sensing electrode 09 0563 11 HT lead ignition electrode 09 1534 12 Expansion vessel 18 1045 13 Pump 16 1111 14 Gas valve natural gas 05 3369 15 Modulating regulator natural gas 17...

Page 58: ...684 1 13 fig 90 GW 686 1 15 fig 92 GW 682 1 09 fig 87 GW 683 1 12 fig 89 GW 693 1 14 fig 91 GW 691 1 16 fig 93 GW 689 1 17 fig 94 GW 690 1 N L 3 4 5 7 8 9 18 19 fig 95 GW 692 1 20 fig 96 GW 685 2 21...

Page 59: ...MJ m3 Gas consumption s t 1 09 Propane 1 27 Propane m3 h 0 84 Butane 0 98 Butane m3 h 59 Technical Data L P G Appliances VUW 242 1 EB VUW 282 1 EB The appliance delivered is designed for use with LPG...

Page 60: ...bject to alteration We do not accept liability for damage arising as a result of the non observance of these instructions Head Office Vaillant Ltd Vaillant House Medway City Estate Trident Close Roche...

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