Vaillant TURBOmax Plus SERIES Installation Manual

INSTRUCTIONS FOR INSTALLATION AND SERVICING

TURBOmax Plus 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

TABLE OF CONTENTS

Introduction

Boiler Specification

General Requirements

Boiler Installation Sequence

General Information . . . . . . . . . . . . . . . . . . . . . . . . . .6

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

List of Contents

Contents included with boiler (TURBOmax Plus) . . . . . . . .4

Contents included with boiler (THERMOcompact) . . . . . . .5

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Boiler connections (TURBOmax Plus) . . . . . . . . . . . . . . . .8

Boiler connections (THERMOcompact) . . . . . . . . . . . . . .8

Functional diagram (TURBOmax Plus) . . . . . . . . . . . . . . .9

Functional diagram (THERMOcompact) . . . . . . . . . . . . .10

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . .11

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Top outlet flue system . . . . . . . . . . . . . . . . . . . .13

Rear outlet flue system . . . . . . . . . . . . . . . . . . . .13

Extended top outlet flue system . . . . . . . . . . . . . .13

Flue termination . . . . . . . . . . . . . . . . . . . . . . . .14

Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Cupboard or compartment ventilation . . . . . . . . . . . . . .15

Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Guide to system requirements . . . . . . . . . . . . . . . . . . .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

Removing boiler casing . . . . . . . . . . . . . . . . . . . . . . .22

Gas supply (TURBOmax Plus) . . . . . . . . . . . . . . . . . . .23

Cold water mains inlet and hot water outlet

(TURBOmax Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Central heating flow and return pipework

(TURBOmax Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Gas supply (THERMOcompact) . . . . . . . . . . . . . . . . . .26

Central heating flow and return pipework

(THERMOcompact) . . . . . . . . . . . . . . . . . . . . . . . . . .27

Connection to a Vantage unvented cylinder (THERMOcompact) 28

Connect the flue system to the boiler . . . . . . . . . . . . . . .28

Electrical installation general requirements . . . . . . . . . . .30

Connection to the main supply . . . . . . . . . . . . . . . . . .31

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

TURBO

max

THERMO

compact

TABLE OF CONTENTS

Gas supply adjustments (Commissioning Part II)

Servicing

Fault Finding

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Logical fault finding procedure . . . . . . . . . . . . . . . . . .73

Status mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Diagnostic modes . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Fault finding charts . . . . . . . . . . . . . . . . . . . . . . . . . .78

Diagrams

Functional flow diagrams . . . . . . . . . . . . . . . . . . . . . .85

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Short parts list

Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Cleaning the burner and primary heat exchanger . . . . . .58

Parts replacement

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Temperature sensors (NTCs) . . . . . . . . . . . . . . . . . . . .63

Main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . .63

Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Electronic control board . . . . . . . . . . . . . . . . . . . . . . .65

Main transformer . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Air 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 inlet working pressure . . . . . . . . . . . . . . . . . . . . .44

Main burner pressure . . . . . . . . . . . . . . . . . . . . . . . . .45

Adjusting the central heating output (range rating) . . . . .46

Adjusting the ignition rate . . . . . . . . . . . . . . . . . . . . . .48

Adjusting to the maximum heat load (nominal load) . . . .49

Burner pressure and gas rate . . . . . . . . . . . . . . . . .50/51

Commissioning Part I

Preliminary electrical checks . . . . . . . . . . . . . . . . . . . .39

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Cold water supply (TURBOmax Plus only) . . . . . . . . . . .39

Filling the heating system (TURBOmax Plus) . . . . . . . . . .40

Filling the heating system (THERMOcompact) . . . . . . . . .42

Initial system flush (`cold`) . . . . . . . . . . . . . . . . . . .41/43

TURBO

max

LIST OF CONTENTS

Contents included with boiler (TURBOmax Plus)

Ensure that all contents are included before commencing installation.

DO NOT remove the boiler from the polystrene base at this stage.

TURBOmax Plus

BEDIENUNGSANLEITUNG

Instructions for Installation

-V

Fig. L.1: Items 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 and Benchmark log book

10 1

Installation and connection accessories and PRV packages incl. DHW outlet union nut

11 3

Installation and Servicing, Users and Flue Installation Instructions

12 1 Hanging bracket

LIST OF CONTENTS

Contents included with boiler (THERMOcompact)

Ensure that all contents are included before commencing installation.

BEDIENUNGSANLEITUNG

Instructions for Installation

VRC-VC

Fig. L.2: Items supplied with unit (THERMOcompact)

Table L.2: Items supplied with 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 accessories and PRV packages

11 1 Hanging bracket

5 3 Flow and return service value, gas service valve

THERMOcompact

10 3

Installation and Servicing, Users and Flue Installation Instructions

INTRODUCTION

THERMOcompact boiler

The THERMOcompact is a fully automatic, wall mounted, room sealed system boiler for central heating and domestic hot water (where a separate indirect hot water storage cylinder is also incorporated in the system).

The THERMOcompact range consists of models with outputs of 15, 20, 24 kW and 28 kW.

All THERMOcompact boilers are available in Natural Gas. The 20 and 28 kW versions are also available in LPG.

General Notes

The boilers have been designed for use with a sealed central heating system, and come fully tested and assembled with a built in circulating pump, expansion vessel and diverter valve (TURBOmax Plus only). The boilers are not suitable for use on open vented systems.

The boilers are easily sited on any internal wall and can be installed with either a horizontal or vertical RSF (room sealed fan assisted) flue. Two types of flue systems are available, the standard concentric flue system (100 mm outside diameter) and a larger diameter concentric flue system (125 mm outside diameter) which allows longer flue lengths to be achieved. Flue extensions and additional bends and elbows are available for both flue systems to increase the siting flexibility. There is also a 100 mm diameter concentric flue accessory which connects to the alternative rear flue outlet on the boiler for direct through the wall installations. The boilers are not suitable for external installation. If desired, an inhibitor may be used in the system. Guidance on the use of inhibitors is contained in these instructions.

All boilers have a built in diagnostic system which indicates the

This feature provides key information to aid commissioning and fault finding.

The data badge is fitted on the rear of the control panel.

See text of General Requirements for installation requirements or notes.

Vaillant Ltd. support the Benchmark initiative.

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 satisfactory standard.

General Information

TURBOmax Plus boiler

EC designation

TURBOmax Plus (824/828) and THERMOcompact boilers (615/620/624/628) carry the "CE" Mark. This demonstrates that the boilers fulfil the essential requirements of the Gas Appliance Directive (90/396/EEC) and the Gas Appliance (Safety) Regulations 1992.

The "CE" Mark also demonstrates that the boilers comply with the requirements of the Electromagnetic Compatibility Directive (89/336/EEC), the Low Voltage Directive (72/23/EEC), the Boiler Efficiency Directive (92/42/EEC) and the Boiler (Efficiency) Regulations

1993.

The TURBOmax Plus is a fully automatic, wall mounted, room sealed combination boiler for central heating and domestic hot water. Domestic hot water is supplied directly from the boiler, without requiring a copper cylinder, cold water tank, feed and expansion tank and associated pipework. Domestic hot water has priority over central heating. The TURBOmax Plus range consists of models with outputs for domestic hot water of 24 kW and 28 kW. Both versions are available in natural gas and LPG.

TURBOmax Plus combination boilers incorporate a warmstart facility that keeps the domestic hot water heat exchanger hot, providing an instantaneous delivery of domestic hot water.

The temperature in the domestic hot water 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 formation in the property hot water system pipework, a scale reducer may be fitted.

The heating system can be filled using the built-in filling loop contained within the boiler.

BOILER SPECIFICATION

Technical data

THERMOcompact

615/2 E

(VU GB 152/2-5)

Units

CH heat output range (80/60 °C)

6.5 - 15

(22300 - 51200)

kW (Btu/h)

DHW heat output --- kW DHW flow rate ∆T = 35 °C rise --- l/min

DHW flow rate at factory set temperature rise (∆T 42 °C)

--- l/min

Mains water pressure required for max. flow rate

--- bar

Maximum inlet water pressure --- bar Inlet gas working pressure

required (natural gas)

20 mbar

Gas burner pressure ignition rate 2.3 mbar Gas rate max. (DHW) --- m3/h

Weight 38 kg Primary water content 2.0 l

Maximum CH heat input (net 16.5 (56.100)

kW (Btu/h)

Mains water pressure required for min. flow rate

--- bar

Minimum water flow rate --- l/min

Gas supply (G20) Gross CV (s.t.) 37.8 MJ/m

Gas burner pressure max. rate 10.5 mbar

CH temperature flow 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)

11.5

9.5

0.5

37.8

10.8

1.8

3.3

43/45

2.0

31.1 (106200)

0.15

1.5

35 - 82

1203

0.25 (25)

0.75

230/50

150

31.1 (106200)

Case height 800 mm800 Case width 440 mm440 Case depth 338 mm338

THERMOcompact

624/2 E

(VU GB 242/2-5)

TURBOmax Plus

824/2 E

(VUW GB 242/2-5)

8.9 - 24

(30400 - 81900)

9.8

8.2

0.5

37.8

800

9.8

440

1.9

2.8

41/43

2.0

26.7 (91200)

0.15

1.5

35 - 82

1032

0.25 (25)

0.75

230/50

338

150

26.7 (91200)

THERMOcompact

620/2 E

(VU GB 202/2-5)

7.7 - 20

(26300 - 68300)

---

37.8

---

800

9.6

440

1.8

---

2.0

22.0 (74.800)

---

35 - 82

860

0.25 (25)

0.75

230/50

338

150

---

BOILER SPECIFICATION

Key: 1 Heating system return

(22 mm tail)

2 Cold water connection with shut

off valve (15 mm tail)

3 Gas connection (15 mm tail) 4 Hot water connection

(15 mm tail)

5 Heating system flow

(22 mm tail)

6 Flue outlet (100 mm flue with

turret)

7 Hanging bracket 8 Rear flue outlet

Boiler connections (TURBOmax Plus)

543 21

148

6 8

310

592

145

100100

35 35

432

130

180

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)

32 1

148

4 6

310

592

145

100100

130

180

Fig. B.2: Connection diameters THERMOcompact

Euro B/S_VC_009/2

TURBOmax Plus THERMOcompact

BOILER SPECIFICATION

Functional Diagram (TURBOmax Plus)

4 5

13 14

17 16

1 Air duct 2 Fan 3 Main heat exchanger 4 Temperature sensor (NTC I) 5 Flame sensing electrodes 6 Modulating burner 7 Fully modulating automatic gas

value

8 Maximum hot water temperature

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 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 27 Automatic air vent 28 Ignition electrode 29 Temperature sensor (NTC II) 30 Air pressure switch 31 Flue gas duct

Fig. B.3: Functional Diagram TURBOmax Plus

Euro B/S 196/0

TURBOmax Plus

BOILER SPECIFICATION

Functional Diagram (THERMOcompact)

4 5

1 Air duct 2 Fan 3 Main heat exchanger 4 Temperature sensor (NTC I) 5 Flame sensing electrodes 6 Modulating burner 7 Fully modulating automatic gas

value

8 This control has no 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 pressure switch 25 Flue gas duct

Fig. B.4: Functional Diagram THERMOcompact

Euro B/S_VC_079/0

THERMOcompact

GENERAL REQUIREMENTS

Ensure that ALL regulations are observed.

Fig. R.1

Euro B/S 006/0_GB

Related Documents

The installation of the boiler must be in accordance with the relevant requirements of Gas Safety (Installation and Use) Regulations 1998, Health and Safety Document No. 635 (The Electricity at Work Regulations 1989), BS7671 (IEE Wiring Regulations) and the Water Supply (Water Fittings) Regulations. It should also be in accordance with the relevant requirements of the Local Authority, Building Regulations, Building Standards (Scotland) Regulations and the relevant recommendations of the following British Standards:

BS 5440: Flues and ventilation of gas fired boilers not exceeding 70 kW net:

- Part 1: Flues

- Part 2: Ventilation

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 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 premises (2ndfamily gas).

BS 7593: Treatment of water in domestic hot water central heating systems. Institute of Gas Engineers Publication IGE/UP/7/1998: Guide for Installation in Timber Framed Housing.

Important: The appliance must be installed and serviced by a competent person as stated in the Gas Safety (Installation and Use) Regulations 1998.

Preliminary remarks

This appliance should only be installed in conjunction with a Vaillant flue system.

Install the flue system as detailed in the separate flue installation instructions supplied with this boiler.

GENERAL REQUIREMENTS

Gas Supply

The gas supplier should ensure the availability of an adequate supply of gas.

A gas meter may only be connected to the service pipe by the supplier of gas or their contractor.

An existing meter should be checked to ensure that it is capable of passing the rate of gas supply required.

Installation pipes should be fitted in accordance with BS 6891.

Pipework from the meter to the boiler must be of an adequate size. Do not use pipes of a smaller size than the boiler gas connection (15 mm).

The complete installation must be tested for soundness and purged as described in BS 6891.

Boiler location

The location chosen 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 installed in any room, although particular attention is drawn to the requirements of BS7671 (IEE Regulations) and, in Scotland, the electrical provisions of the Building Standards (Scotland) 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 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 combustible wall, subject to the requirements of the Local Authorities and Building Regulations. A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. (An existing cupboard or compartment may be used provided that it is modified for the purpose). Details of essential features of cupboard/compartment design including airing cupboard installations are given in BS 6798. If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication IGE/UP/7/1998 „Guide for Gas Installation in Timber Framed Housing“.

Note: Where a room sealed boiler is installed in a room containing a bath or shower, any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

GENERAL REQUIREMENTS

Top outlet flue system (100 mm outside diameter)

The top outlet horizontal flue system (Art. No. 303 807) is suitable for installations up to 720 mm measured from the centre of the boiler flue outlet to the outside face of the wall. Flue extensions are available to extend this length up to 5.3 m for 15/20 kW; 4.5 m for 24 kW and

3.2 m for 28 kW. Both 90° bends and 45° elbows are also available to increase siting flexibility.

A vertical flue system is also available (Art. No. 303 800).

Refer to flue system installation instructions for full details.

Rear outlet flue system (100 mm outside diameter)

The rear outlet horizontal flue system (Art. No. 303 817) is suitable for installations up to 600 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 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. 303 600).

Refer to flue system installation instructions for full details.

Flue system

Note: The boilers are delivered ready for installation utilising a top outlet flue assembly. For installation with a rear outlet flue assembly refer to the boiler flue outlet adaptation instructions supplied with the rear flue accessory.

800

Fig. R.2: Art.-No. 303 807

LAS Euro B/S 037/0

1285

603

Fig. R.3: Art.-No. 303 800

LAS Euro B/S 036/0

800

Fig. R.4: Art.-No. 303 817

LAS Euro B/S 073/0

Fig. R.5: Art.-No. 303 609

GU LAZ 082/0

1103

GENERAL REQUIREMENTS

BCD

A G

H, I

Flue termination

The following details refer to both flue systems.

a. The terminal must be positioned

such that the products of combustion can disperse freely at all times.

b. In certain weather conditions a

plume of water vapour may be visible from the flue terminal. Positions where this could be a nuisance should be avoided.

c. If the terminal is fitted less than

2 m above a balcony, above ground or above a flat roof to which people have access then a suitable terminal guard; 280 mm x 280 mm x 270 mm deep, must be provided and fitted (made by Tower Flue Components, Tonbridge, TN9 1TB).

Fig. R.6: Flue termination

Terminal position for fan-assisted flue (minimum distance)

300

Note: Vertical flues must not terminate within 600 mm of an openable window, air vent or any other ventilation opening.

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 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 painted eaves or any other painted surface then a suitable shield at least 1 m long should be fitted to protect the surface.

In addition, the terminal should not be nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window.

* BS 5440-1 It is recommended that a fanned flue

terminal should be positioned as follows: a) at least 2m from an opening in a building directly opposite, and b) so that the products of combustion are not directly directed to discharge across a boundary.

From an opening in a car port (e.g. door, window) into a dweling

1200

H From a surface or boundary facing a terminal 600*

Directly below an openable, above an opening or horizontal to an opening i.e. air brick, opening window or other , etc

GENERAL REQUIREMENTS

Cupboard or compartment ventilation

The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during operation is very low. For cupboard or compartment installations it is therefore not necessary to provide any high or low level permanent air vents for cooling purposes.

Air supply

Detailed recommendations for air supply are given in BS 5440: Part 2.

It is not necessary to 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 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. Isolation is preferably by the use of a fused three pin plug and unswitched shuttered socket outlet, both complying with the requirements of BS 1363. Alternatively, a 3 Amp. fused doublepole switch with a 3 mm contact separation on both poles may be used.

This appliance must be earthed.

GENERAL REQUIREMENTS

Guide to system requirements

Water circulation system

Detailed recommendations for the water circulation system are given in BS 6798 and BS 5449: Part 1 (for small bore and micro bore central heating systems).

Pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated underfloor spaces.

Draining taps must be located in accessible positions which permit the draining of the whole system including the boiler and the hot water system. Draining taps should be at least 1/2 in. BSP nominal size and be in accordance with BS 2879.

The boiler is suitable for use with minibore or microbore systems. Copper tubing to BS 2871: Part 1 should be used for water carrying pipework. All capillary joints in all DHW pipework must be made with lead free solder.

Particularly where a new boiler is to be fitted to an existing system, it is good practice that the system is thoroughly cleansed. This cleansing should take place 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 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 only) or via a separate filling point fitted at a convinient position on the heating circuit (THERMOcompact). The connection must be removed when filling is completed. Where local Water Authority regulation does not allow temporary connection, a sealed system filler 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).

Pressure relief valve

A pressure relief valve is provided with the boiler. This safety device is required on all sealed C.H. systems and is preset at 3 bar and provided with a 15 mm compression connection for a discharge pipe, which must be of no less than 15 mm in diameter. The Pressure Relief Valve must not be used for draining purposes.

Pressure gauge

This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing.

GENERAL REQUIREMENTS

Expansion vessel

The 15 and 20 kW THERMOcompact boilers as well as the 24 kW TURBOmax Plus boiler incorporate a 6 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 60 litres. A 10 litre expansion vessel kit is available as an optional accessory for for the TURBOmax Plus 24 kW boiler and the 15 and 20 kW THERMOcompact boilers.

The 28 kW TURBOmax Plus and 24, 28 kW THERMOcompact boilers incorporate a 10 litre expansion vessel which is suitable for a sealed heating system with a maximum water content of 100 litres.

If the nominal capacity of the built in expansion vessel is not sufficient for the 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] Initial system pressure (bar) 1.0 1.5 Pressure relief valve setting (bar) 3.0

Total water content of system

litres

50 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500

2.7

5.4

10.9

13.6

16.3

19.1

21.8

24.5

27.2

30.0

32.7

35.7

38.1

40.9

43.6

46.3

49.0

51.8

54.5

3.9

7.8

15.6

19.5

23.4

27.3

31.2

35.1

39.0

42.9

46.8

50.7

54.6

58.5

62.4

66.3

70.2

74.1

78.0

For system volumes other than those given above, multiply the system volume by the factor across

0.109 0.156

GENERAL REQUIREMENTS

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

100

150

200

250

300

350

400

450

500

550

600

650

700

Volume flow [l/min]

Lift [mbar]

Pump switch in position II (pre-delivery setting)

Pump switch in position I

Fig. R.7: Pump specifications

Euro B/S_VC_010/0GB

Pump specifications Circulating pump

The circulating pump is included in the boiler. The pump head available for the heating system is shown in fig. R.7.

System by-pass

An automatic system by-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 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 only)

A DHW expansion vessel kit (Art. No. 306 237) is available as an optional extra from Vaillant Ltd. This expansion vessel kit should be fitted to the boiler whenever, either a stop valve of the loose jumper type or a non return valve are present in the cold water mains supply to the boiler.

BOILER INSTALLATION SEQUENCE

General

Preparation of boiler location

Clearances required

Mount the boiler on a flat and vertical area of wall of sufficient area for the boiler plus the required clearances for installation and servicing.

The clearances are as detailed below and are shown on the installation template supplied with the boiler:

- 150 mm below the boiler

- 5 mm on either side of the boiler

- 210 mm on top of the boiler

- 500 mm in front of the boiler*

* Clearance is only required to

enable easier access to the boiler for servicing and may be provided by an openable door, etc.

Selecting position 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 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.

Fig. I.2: Free space required for installation

Euro B/S 088/0GB

Note: If the boiler is to be fitted in a timber framed building, it should be fitted in accordance with Institute of Gas Engineers Publication IGE/UP/7/1998 „Guide for Gas Installations in Timber Framed Dwellings“.

440

800

338

Fig. I.1: Dimensions of boiler

Euro B/S 089/0

Note: Should it be necessary to run system pipework to above the boiler within the width of the casing, use the optional top connection accessory (Art.No. 306 251).

BOILER INSTALLATION SEQUENCE

210

124163 03240/242/280/282/824/828 Pro/Plus

60/100

07/2000

Fig. I.3: Using Boiler template

124163_03

Using boiler template

Fix the paper template to the wall ensuring that the correct flue exit point has been identified, ensure that the template is vertical.

The template shows

- The position of the fixing holes for the boiler mounting bracket (1).

- The position of the connections.

- The position of the flue exit hole.

- Upper hole (2) indicates top outlet flue with flue turret facing rearward.

- Lower hole (3) indicates rear outlet flue exiting directly through wall.

Mark the 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 other flue systems such as vertical RSF flues, flues run to the side of the boiler and the use of additional bends etc. are detailed in the flue installation instructions provided with the boiler.

Remove the template from the wall and plug the drilled holes using the wallplugs supplied.

Note: Use alternative fixing holes where necessary.

240/242/280/282/615/620/624/628/824/828 Pro/Plus

TURBOmax only

320

131

26,5

131

105

Euro B/S 091/0

BOILER INSTALLATION SEQUENCE

Fig. I.4: Fitting the boiler

Fitting the boiler

● Lift the boiler (3) up to the wall so

that it is slightly above the hanging bracket (1).

● Lower the boiler slowly onto the

hanging bracket so that the cross member at the rear 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 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 timber framed building ensure that the bracket is secured to a substantial part of the timber frame capable of taking the weight of the boiler.

BOILER INSTALLATION SEQUENCE

Removing boiler casing

● Turn both securing fasteners (1)

anti-clockwise 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

90°90°

Fig. I.5: Remove of boiler casing

Euro B/S 087/1

☞ picture shows TURBOmax Plus

BOILER INSTALLATION SEQUENCE

Gas supply (TURBOmax Plus)

● Connect the 15 mm compression

gas service cock (1) and 15 mm copper outlet tail (3) as supplied with 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).

Euro B/S 046/0GB

Fig. I.6: Fitting the gas connection TURBOmax Plus

TURBOmax Plus

BOILER INSTALLATION SEQUENCE

Cold water mains inlet and hot water outlet (TURBOmax Plus)

Flush all foreign matter from the mains supply before connecting to the boiler.

● Connect the cold water service

valve (1) to the cold inlet water connection (3) of the appliance with the washer (2) provided and tighten.

● Connect the 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.

Euro B/S 045/0GB_Plus

Fig. I.7: Fitting the hot and cold water connections TURBOmax Plus

TURBOmax Plus

BOILER INSTALLATION SEQUENCE

Central heating flow and return pipework (TURBOmax Plus)

Before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris.

● Connect the central heating flow

(6) and return (1) service valves to the appliance (8 and 3) with the washers provided (2 and 7) and tighten the nuts. Ensure that the valve spindles face downwards and the drain points face to either side of the boiler.

● Connect the 22 mm copper pipe

tails to the service valves as shown in 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 water or steam from the valve cannot create a hazard to persons in or about the premises, or cause damage to any electrical components or external wiring, and the point of discharge should be clearly visible (see diagram in plastic bag).

Fig. I.8: Central heating flow and return pipework TURBOmax Plus

Euro B/S 044/0GB_Plus

TURBOmax Plus

BOILER INSTALLATION SEQUENCE

Gas supply (THERMOcompact)

● Connect the 15 mm compression

gas service cock (1) and 15 mm copper outlet tail (3) as supplied with 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

Euro B/S_VC_027/0

Fig. I.9: Fitting the gas connection THERMOcompact

THERMOcompact

BOILER INSTALLATION SEQUENCE

Central heating flow and return pipework (THERMOcompact)

Before connecting the heating circuit to the boiler appliance, all pipework and radiators must be thoroughly flushed to remove any installation debris.

● Connect the central heating flow

(6) and return (1) service valves to the appliance (8 and 3), with the washers (2 and 7) provided and tighten the nuts. Ensure that the valve spindles face downwards and the drain points face to either side of the boiler.

● Connect the 22 mm copper pipe

tails to the service valves as shown in 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.

Fig. I.10: Central heating flow and return pipework THERMOcompact

Euro B/S_VC_017/0

THERMOcompact

BOILER INSTALLATION SEQUENCE

Connection to a Vantage unvented cylinder (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.

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