Vaillant TURBOmax Plus SERIES Installation Manual

4.5 (2)

INSTRUCTIONS FOR INSTALLATION AND SERVICING

TURBOmax Plus824/2 E, 828/2 E

Wall hung room sealed fan assisted combination boilers

THERMOcompact615/2 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

List of Contents

Introduction

Contents included with boiler (TURBOmax Plus) . . . . . . . .4 Contents included with boiler (THERMOcompact) . . . . . . .5

General Information . . . . . . . . . . . . . . . . . . . . . . . . . .6 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Boiler Specification

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Boiler connections (TURBOmax Plus) . . . . . . . . . . . . . . . .8 Boiler connections (THERMOcompact) . . . . . . . . . . . . . .8 Functional diagram (TURBOmax Plus) . . . . . . . . . . . . . . .9 Functional diagram (THERMOcompact) . . . . . . . . . . . . .10

General Requirements

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

Boiler Installation Sequence

TURBO max

THERMO compact

2

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

Commissioning Part I

Gas supply adjustments (Commissioning Part II)

Functional checks (Commissioning Part III)

TABLE OF CONTENTS

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

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

Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Functional check of operation . . . . . . . . . . . . . . . .53/54 Adjusting pump speed . . . . . . . . . . . . . . . . . . . . . . . .55 Final system flush (hot) . . . . . . . . . . . . . . . . . . . .55 Handing over to the user . . . . . . . . . . . . . . . . . . . . . .56

Servicing

Parts replacement

Fault Finding

Diagrams

Short parts list

 

Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .

.57

 

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

.58

 

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

TURBO max

 

 

 

Aqua sensor (TURBOmax Plus only) . . . . . . . . . . . . . . .

68

 

DHW heat exchanger (TURBOmax Plus only) . . . . . . . . .

69

 

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .

69

 

Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . .

70

 

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

 

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

85

 

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

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

3

LIST OF CONTENTS

Plus TURBOmax

12

Instructions for Installation

BEDIENUNGSANLEITUNG

11 BEDIENUNGSANLEITUNG

BEDIENUNGSANLEITUNG

BEDIENUNGSANLEITUNG

11

BEDIENUNGSANLEITUNG

11

10

9

8

7

6

Fig. L.1: Items supplied with unit (TURBOmax Plus)

1 2

3

4

5

086/0GB_Plus

 

 

Euro B/S

Item

Quantity

Description

 

 

 

1

1

Boiler

 

 

 

2

1

Flue restriction ring

 

 

 

3

1

Controls cover door

 

 

 

4

1

Lower cover plate (packed in bottom packaging)

 

 

 

5

1

Cold water inlet valve

 

 

 

6

3

Flow and return service value, gas service valve

 

 

 

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

 

 

 

Table L.1: Items supplied with unit (TURBOmax Plus)

4

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.

11

Instructions for Installation

BEDIENUNGSANLEITUNG

10 BEDIENUNGSANLEITUNG

BEDIENUNGSANLEITUNG

BEDIENUNGSANLEITUNG

10

BEDIENUNGSANLEITUNG

10

 

9

8

7

6

5

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

1

2

3

4

Euro B/S_VC_025/0

Item

Quantity

Description

 

 

 

 

 

1

1

Boiler

 

 

 

 

 

2

1

Flue restriction ring

 

 

 

 

3

1

Controls cover door

 

 

 

4

1

Lower cover plate (packed in bottom packaging)

 

 

 

5

3

Flow and return service value, gas service valve

 

 

 

6

3

Copper tails for gas and water pipework

 

 

 

 

7

1

Template

 

 

 

 

8

2

Guarantee Card and Benchmark log book

 

 

 

9

1

Installation and connection accessories and

PRV packages

 

 

 

 

10

3

Installation and Servicing, Users and Flue Installation

Instructions

 

 

 

 

11

1

Hanging bracket

 

 

 

 

 

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

* for THERMOcompact 624/628 only

LIST OF CONTENTS

Contents included with boiler (THERMOcompact)

Ensure that all contents are included before commencing installation.

THERMOcompact

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

5

INTRODUCTION

General Information

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.

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.

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.

TURBOmax Plus boiler

General Notes

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.

6

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

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.

BOILER SPECIFICATION

Technical data

 

 

 

THERMOcompact

THERMOcompact

 

 

THERMOcompact

THERMOcompact

624/2 E

628/2 E

 

 

(VU GB 242/2-5)

(VU GB 282/2-5)

Units

 

615/2 E

620/2 E

 

TURBOmax Plus

TURBOmax Plus

 

(VU GB 152/2-5)

(VU GB 202/2-5)

 

 

824/2 E

828/2 E

 

 

 

 

 

 

 

 

(VUW GB 242/2-5)

(VUW GB 282/2-5)

 

 

 

 

 

 

 

Maximum CH heat input (net

16.5 (56.100)

22.0 (74.800)

26.7 (91200)

31.1 (106200)

kW (Btu/h)

 

 

 

 

 

 

CH heat output range

6.5 - 15

7.7 - 20

8.9 - 24

10.4 - 28

kW (Btu/h)

(80/60 °C)

(22300 - 51200)

(26300 - 68300)

(30400 - 81900)

(35500 - 95500)

Maximum DHW heat input (net)

---

---

26.7 (91200)

31.1 (106200)

kW (Btu/h)

 

 

 

 

 

 

DHW heat output

---

---

24

28

kW

 

 

 

 

 

 

DHW flow rate T = 35 °C rise

---

---

9.8

11.5

l/min

 

 

 

 

 

 

DHW flow rate at factory set

---

---

8.2

9.5

l/min

temperature rise ( T 42 °C)

 

 

 

 

 

Mains water pressure required

---

---

0.5

0.5

bar

for max. flow rate

 

 

 

 

 

Minimum water flow rate

---

---

1.5

1.5

l/min

 

 

 

 

 

 

Mains water pressure required

---

---

0.15

0.15

bar

for min. flow rate

 

 

 

 

 

Maximum inlet water pressure

---

---

10

10

bar

 

 

 

 

 

 

Inlet gas working pressure

20

20

20

20

mbar

required (natural gas)

 

 

 

 

 

Gas supply (G20) Gross CV (s.t.)

37.8

37.8

37.8

37.8

MJ/m3

Gas burner pressure max. rate

10.5

9.6

9.8

10.8

mbar

 

 

 

 

 

 

Gas burner pressure ignition rate

2.3

1.8

1.9

1.8

mbar

 

 

 

 

 

 

Gas rate max. (DHW)

---

---

2.8

3.3

m3/h

CH temperature flow range

35 - 82

35 - 82

35 - 82

35 - 82

°C

 

 

 

 

 

 

Minimum CH water flow

650

860

1032

1203

l/h

(for 20 °C rise)

 

 

 

 

 

Pump pressure available

0.25 (25)

0.25 (25)

0.25 (25)

0.25 (25)

bar (KPa)

 

 

 

 

 

 

Expansion vessel

0.75

0.75

0.75

0.75

bar

pre-charge pressure

 

 

 

 

 

Maximum CH system pressure

3

3

3

3

bar

 

 

 

 

 

 

Weight

38

39

41/43

43/45

kg

 

 

 

 

 

 

Primary water content

2.0

2.0

2.0

2.0

l

 

 

 

 

 

 

Electrical supply

230/50

230/50

230/50

230/50

V~/Hz

 

 

 

 

 

 

External fuse

3

3

3

3

A

 

 

 

 

 

 

Power input

150

150

150

150

W

 

 

 

 

 

 

Case height

800

800

800

800

mm

 

 

 

 

 

 

Case width

440

440

440

440

mm

 

 

 

 

 

 

Case depth

338

338

338

338

mm

 

 

 

 

 

 

 

 

 

 

 

7

 

 

BOILER SPECIFICATION

 

 

 

 

 

 

PlusTURBOmax

310

148

 

 

7

145

 

 

 

 

Boiler connections

 

 

 

 

 

 

 

off valve (15 mm tail)

 

 

 

 

 

6

 

 

 

 

 

(TURBOmax Plus)

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Key:

 

 

 

 

 

 

 

 

 

 

 

1

Heating system return

 

 

 

 

 

 

 

 

 

 

 

 

(22 mm tail)

 

 

 

 

 

 

 

 

 

 

 

2

Cold water connection with shut

 

 

 

 

 

 

 

 

 

 

 

3

Gas connection (15 mm tail)

 

592

 

 

 

 

 

 

 

6

 

4

Hot water connection

 

 

 

 

 

 

 

 

 

 

(15 mm tail)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

Heating system flow

 

 

 

 

 

 

 

 

 

 

 

 

(22 mm tail)

 

 

5

4 3

2

1

 

 

 

 

 

6

Flue outlet (100 mm flue with

 

 

 

 

 

 

 

 

turret)

 

 

 

 

 

 

 

 

 

 

 

7

Hanging bracket

 

 

 

 

 

 

130

 

 

 

 

8

Rear flue outlet

 

 

 

35

35

 

 

 

 

 

180

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

4

3

2

1

B/S 090/2

 

 

Fig. B.1: Connection diameters TURBOmax Plus

 

 

 

 

 

Euro

 

THERMOcompact

310

148

 

 

5

145

 

 

 

 

Boiler connections

 

 

 

 

 

 

3

Heating system flow

 

 

 

 

 

4

 

 

 

 

 

(THERMOcompact)

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Key:

 

 

 

 

 

 

 

 

 

 

 

1

Heating system return

 

 

 

 

 

 

 

 

 

 

 

 

(22 mm tail)

 

 

 

 

 

 

 

 

 

 

 

2

Gas connection (15 mm tail)

 

592

 

 

 

 

 

 

 

 

 

 

(22 mm tail)

 

 

 

 

 

 

 

 

4

 

4

Flue outlet (100 mm flue with

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

turret)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

Hanging bracket

 

 

 

 

 

 

 

 

 

 

 

6

Rear flue outlet

 

 

3

2

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

130

 

 

 

 

180

 

 

 

 

100

100

 

 

 

 

 

 

B/SVC 009/2

 

 

 

 

 

 

 

3

 

2

 

1

 

 

 

 

 

 

 

 

 

 

 

 

Fig. B.2: Connection diameters THERMOcompact

 

 

 

 

 

Euro

 

 

8

 

 

 

 

 

 

 

 

 

 

 

Vaillant TURBOmax Plus SERIES Installation Manual

BOILER SPECIFICATION

1

 

 

 

 

31

2

 

30

 

 

3

 

29

 

 

4

u

 

 

 

5

 

28

 

 

6

 

 

 

 

27

7

 

26

 

 

 

 

25

 

 

24

8

C

23

 

9

 

i

C

 

 

22

 

 

 

 

21

10

 

 

 

 

20

11

 

19

 

 

12

 

 

 

 

18

13

 

17

14

 

16

15

 

 

Fig. B.3: Functional Diagram TURBOmax Plus

Euro B/S 196/0

Functional Diagram

(TURBOmax Plus)

1Air duct

2Fan

3Main heat exchanger

4Temperature sensor (NTC I)

5Flame sensing electrodes

6Modulating burner

7Fully modulating automatic gas value

8Maximum hot water temperature control

9Maximum radiator temperature control

10Diverter valve

11DHW heat exchanger

12Automatic bypass valve

13CH flow service valve

14Hot water outlet

15Gas service valve

16Cold water service valve

17CH return service valve

18Pressure relief valve

19Aqua sensor (DHW flow switch)

20Temperature sensor (NTC III)

21Main on/off control

22Pressure gauge

23Display

24Expansion vessel

25Expansion vessel charging valve

26Circulating pump

27Automatic air vent

28Ignition electrode

29Temperature sensor (NTC II)

30Air pressure switch

31Flue gas duct

TURBOmax Plus

9

BOILER SPECIFICATION

 

1

 

 

 

25

 

2

24

 

 

 

3

23

 

 

THERMOcompact

4

 

5

22

 

6

 

 

21

7

20

 

 

 

19

 

 

18

 

8

17

 

9

16

 

 

 

 

15

 

10

 

 

 

14

 

11

13

 

12

 

 

 

B/S VC 079/0

 

Fig. B.4: Functional Diagram THERMOcompact

Euro

 

10

 

Functional Diagram (THERMOcompact)

1Air duct

2Fan

3Main heat exchanger

4Temperature sensor (NTC I)

5Flame sensing electrodes

6Modulating burner

7Fully modulating automatic gas value

8This control has no function on this boiler

9Maximum radiator temperature control

10Automatic bypass valve

11CH flow service valve

12Gas service valve

13CH return service valve

14Pressure relief valve

15Main on/off control

16Pressure gauge

17Display

18Expansion vessel

19Expansion vessel charging valve

20Circulating pump

21Automatic air vent

22Ignition electrode

23Temperature sensor (NTC II)

24Air pressure switch

25Flue gas duct

GENERAL REQUIREMENTS

 

Ensure that ALL regulations

 

are observed.

 

006/0 GB

Fig. R.1

Euro B/S

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.

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 (2nd family 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.

11

GENERAL REQUIREMENTS

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.

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.

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“.

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.

12

GENERAL REQUIREMENTS

800

 

 

48

4

 

48

B/S 037/0

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

LAS Euro

1285

 

603

 

48

B/S 036/0

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

LAS Euro

800

 

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

LAS Euro B/S 073/0

1103

 

 

70

15

 

70

082/0

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

GU LAZ

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.

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.

13

GENERAL REQUIREMENTS

 

A

 

 

 

 

 

 

 

G

 

BCD

B

 

 

 

 

 

 

F

M

 

 

 

 

 

G

 

 

 

 

 

 

 

 

 

F

J

A

 

 

 

 

L

I

F

 

 

K

H,

 

A

F

 

 

 

 

L K

 

 

 

 

 

 

 

E

A

 

 

 

 

 

 

 

G

 

 

 

 

 

Fig. R.6: Flue termination

 

 

 

 

 

595/2

 

 

 

 

 

GW

 

 

 

 

 

 

 

 

Terminal positionfor fan-assisted flue (minimum distance)

mm

 

 

 

A1)

Directly below an openable, above an opening or

 

horizontal to an opening i.e. air brick, opening

300

 

window or other , etc

 

 

 

 

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

 

 

 

H

From a surface or boundary facing a terminal

600*

 

 

 

I

From a terminal facing a terminal

1200

 

 

 

J

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

1200

into a dweling

 

 

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

 

 

 

14

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).

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

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.

1)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.

GENERAL REQUIREMENTS

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.

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.

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.

15

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

16

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

 

Vessel Volume [L]

Initial system pressure (bar)

1.0

1.5

Pressure relief valve setting (bar)

 

3.0

Total water content of system

 

 

litres

 

 

25

2.7

3.9

50

5.4

7.8

100

10.9

15.6

125

13.6

19.5

150

16.3

23.4

175

19.1

27.3

200

21.8

31.2

225

24.5

35.1

250

27.2

39.0

275

30.0

42.9

300

32.7

46.8

325

35.7

50.7

350

38.1

54.6

375

40.9

58.5

400

43.6

62.4

425

46.3

66.3

450

49.0

70.2

475

51.8

74.1

500

54.5

78.0

For system volumes other than those given above,

0.109

0.156

multiply the system volume by the factor across

 

 

 

 

 

Table R.2: Sizing of additional expansion vessel

 

 

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.

17

GENERAL REQUIREMENTS

Pump specifications

 

700

[mbar]

650

600

 

Lift

550

500

 

 

450

400

350

300

Pump switch in position II (pre-delivery setting)

250

 

200

 

150

Pump switch in position I

 

100

 

50

 

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

Volume flow [l/min]

Fig. R.7: Pump specifications

Euro B/S_VC_010/0GB

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.

18

BOILER INSTALLATION SEQUENCE

440

 

 

800

 

338

Fig. I.1: Dimensions of boiler

Euro B/S 089/0

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

,,,,,,,,,,yyyyyyyyyy

Fig. I.2: ,,,,,,,,,yyyyyyyyyFree space required for installation EuroB/S088/0GB

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.

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“.

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.

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).

19

BOILER INSTALLATION SEQUENCE

 

 

60/100

 

210

2

 

 

 

 

 

5

 

 

5

 

3

 

 

 

 

1

 

 

 

TURBOmax only

07/2000

240/242/280/282/615/620/624/628/824/8288240/242/280/282/824 Pro/Plus

Pro/Plus

124163 03

 

Fig. I.3: Using Boiler template

20

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.

Note: Use alternative fixing holes where necessary.

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.

124163_03

BOILER INSTALLATION SEQUENCE

 

320

 

131

131

 

105

105

2

22

 

 

 

 

27

 

 

26,5

 

 

1

3

 

 

Fig. I.4: Fitting the boiler

 

Euro B/S 091/0

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.

Install the flue system

Install the flue system (refer to separate air/flue duct installation instructions).

Fitting the boiler

Lift the boiler 3( ) up to the wall so that it is slightly above the hanging bracket (1).

Note: Lift the boiler from either side at the bottom edge.

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.

21

BOILER INSTALLATION SEQUENCE

 

 

 

Removing boiler casing

90°

90°

● Turn both securing fasteners1()

 

 

anti-clockwise by 90° to release

 

 

control panel (2).

 

1

● Pull the case 3( ) forward at the

VRC-VC

bottom to disengage from the

 

I

securing clips.

 

0

 

 

 

● Lift the case slightly to clear the top

 

 

locations and pull forward to

 

 

remove.

 

2

 

I

 

 

0

 

 

 

3

 

picture shows TURBOmax Plus

 

 

Fig. I.5: Remove of boiler casing

 

Euro B/S 087/1

22

 

 

 

BOILER INSTALLATION SEQUENCE

 

 

 

Gas supply

Plus

 

 

(TURBOmax Plus)

 

 

 

 

 

● Connect the 15 mm compression

TURBOmax

 

 

less than 15 mm diameter to the

 

 

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

 

 

 

copper tail.

 

 

I

● Tighten all connections.

 

 

(Ensure the gas supply pipework is

 

 

 

 

 

0

adequately sized such that a 20

 

 

 

 

 

 

mbar gas pressure is available at

 

 

 

the boiler inlet at full flow rate).

 

3

 

 

 

 

1

 

 

 

2

 

 

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

 

Euro B/S 046/0GB

 

 

 

23

 

BOILER INSTALLATION SEQUENCE

 

TURBOmax

Cold water mains inlet

supply before connecting to the

 

and hot water outlet

 

(TURBOmax Plus)

 

Flush all foreign matter from the mains

Plus

boiler.

● Connect the cold water service

 

 

valve (1) to the cold inlet water

I

connection (3) of the appliance

0

with the washer 2() provided and

 

tighten.

 

● Connect the 15 mm cold water

 

inlet pipe copper tail4() 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.

4

● Connect the cold water service

 

 

pipe and hot water outlet pipework

6

to the copper tails.

 

1

 

2

 

7

 

 

3

8

 

 

045/0GB Plus

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

Euro B/S

24

 

BOILER INSTALLATION SEQUENCE

 

I

 

0

4

 

 

1

 

2

9

 

6

3

 

7

 

8

 

 

044/0GB Plus

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

Euro B/S

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).

TURBOmax Plus

25

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.

 

I

● Tighten all connections.

THERMOcompact

0

(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).

3

 

 

1

 

 

 

2

 

 

 

B/S VC 027/0

Fig. I.9: Fitting the gas connection THERMOcompact

 

Euro

26

 

 

BOILER INSTALLATION SEQUENCE

 

I

 

0

4

 

 

1

 

2

9

 

6

3

 

7

 

8

 

 

B/S VC 017/0

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

Euro

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.

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).

THERMOcompact

27

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.

28

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