Vaillant turboMAX pro 24/2 E, turboMAX pro 28/2 E Instructions For Installation And Servicing
For the installer
Instructions for Installation and Servicing
turboMAX pro
Wall hung room sealed fan assisted
combination and system boilers
24/2 E
28/2 E
GB
Table of Contents
1 List of Contents . . . . . . . . . . . . . . . . . . . . . 3
1.1 Contents included with boiler (turboMAX pro)3
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 General Information . . . . . . . . . . . . . . . . . . . . . 4
2.2 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Boiler Specification . . . . . . . . . . . . . . . . . . . 5
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Boiler connections . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Functional diagram . . . . . . . . . . . . . . . . . . . . . . 6
4 General Requirements . . . . . . . . . . . . . . . . . 7
4.1 Related documents . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4.1 Top outlet flue system . . . . . . . . . . . . . . . . . . . . 8
4.4.2 Rear outlet flue system . . . . . . . . . . . . . . . . . . . 8
4.4.3 Extended top outlet flue system . . . . . . . . . . . 8
4.4.4 Flue termination . . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Cupboard or compartment ventilation . . . . . . 9
4.7 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.8 Guide to system requirements . . . . . . . . . . . . . 10
4.8.1 Water circulation system . . . . . . . . . . . . . . . . . . 10
4.8.2 Filling and make up . . . . . . . . . . . . . . . . . . . . . . 10
4.8.3 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 10
4.8.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.8.5 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . 10
4.8.6 Circulating pump . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8.7 System by-pass . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8.8 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Gas supply adjustments (Commissioning Part II) 21
7.1 Gas inlet working pressure . . . . . . . . . . . . . . . . 21
7.2 Main burner pressure . . . . . . . . . . . . . . . . . . . . 21
7.3 Adjusting the central heating output
(range rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.4 Burner pressure and gas rate . . . . . . . . . . . . . . 23
7.5 Fit combustion chamber cover . . . . . . . . . . . . . 24
7.6 Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Functional checks (Commissioning Part III) . 25
8.1 Functional checks . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Functional check of operation . . . . . . . . . . . . . 25
8.3 Adjusting pump speed . . . . . . . . . . . . . . . . . . . . 26
8.4 Handing over to the user . . . . . . . . . . . . . . . . . 26
9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1 Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.2 Cleaning the burner and primary heat
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . 29
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 Logical fault finding procedure . . . . . . . . . . . . 29
11 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.1 Functional flow diagram . . . . . . . . . . . . . . . 37
11.2 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Benchmark gas boiler commissioning
checklist..................................... 39
5 Boiler Installation Sequence . . . . . . . . . . . . 12
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Using boiler template . . . . . . . . . . . . . . . . . . . . 13
5.3 Fitting the boiler hanging bracket . . . . . . . . . . 13
5.4 Install the flue system . . . . . . . . . . . . . . . . . . . . 14
5.5 Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Removing boiler casing . . . . . . . . . . . . . . . . . . . 14
5.7 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.8 Cold water mains inlet and hot water outlet . . 15
5.9 Central heating flow and return pipework . . . 15
5.10 Connect the flue system to the boiler . . . . . . . 16
5.11 Electrical installation . . . . . . . . . . . . . . . . . . . . . 16
5.12 Connection to the main supply . . . . . . . . . . . . 16
5.13 Electronic board layout . . . . . . . . . . . . . . . . . . . 17
5.14 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Commissioning Part I . . . . . . . . . . . . . . . . . 20
6.1 Preliminary electrical checks . . . . . . . . . . . . . . 20
6.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Cold water supply . . . . . . . . . . . . . . . . . . . . . . . 20
6.4 Filling the heating system . . . . . . . . . . . . . . . . . 20
6.5 Initial system flush („cold“) . . . . . . . . . . . . . . . 20
Instructions for Installation and Servicing turboMAX pro R32
1 List of contents
8
7
6
1
2
5
4
I
0
3
9
10
1.1 Contents included with boiler
Ensure that all contents are included before commencing installation.
Note!
DO NOT remove the boiler from the polystrene
base at this stage.
List of contents 1
Fig. 1.1: Items supplied with unit (turboMAX pro)
Item Quantity Description
1 1 Boiler
2 1 Flue restriction ring
3 1 Cold water inlet valve
4 3 Flow and return service value, gas service
valve
5 5 Copper tails for water outlet connection
6 1 Template
7 1 Guarantee Card
8 1 Installation and connection accessories and
PRV packages incl. DHW outlet union nut
9 3 Installation and Servicing, Users and Flue
Installation Instructions
10 1 Hanging bracket
Instructions for Installation and Servicing turboMAX pro R3 3
2 Introduction
2 Introduction
2.1 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.
The turboMAX pro 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 boiler has been designed for
use with a sealed central heating system, and comes
fully tested and assembled with a built in circulating
pump, expansion vessel and diverter valve.
The turboMAX pro has an output for domestic hot water
of 24 or 28 kW. The boiler is 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 system are available, rear flue outlet, top outlet
(with turret) concentric flue system (100 mm outside
diameter) and an extended concentric flue system
(125 mm outside diameter). Flue extensions and additional bends and elbows are available for both flue systems
to increase the siting flexibility. The boiler is not suitable
for external installation. This boiler is available in Natural
Gas. An optional LPG conversion kit is available. If desired, an inhibitor may be used in the system. Guidance on
the use of inhibitors is contained in these instructions.
The boiler contains a domestic hot water heat exchanger. The temperature in the heat exchanger is limited by
the boiler control system and it is not necessary to
install a scale reducer on the cold mains to the boiler.
However, in exceptionally hard water areas to prevent
scale formation in the property hot water system pipework, a scale reducer may be fitted.
turboMAX pro combination boilers have a built in diagnostic system which indicates the operational status of
the boiler. 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.
In this installation manual you will find the Benchmark
gas boiler commissioning checklist. It is very important
that this is completed correctly at the time of installation and commissioning..
Important!
When tightening or slackening screwed connections always use suitable open-ended spanners
(not pipe wrench, or extensions, etc.).
Incorrect use and/or unsuitable tools can lead to
damage being caused (e.g. gas or water leakage)!
2.2 EC designation
turboMAX pro (24/28) a 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.
Instructions for Installation and Servicing turboMAX pro R34
Boiler Specification 3
3 Boiler Specification
3.1 Technical Data
turboMAX pro 24/2 E turboMAX pro 28/2 E Units
(VUW GB 242/2-3) (VUW GB 282/2-3)
Maximum CH heat input (net) 29.7 (101.000) 31.1 (106.200) kW (Btu/h)
CH heat output range (80/60 °C) 8.9 - 24 10.4 - 28
(30.400 - 81.900) (35.500 - 95.500) kW (Btu/h)
Maximum DHW heat input (net) 26.7 (91.200) 31.1 (106.200) kW (Btu/h)
SEDBUK Band D D
SAP Seasonal Efficiency 79.6 79.7 %
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
temperature rise (∆T 42 °C) 8.2 9.5 l/min
Mains water pressure required
for max. flow rate 0.5 0.5 bar
Minimum water flow rate 1.5 1.5 l/min
Mains water pressure required
for min. flow rate 0.15 0.15 bar
Maximum inlet water pressure 10 10 bar
Inlet gas working pressure
required (natural gas) 20 20 mbar
Gas supply (G20) Gross CV (s.t.) 37.8 37.8 MJ/m
Gas burner pressure max. rate (natural gas) G 20 9.8 10.8 mbar
(LPG 3+) G 30/31 28 - 30/37 28 - 30/37 mbar
Gas burner pressure ignition rate G 20 1.9 1.8 mbar
G 30/31 3.9/5.4 3.8/5.3 mbar
Gas rate max. (DHW) - 2.8 3.3 m3/h
CH temperature flow range 35 - 82 35 - 82 °C
Minimum CH water flow
(for 20 °C rise) 1032 1203 l/h
Pump pressure available 0.25 (25) 0.25 (25) bar (KPa)
Expansion vessel
pre-charge pressure 0.75 0.75 bar
Maximum CH system pressure 3 3 bar
Weight 42 45 kg
Primary water content 2.0 2.0 l
Electrical supply 230/50 230/50 V~/Hz
External fuse 3 3 A
Power input 150 150 W
Case height 800 800 mm
Case width 440 440 mm
Case depth 338 338 mm
3
Instructions for Installation and Servicing turboMAX pro R3 5
3 Boiler Specification
C
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
18
19
21
22
23
24
25
26
27
28
29
30
31
0
7
6
264638
145
6
5
100
100
35 35
432
130
180
1
148
8
543 2 1
902
3.2 Boiler connections
3.3 Functional Diagram
Fig. 3.1: Connection diameters turboMAX pro
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)
Fig. 3.2: Functional Diagram
6 Flue outlet (100 mm flue with turret)
7 Hanging bracket
8 Rear flue outlet
1 Air duct
2Fan
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)
21 Main on/off control
22 Pressure gauge
23 Indicator lights
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
Instructions for Installation and Servicing turboMAX pro R36
General Requirements 4
4 General Requirements
4.1 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
(WaterFittings) 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 Standard; Including current
amendments to Approved Documents Part L and J.:
BBSS 55444400::
exceeding 70 kW net:
- Part 1: Flues
- Part 2: Ventilation
BBSS 55444499::
for domestic premises.
BBSS 55554466::
domestic premises.
BBSS 66770000::
within buildings and their curtilages.
BBSS 66779988::
boilers not exceeding 70 kW input net.
BBSS 66889911::
gas pipework up to 28 mm (R1) in domestic premises
nd
family gas).
(2
BBSS 77559933::
central heating systems.Institute of Gas Engineers
Publication IGE/UP/7/1998: Guide for Installation in
Timber Framed Housing. Benchmark Code of Practice.
Building Regulations Approved Documents Part L 2002
Part J 2002.
Flues and ventilation of gas fired boilers not
Specification for forced circulation hot water
Specification for gas hot water supplies for
Services supplying water for domestic use
Specification for installation of gas fired
Specification for installation of low pressure
Treatment of water in domestic hot water
Important!
The appliance must be installed and serviced by
a competent person as stated in the Gas Safety
(Installation and Use) Regulations 1998.
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“.
4.3 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.
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.
4.2 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
Instructions for Installation and Servicing turboMAX pro R3 7
4.4 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.
4 General Requirements
70
1103
70
15
48
1285
603
4.4.1 Top outlet flue system
(100 mm outside diameter)
The top outlet horizontal flue system (Art. No. 303 807)
is suitable for installations up to 720mm 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 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.
800
48
4
48
Fig. 4.1: Art.-No. 303 807
A vertical flue system is also available
(Art. No. 303 800).
Refer to flue system installation instructions for full
details.
4.4.2 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.
800
Fig. 4.3: Art.-No. 303 817
4.4.3 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 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.
Fig. 4.2: Art.-No. 303 800
Fig. 4.4: Art.-No. 303 609
Instructions for Installation and Servicing turboMAX pro R38
General Requirements 4
A
BCD
A
G
H, I
F
J
B
F
M
L
L
K
K
G
G
F
F
E
A
A
4.4.4 Flue termination
The following details refer to both flue systems.
a. The terminal must be positioned such that the pro-
ducts 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 bal-
cony, 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.
The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of the building.
Terminal position for fan-assisted flue
(minimum distance) mm
A1)Directly below an openable, above an opening
or horizontal to an opening i.e. air brick, opening
window or other, etc 300
B Below gutters, soil pipes or drain pipes 25
C Below eaves 25
D Below balconies (below car port roof) 25
E From vertical drain pipes and soil pipes 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*
H From a terminal facing a terminal 1200
J From an opening in a car port (e.g. door, window)
into a dweling 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
1) In addition, the terminal should not be nearer than 150mm 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.
4.5 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.
Fig. 4.5: Flue termination
4.6 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.
4.7 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
Instructions for Installation and Servicing turboMAX pro R3 9
switch with a 3 mm contact separation on both poles
may be used.
4 General Requirements
Important!
This appliance must be earthed.
4.8 Guide to system requirements
4.8.1 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.
Important:
To prevent the formation of deposits and prevent serious damage to the appliance and
system , cleansers must be used carefully and
must be completely removed by thoroughly
flushing the system. Cleansers should only be
left in systems for a maximum of 24 hours.
This cleansing must 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, GE Betz. Widnes, Cheshire,
WA8 8UD. Tel: 0151 420 9595
4.8.2 Filling and make up
The system can be filled using the built in filling loop.
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).
4.8.3 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.
4.8.4 Pressure gauge
This is factory fitted to the boiler and indicates the
primary circuit pressure to facilitate filling and
testing.
4.8.5 Expansion vessel
The 24 kW 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.
The 28 kW 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.
Vessel Volume [L]
Initial system pressure (bar) 1.0 1.5
Pressure relief valve setting (bar) 3.0
Total water content of system ltres
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 62.4
450 49.0 58.5
475 51.8 74.1
500 54.5 78.0
For system volumes other than those given
above, multiply the system volume by the
factor across 0.109 0.156
Instructions for Installation and Servicing turboMAX pro R310
4.8.6 Circulating pump
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
50
100
150
200
250
300
350
400
450
500
550
600
650
700
Volume flow [l/h]
Lift [mbar]
setting III
setting II
The circulating pump is included in the boiler. The pump
head available for the heating system is shown in
fig. 4.6.
General Requirements 4
Fig. 4.6: Pump specifications
4.8.7 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.
4.8.8 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.
Instructions for Installation and Servicing turboMAX pro R3 11
150
5
200
500
5
I
0
0120
60
9030
°C
bar
4
3
2
1
0
5 Boiler Installation Sequence
440
800
338
I
0
0120
60
9030
°C
bar
4
3
2
1
0
5 Boiler Installation Sequence
5.1 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“.
Fig. 5.2: Free space required for installation
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 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).
Fig. 5.1: Dimensions of boiler
Instructions for Installation and Servicing turboMAX pro R312
Boiler Installation Sequence 5
55
210
124163 21200/202/240/242/280/282/824/828 Pro/Plus
60/100
07/2002
2
3
1
turboMAX only
3
402
171
174,5
12,5
1
1
2
5.2 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.
5.3 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).
Fig. 5.3: Using Boiler template
Fig. 5.4: Free space required for installation
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.
Instructions for Installation and Servicing turboMAX pro R3 13
I
0
1
2
5 Boiler Installation Sequence
3
I
0
2
I
0
90°90°
1
5.4 Install the flue system
Install the flue system (refer to separate air/flue duct
installation instructions).
5.5 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.
5.6 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.
5.7 Gas supply
• Connect the 15 mm compression gas service cock (1)
supplied with the appliance (2) and tighten.
• Connect a gas supply pipe of not less than 15 mm
diameter to the gas service cock.
• 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).
Fig. 5.5: Remove of boiler casing
Fig. 5.6: Fitting the gas connection
Instructions for Installation and Servicing turboMAX pro R314
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