For the installer Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT Wall hung room sealed fan assisted 824/2 E combination and system boilers 828/2 E 837 E 615/2 E 620/2 E 624/2 E 628/2 E 637 E GB
Table of Contents Page 1 List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Contents included with boiler (turboMAX plus) 4 1.2 Contents included with boiler (thermoCOMPACT) 4 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . 2.1 2.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Boiler Specification . . . . . . . .
Table of Contents Page 10 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Indicator lights (turboMAX plus only) . . . . . . . 10.3 Indicator lights (thermoCOMPACT only) . . . . . 10.4 Logical fault finding procedure . . . . . . . . . . . . 10.5 Status Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 Fault codes . . . . . .
1 List of contents 1 List of contents 1.2 Contents included with boiler (thermoCOMPACT) Ensure that all contents are included before commencing installation. 1.1 Contents included with boiler (turboMAX plus) Ensure that all contents are included before commencing installation. Note! DO NOT remove the boiler from the polystrene base at this stage. Note! DO NOT remove the boiler from the polystrene base at this stage.
Introduction 2 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. turboMAX plus boiler The turboMAX plus is a fully automatic, wall mounted, room sealed combination boiler for central heating and domestic hot water.
3 Boiler Specification 3 Boiler Specification 3.1 Technical Data turboMAX plus turboMAX plus turboMAX plus 824/2 E 828/2 E 837 E (VUW GB 242/2-5) (VUW GB 282/2-5) (VUW GB 362/2-5) Units Maximum CH heat input (net) 26.7 (91,200) 31.1 (106,200) 31.1 (106,200) kW (Btu/h) CH heat output range (80/60 °C) 8.9 - 24 10.4 - 28 10.9 - 28* (36,.9) (30,400 - 81,900) (35,500 - 95,500) (37,200 - 95,500) kW (Btu/h) Maximum DHW heat input (net) 26.7 (91,200) 31.1 (106,200) 40.
Boiler Specification 3 thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT thermoCOMPACT 615/2 E 620/2 E 624/2 E 628/2 E 637 E Units (VU GB 152/2-5) (VU GB 202/2-5) (VU GB 242/2-5) (VU GB 282/2-5) (VU GB 362-5) Maximum CH heat input 16.5 22.0 26.7 31.1 40.5 kW (net) (56,100) (74,800) (91,200) (106,200) (138,300) (Btu/h) CH heat output range 6.5. - 15 7.7 - 20 8.9 - 24 10.4 - 28 10.5 - 36.
3 Boiler Specification Key: 1 2 3 4 5 6 3.2 Boiler connections (turboMAX plus) 264 6 145 102 8 Heating system return (22 mm tail) Gas connection (15 mm tail) Heating system flow (22 mm tail, 22 mm for 637) Flue outlet (100 mm flue with turret) Hanging bracket Rear flue outlet 3.4 Functional Diagram (turboMAX plus) 7 638 902 1 31 6 2 30 5 4 3 2 4 130 35 100 29 3 1 180 35 u 5 28 6 100 27 5 4 3 2 1 7 26 25 Fig. 3.
Boiler Specification 3 22 23 24 25 26 27 28 29 30 31 Pressure gauge Display Expansion vessel Expansion vessel charging valve Circulating pump Automatic air vent Ignition electrode Temperature sensor (NTC II) Air pressure switch Flue gas duct 19 20 21 22 23 24 25 Expansion vessel charging valve Circulating pump Automatic air vent Ignition electrode Temperature sensor (NTC II) Air pressure switch Flue gas duct 3.
4 General Requirements 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 (Water Fittings) Regulations 1999, or the Water Bylaws 2000 (Scotland).
General Requirements 4 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 in the flue instructions. 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 720 mm measured from the centre of the boiler flue outlet to the outside face of the wall.
4 General Requirements 4.4.4 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.
General Requirements 4 requirements of BS 1363. Alternatively, a 3 Amp. fused doublepole switch with a 3 mm contact separation on both poles may be used. 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).
4 General Requirements Vessel Volume [L] 1.0 1.5 3.0 700 Lift [mbar] Initial system pressure (bar) Pressure relief valve setting (bar) Total water content of system ltres 25 2.7 3.9 50 5.4 7.8 100 10.9 15.6 125 13.6 19.5 650 600 550 500 450 400 350 300 150 16.3 23.4 175 19.1 27.3 200 21.8 31.2 Pump switch in position III (pre-delivery setting) 250 200 150 Pump switch in position II 100 50 225 24.5 35.1 250 27.2 39.0 275 30.0 42.9 300 32.7 46.8 325 35.7 50.
Boiler Installation Sequence 5 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.
5 Boiler Installation Sequence 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.
Boiler Installation Sequence 5 5.7 Gas supply (turboMAX plus) • Connect the 15 mm compression gas service cock (1) and 15 mm copper outlet tail (22mm copper tail with 837) (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 (minimum 22 mm gas supply pipe with 837). • 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).
5 Boiler Installation Sequence 5.8 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.
Boiler Installation Sequence 5 5.10 Gas supply (thermoCOMPACT) • Connect the 15 mm compression gas service cock (1) and 15 mm copper outlet tail (22 mm copper tail with 637) (3) as supplied with the appliance and tighten. • Connect a gas supply pipe of not less than 15 mm diameter to the copper tail (minimum 22 mm with 637). • 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). 5.
5 Boiler Installation Sequence 5.12 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. 3 5.13 Connect the flue system to the boiler • Refer to separate air/flue duct installation instructions included with the boiler. 5.
Boiler Installation Sequence 5 5.16 Electronic board layout Socket X2 for internal unit components Socket X4 for diverter valve Socket X7 for accessory box connection Socket X8 for VRC-VC connection Socket for fan control cable (637 and 837 only) F3 7 8 9 24V Do not use! L N Mains power supply: connections L, N and earth 3 4 5 230V Room thermostat, 230 V: connections 3, 4 and 5 Socket X12: pump connection Socket X14: gas valve connection Socket X13: fan connection Abb. 0.
5 Boiler Installation Sequence 5.17 Controls (turboMAX plus boiler) External electrical controls The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat. Terminals 3 and 4 are linked together when the boiler is supplied. If external controls are used, this link must be removed and the controls connected across terminals 3 and 4.
Boiler Installation Sequence 5 DO NOT USE IN UK! Connection details for control systems utilising 3 port motorised valve via external wiring centre/junction box 20 VDC 7 8 9 L N 34 5 Diagram only applies to the specific controls mentioned 3 amp fused main supply MAINS SUPPLY 230 V 50 Hz N L 3 A FUSE SWITCH CONTACTS Programmer for programmer connections see fig. 16.
5 Boiler Installation Sequence Connection details for control systems utilising 2 x 2 port motorised valves via external wiring centre/junction box Diagram only applies to the specific controls mentioned 3 amp fused main supply L N L N THERMOcompact terminal strip E Programmer for programmer connections see fig. 16.
Commissioning Part I 6 6 Commisioning Part I 6.1 Preliminary electrical checks Check the electrical installation by carrying out short circuit, earth continuity and resistance to earth tests and a check for correct polarity. 2 6.2 Gas supply The complete gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with BS 6891. In IE the current edition of IS 813. The gas supply to the boiler can be purged by slackening the gas service valve beneath the boiler.
6 Commissioning Part I Gas supply adjustments (Com. Part II) 7 6.5 Filling the heating system (thermoCOMPACT) The boiler and the heating system should be filled using a filling method as described on page 13. • Ensure that the boiler CH service valves are open. • Partially open the filling valve and allow water to enter the system. Starting with the lowest radiator, open the radiator air release until water (clear of bubbles) is emitted.
Gas supply adjustments (Commissioning Part II) 7 7.2 Main burner pressure The burner pressure on this appliance has been factory set and does not require adjustment. To check the main burner pressure connect the U-Gauge as follows depending on the gas type. • Remove front case and combustion chamber cover. Note! All measurements and adjustments to the gas valve must be done with the combustion chamber cover removed.
7 Gas supply adjustments (Commissioning Part II) • Press the ”i” button and a value between 1 and 15 will be displayed. Note! Following adjustment of the central heating output, the new output can be checked using the gas rate table as detailed. 1 • Use the ”+” or ”-” buttons to increase or decrease the value. Observe the U-gauge as the button is pushed and stop pushing when the required main burner pressure has been achieved. Fig. 7.
Gas supply adjustments (Commissioning Part II) 7 7.4 Adjusting to the maximum heat load (nominal load) • Undo screw and remove the cap (1) turboMAX only: • Set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap. thermoCOMPACT only: • Turn off the boiler at the main ON/OFF control. • Press and hold the ”+” button, while pressing the button turn the main ON/OFF control to the ”1” ON position.
7 Gas supply adjustments (Commissioning Part II) 7.6 Checking the gas valve mid setting point (turboMAX plus 837 and thermoCOMPACT 637 only) To ensure the most efficient operation of the boiler a gas valve mid setting point is necessary. This mid setting point has been factory set and adjustment of this point is only required after exchanging either the electronic circuit board or gas valve or converting the boiler to another gas type.
Gas supply adjustments (Commissioning Part II) 7 Burner Pressure and gas rate Burner Pressure thermoCOMPACT 615/2 E Output[kW] Gas type Natural gas 2H Burner pressure1) [mbar] Main burner jet mark2) for G20 Ignition rate 6.5 8.0 10.0 12.0 14.0 15.0 2.2 2.2 3.2 4.7 6.6 8.7 9.9 7 / 120 LPG 3 B/P Burner pressure1) [mbar] Main burner jet mark2) for G30 4.1 4.1 6.2 9.6 13.6 18.1 20.6 7 / 072 for G31 5.8 5.8 8.7 13.3 18.7 24.9 28.
7 Gas supply adjustments (Commissioning Part II) Burner Pressure thermoCOMPACT 637, turboMAX plus 837 E Gas type Output[kW] Ignition rate 10.5 12.0 16.0 18.0 20.0 24.0 28.0 30.0 33.0 36.9 Natural gas 2H Burner pressure [mbar] 1) Main burner jet mark 2) 1.2 for G20 1.2 1.5 2.5 3.1 3.8 5.3 7.1 8.1 9.7 12.0 19.1 22.9 28.2 7 / 120 Setting-up program: P.11 mid. setting point pressure: 5.3 mbar LPG 3 B/P Burner pressure1) [mbar] Main burner jet mark2) for G30 2.8 2.8 3.5 5.9 7.
Gas supply adjustments (Com. Part II) 7 7.8 Fit combustion chamber cover Carefully re-fit the combustion chamber cover to the boiler ensuring it is correctly sealed. Secure cover with retaining clamps. 7.9 Fit boiler casing • Carefully push case (1) onto the boiler such that the locating points either side at the top of the boiler engage. Push the casing onto the securing clips at the bottom of the boiler. • Close control panel (2).
8 Functional Checks (Commissioning Part III) • Yellow flame indicator (2) ON. • Green warmstart indicator (3) FLASHING (hot water is being drawn from the system). Central Heating operation • Operate the heating system. If boiler is operating correctly, the status of the indicators will be as follows: • Red lock out indicator (1) OFF. • Yellow flame indicator (2) ON (burner active). • Green warmstart indicator (3) ON, OFF or FLASHING (see above).
Functional Checks (Commissioning Part III) 8 9 Servicing 1 9.1 Initial Inspection To ensure the continued safe and efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate. It is the law that all servicing work is carried out by a competent person (Corgi registered).
9 Servicing • Turn off the boiler CH service valves. • Turn off the cold water inlet service valve. • Release the three clamps (1), remove the combustion chamber cover (2). 2 1 9.2.1 For thermoCOMPACT 615, 637 and turboMAX plus 837 • Remove the flue gas connector (2a) on the fan. • Remove the retaining spring (3). • 15 kW: Pull the three cables (4) and two tubes (5) from the fan assembly. • 37 kW: Remove both plugs (not illustrated) and both hoses (5) from the fan. • Remove the fan assembly (6).
Servicing 9 10 Fault Finding 10.1 Introduction The turboMAX plus and thermoCOMPACT boilers have an inbuilt advanced multifunction diagnostic display to assist with fault finding in the unlikely event of a boiler malfunction. The display features the following four modes: Normal Mode Under normal conditions the boiler display will show the boiler flow temperature, this indicates that the boiler is operating correctly after an internal self check.
10 Fault Finding 10.5 Status Modes The status mode provides information about the current operating status of the boiler. To display status mode proceed as follows: • Press the “i” button below the display, and a status code will appear in the display indicating the current operational status of the boiler (see table below). To cancel the status code mode proceed as follows: • Press the “i” button below the display or • Do not press any key for approximately four minutes.
Fault Finding 10 10.6 Diagnostic Modes In order to assist with the pinpointing of a particular fault it is possible to use the boiler display in a diagnostic mode to interrogate the boiler about the status of certain components. • Press the “i“ and “+“ buttons below the display simultaneously. The display will now show “d.00“. • Use “+“ or “-“ buttons to scroll up or down to the desired diagnosic number. • Press “i“ button to display the corresponding diagnosic information. Display d.00 d.01 d.02 d.05 d.
10 Fault Finding 10.7 Fault codes Fault codes take priority over all other display functions in the event of a system fault occurring. If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each. 10.8 Fault memory The fault memory stores details of the ten most recent faults. Display F.00 F.01 • Press the “i“ and “-“ buttons simultaneously. • Use the “+“ button to scroll back through the list of memorised errors.
Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 No Go to sheet B No Is the continuity across fuse F1? No Replace LCD display Yes Replace electronic board No Is 5 VDC present between 5V and GND test points on electronic board? Is there continuity across fuse F3? No No Yes Yes Is voltage between 16-26 VDC present across terminals 8 and 9? Yes Is 230VAC present across terminals 3 and 5? Yes Is 230VAC present across terminals L and N? Does ON/OFF knob operate sw
If fan commences operation, exchange gas valve No Yes Check/replace fan Replace electronic board Is there a display on the LCD panel? After approx. 20 secs. Does fuse F1 blow? Check/replace pump Check transformer 230 VAC primary (black/red) and approx. 17 VDC secondary (blue/brown) No Yes No No Produce central heating demand.
Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 Yes Replace defective timer No External fault: Check all external controls are calling for heat, replace or repair as necessary (see also note 1 sheet A) Disconnect built in timer (if fitted) Go to sheet D Does ignition commence? Yes No Is 230 VAC present across terminals 4 and 5 Does failure code show on LCD display? No Yes No Check diagnostic code D.08 (see page 53).
Yes No Replace electronic board No Is 230 VAC present across fan terminals? No Yes Check/replace fan Replace electronic board Check air/flue gas system is correctly fitted and not obstructed Check flue restrictor correspond to flue length Check pitot tube (in fan outlet) and air hoses are not obstructed and correctly aligned. Check or replace air pressure switch. 837/637 Check 4 pin connector for fan speed control. Does the fan run now? Yes Yes No Check electrodes and electrode leads.
Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 Yes Check burner pressure settings are correct Yes Does burner light? Check gas supply Yes Does burner light within 3 ignition attempts? No Does burner light 1st attempt? No No Replace electronic board No Does burner light? Check/replace gas valve as necessary Reset boiler Yes No Is burner indicator illuminated Replace electronic board No Is 230 VAC present at the pump plug connection? No Check pump is run
Go to sheet G No Check partial load setting Yes Replace electronic board Check operation of boiler in DHW mode, does flame increase in size to full rate? (TURBOmax Plus only) Check connections and modulator, replace gas valve if burner still fails to increase to full rate Yes (see page 53) equals 1 (TURBOmax Plus only) Check diagnostic code D.
Instructions for Installation and Servicing turboMAX plus and thermoCOMPACT R1 No No Check/replace hall sensor Does hot water indicator glow/flash now? Draw hot water at high rate Yes Replace electronic board Does green warmstart indicator flash now? Check/Clear impeller in Aquasensor, replace if necessary No indicator flash now? Does green warmstart Check cold water inlet is fully open and adjustment is at maximum flow rate Check cold water inlet pressure is sufficient and that cold water inle
11 Diagrams 11.
Diagrams 11 Functional Flow diagram: thermoCOMPACT 615/2 E, 620/2 E, 624/2 E, 628/2 E, 637 E CONTROL BOX MAIN SWITCH F2A L 1 2 N Burner lock out indicator (red) Ignition indicator MAIN TRANSFORMER 230V 20V POWER SUPPLY display F1,25A MAIN SWITCHBOARD AIR PRESSURE SWITCH gr gr plug in connector 637 only r bl b b gr FAN br y/g plus / minus buttons b br reset button PUMP info button y/g NTC FLOW TEMPERATURE SENSOR t w NTC RETURN TEMPERATURE SENSOR br Legend b br y/g r p or t bl g
Ionisation electrode T 1,25 = F3 L N 3 4 5 2 1 3 NTC flow 9 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1 13 NTC Warmstart X3 X12 X14 X13 U100 T2 = F1 NTC earth Ionisation electrode NTC flow Coding resistor Pressure sensor NTC Warmstart NTC return Pump Aqua sensor Lifting magnet 1 22 10 X2 X1 2 7 8 9 3 13 21 X2 X20 4 14 X4 (VUV) X7 Accessories X8 5 15 Switchgear cabinet 6 16 Aqua sensor 7 17 4 Gas valve 8 18 Diverter valve 9 19 Air pressure switch 4 20 Ignition el
Fan unit X2 T 1,25 = F3 X1 L N 3 4 5 X3 X14 X13 U100 T2 = F1 Bridge 1 X2 NTC return Pressure sensor 2 NTC earth 3 13 NTC flow Lifting magnet Coding resistor Ionisation electrode 4 14 X12 5 15 7 8 9 6 16 NTC flow 9 21 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1 13 X2 X20 7 17 2 4 1 3 X4 (VUV) X7 Accessories X8 8 18 Pump 22 10 Gas valve 9 19 Switchgear cabinet Air pressure switch 4 20 Ignition electrodes EV1 21 Instructions for Installation and Servicing turboMAX pl
83 37 86_30 GB R2 04/2003 Mü Printed on 100 % recycled paper · Subject to alteration Head Office: Vaillant Ltd.
