INSTRUCTIONS FOR INSTALLATION AND SERVICING TURBOmax Plus 824/2 E, 828/2 E Wall hung room sealed fan assisted combination boilers THERMOcompact 615/2 E, 620/2 E, 624/2 E, 628/2 E Wall hung room sealed fan assisted system boilers The code of practice for the installation, commissioning & servicing of central heating systems
TABLE OF CONTENTS Contents included with boiler (TURBOmax Plus) . . . . . . . .4 Contents included with boiler (THERMOcompact) . . . . . . .5 Introduction General Information . . . . . . . . . . . . . . . . . . . . . . . . . .6 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Boiler Specification Technical data . . . . . . . . . . . . . . . . Boiler connections (TURBOmax Plus) . .
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 supply adjustments (Commissioning Part II) Gas inlet working pressure . . . .
LIST OF CONTENTS Contents included with boiler (TURBOmax Plus) TURBOmax Plus 12 1 Instructions for Installation BEDIENUNGSANLEITUNG 11 Ensure that all contents are included before commencing installation. 2 BEDIENUNGSANLEITUNG BEDIENUNGSANLEITUNG BEDIENUNGSANLEITUNG 11 BEDIENUNGSANLEITUNG 11 o C o C VC VRC- I 0 10 3 9 8 4 5 6 Fig. L.
LIST OF CONTENTS Contents included with boiler (THERMOcompact) 11 1 Instructions for Installation Ensure that all contents are included before commencing installation. BEDIENUNGSANLEITUNG 10 BEDIENUNGSANLEITUNG 2 BEDIENUNGSANLEITUNG BEDIENUNGSANLEITUNG 10 BEDIENUNGSANLEITUNG o C o C THERMOcompact 10 VC VRC- I 0 9 3 8 7 4 Euro B/S_VC_025/0 6 5 Fig. L.
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).
BOILER SPECIFICATION Technical data THERMOcompact 615/2 E (VU GB 152/2-5) THERMOcompact 620/2 E (VU GB 202/2-5) Maximum CH heat input (net 16.5 (56.100) 22.0 (74.800) CH heat output range (80/60 °C) 6.5 - 15 7.7 - 20 (22300 - 51200) (26300 - 68300) THERMOcompact THERMOcompact 624/2 E 628/2 E (VU GB 242/2-5) (VU GB 282/2-5) TURBOmax Plus TURBOmax Plus 824/2 E 828/2 E (VUW GB 242/2-5) (VUW GB 282/2-5) 26.7 (91200) 31.1 (106200) Units kW (Btu/h) 8.9 - 24 10.
BOILER SPECIFICATION 6 8 Key: 145 148 310 TURBOmax Plus Boiler connections (TURBOmax Plus) 1 Heating system return (22 mm tail) 2 Cold water connection with shut off valve (15 mm tail) 3 Gas connection (15 mm tail) 4 Hot water connection (15 mm tail) 5 Heating system flow (22 mm tail) 6 Flue outlet (100 mm flue with turret) 7 Hanging bracket 8 Rear flue outlet 592 7 6 4 3 2 1 130 35 180 35 100 100 5 4 3 2 Euro B/S 090/2 5 1 Fig. B.
BOILER SPECIFICATION 1 31 TURBOmax Plus Functional Diagram (TURBOmax Plus) 1 Air duct 2 2 Fan 30 3 Main heat exchanger 4 Temperature sensor (NTC I) 29 3 5 Flame sensing electrodes 6 Modulating burner 4 u 5 7 Fully modulating automatic gas value 28 8 Maximum hot water temperature control 6 9 Maximum radiator temperature control 27 7 10 Diverter valve 26 11 DHW heat exchanger 25 8 12 Automatic bypass valve 24 23 C 13 CH flow service valve i 9 14 Hot water outlet C 22 21 15 Gas
BOILER SPECIFICATION Functional Diagram (THERMOcompact) 1 1 Air duct 25 2 Fan 2 3 Main heat exchanger 24 4 Temperature sensor (NTC I) 5 Flame sensing electrodes 3 23 6 Modulating burner 4 5 8 This control has no function on this boiler 22 6 9 Maximum radiator temperature control 21 7 10 Automatic bypass valve 11 CH flow service valve 20 12 Gas service valve 19 8 13 CH return service valve 18 17 14 Pressure relief valve 15 Main on/off control 9 16 15 16 Pressure gauge 17 Display 18 Exp
GENERAL REQUIREMENTS 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.
GENERAL REQUIREMENTS Boiler location Gas Supply 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.
GENERAL REQUIREMENTS Flue system 800 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. 48 LAS Euro B/S 037/0 4 48 48 LAS Euro B/S 036/0 603 1285 Fig. R.2: Art.-No. 303 807 Fig. R.3: Art.-No.
GENERAL REQUIREMENTS 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. A G B F G BCD F J A A E F F M L K L K A G Fig. R.6: Flue termination 14 c.
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 Electrical supply ventilation A 230 V, ~ 50 Hz single phase The boilers are very high efficiency appliances. As a consequence the heat loss from the appliance casing during operation is very low.
GENERAL REQUIREMENTS Guide to system requirements Water circulation system Filling and make up 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). 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.
GENERAL REQUIREMENTS Initial system pressure (bar) Pressure relief valve setting (bar) Vessel Volume [L] 1.0 1.5 3.0 Total water content of system litres 25 50 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 For system volumes other than those given above, multiply the system volume by the factor across Table R.2: Sizing of additional expansion vessel 2.7 5.4 10.9 13.6 16.3 19.1 21.8 24.5 27.2 30.0 32.7 35.7 38.1 40.9 43.6 46.3 49.0 51.8 54.5 3.9 7.8 15.6 19.5 23.4 27.3 31.2 35.
GENERAL REQUIREMENTS Pump specifications Circulating pump The circulating pump is included in the boiler. The pump head available for the heating system is shown in fig. R.7. Lift [mbar] 700 650 600 550 500 450 System by-pass 400 350 300 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.
BOILER INSTALLATION SEQUENCE |y ,, y { yyy ,,, | z y , ,, z y , | { y ,,,,,,,,,, yyyyyyyyyy General 440 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.
BOILER INSTALLATION SEQUENCE 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 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). 320 131 105 131 Note: If the boiler is to be fitted in a timber framed building ensure that the bracket is secured to a substantial part of the timber frame capable of taking the weight of the boiler.
BOILER INSTALLATION SEQUENCE Removing boiler casing 90° 90° ● 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. 1 VRC-VC I 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.
Gas supply (TURBOmax Plus) ● Connect the 15 mm compression gas service cock (1) and 15 mm copper outlet tail (3) as supplied with the appliance (2) and tighten. ● Connect a gas supply pipe of not less than 15 mm diameter to the copper tail. ● Tighten all connections. (Ensure the gas supply pipework is adequately sized such that a 20 mbar gas pressure is available at the boiler inlet at full flow rate). I 0 3 1 Fig. I.
BOILER INSTALLATION SEQUENCE TURBOmax Plus 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. I 0 ● Connect the 15 mm cold water inlet pipe copper tail (4) to the cold water service valve (1) and tighten.
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.
BOILER INSTALLATION SEQUENCE Gas supply (THERMOcompact) ● Connect the 15 mm compression gas service cock (1) and 15 mm copper outlet tail (3) as supplied with the appliance and tighten. ● Connect a gas supply pipe of not less than 15 mm diameter to the copper tail. ● Tighten all connections. (Ensure the gas supply pipework is adequately sized such that a 20 mbar gas pressure is available at the boiler inlet at full flow rate). I THERMOcompact 0 3 1 Fig. I.
BOILER INSTALLATION SEQUENCE Central heating flow and return pipework (THERMOcompact) ● 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. I 0 ● Connect the 22 mm copper pipe tails to the service valves as shown in the illustration and tighten the nuts.
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. 28 Connect the flue system to the boiler ● Refer to separate air/flue duct installation instructions included with the boiler.
BOILER INSTALLATION SEQUENCE 29
BOILER INSTALLATION SEQUENCE Electrical installation General requirements All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations). 3 The boiler is supplied for connection to 230 V, ~ 50 Hz supply fused at 3 A rating. Connection to the mains supply shall be made via a fused 3 pin plug to an unswitched shuttered socket, both complying to the requirements of BS1363.
BOILER INSTALLATION SEQUENCE Caution Mains connection terminals L and N remain live even when the boiler on/off control is switched off. Connection to the main supply ● Lower the control panel. ● Unclip the terminal box cover (1) from the control panel (2). ● Refit the terminal box cover by pushing into place until it clips back into position. ● Feed the power supply cord in to the appliance as shown (fig I.11). ● Raise the control panel and secure in place. ● Use cable clamps.
BOILER INSTALLATION SEQUENCE Electronic board layout Socket X2 for internal unit components Socket X4 for minority reversing valve Socket X7 for accessory box connection Socket X8 for VRC-VC connection 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 F1 Fig. I.
Controls (TURBOmax Plus boiler) Connection details for programmable thermostats ACL Drayton Lyfestyle PT271, PT371 L L N 3 ACL Drayton Digistat 2, 3, 4 1 2 3 N 3 ACL Drayton Digistat RF - SCR Receiver Danfoss Randall TP4, TP5, TP5E 1 2 3 4 External electrical controls 4 The boiler terminals 3, 4 and 5 are for connecting external electrical controls such as a time switch and/or room thermostat.
BOILER INSTALLATION SEQUENCE Connection details for external time switches and boiler terminal strip. Connection details for time switch L L N 3 ACL Drayton Switchmaster SM300 L N 1 L N 4 ACL Drayton Switchmaster 980 L N 1 L N 4 Danfoss Randall 103 Series 1 2 Danfoss Randall Set 1E, TS975 L N E L N E L N L N 3 L N 1 N 3 4 Danfoss Randall TS715 Grässlin Towerchron QE1, QM1 3 2 3 2 3 Fig. I.
BOILER INSTALLATION SEQUENCE Controls (THERMOcompact boiler) Connection details for control systems utilising 3 port motorised valve via external wiring centre/junction box Diagram only applies to the specific controls mentioned THERMOcompact terminal strip Programmer for programmer connections see fig. 16.
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.
BOILER INSTALLATION SEQUENCE Thermostatic radiator valves Anti-cycling ‘economiser’ control The boiler has a built in automatic bypass valve making it ideal for use in systems with thermostatic radiator valves (no separate system bypass is required). The boiler incorporates a built in anti-cycling control to ensure that energy wasteful short cycling of the boiler cannot occur.
BOILER INSTALLATION SEQUENCE 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). ● Secure control panel by turning both securing fasteners (3) clockwise by 90°. ● Fit and close front door (4). 1 ● Fit lower cover plate (5) using the screws supplied. I 0 2 90° 90° 3 I 0 4 Fig. I.
COMMISSIONING PART I 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. Gas supply The complete gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with BS 6891. The gas supply to the boiler can be purged by slackening the gas service valve beneath the boiler.
COMMISSIONING PART I TURBOmax Plus 1 2 Fig. Com.
COMMISSIONING PART I Proceed as follows to fill the system: ● Open all radiator valves on the system. ● Check flexible filling loop is connected. ● Locate the filling valve handle (1) on the valve as shown. ● Open the valve slowly and fill the unit with water until the required amount has been added (2). ● Bleed the air from the radiators. ● The boiler is equipped with an automatic air release valve. To allow this to vent the boiler, the cap top must be slackened by 1 - 2 turns.
COMMISSIONING PART I Filling the heating system (THERMOcompact) The boiler and the heating system should be filled using a filling method as described on page 16. ● Ensure that the boiler CH service valves are open. THERMOcompact ● 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.
THERMOcompact COMMISSIONING PART I 43
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) ☞ picture shows a TURBOmax Plus boiler Gas inlet working pressure 1 To check the gas inlet working pressure: ● Lower the front panel of the boiler. ● Lower the control panel. ● Slacken the sealing screw (1) located at measuring point „P.IN”. ● Attach U-gauge to the inlet test point on the gas valve (2). ● Ensure that the gas service valve is open. ● Turn off the boiler at the main ON/OFF control. 2 Fig. G.
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) U-Gauge connection points for Natural gas 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. picture shows a TURBOmax Plus boiler 1 For natural gas appliances: Slacken the sealing screw (1) at test point on the gas valve and attach one arm of a U-gauge (2) to the test point.
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) This illustration shows the U-tube pressure gauge connected to a system configured to run on natural gas. When connecting the U-tube pressure gauge to a system running on LPG, please refer to Fig. G.2 on page 45. ☞ picture shows a TURBOmax Plus boiler Adjusting the central heating output (range rating) The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler.
Euro B/S 066/0 Euro B/S 065/0 1 Simultaneously press the „i” and 2 Keep the „+” button pressed until „+” buttons keys. Euro B/S 067/0 GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) 3 Press the „i” button and a value „d.0” is displayed. between 1 and 15 will be displayed. (The display runs from „d.0” to „d.99” before restarting again at „d.0”.) 4 Use the „+” or „-” buttons to increase or decrease the value.
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Adjusting the ignition rate 1 ● Undo screw and remove the cap (1). ● TURBOmax only: Disconnect the modulating coil wires (2) from the gas valve, 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.
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Adjusting to the maximum heat load (nominal load) ● 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. - Continue holding „+” button until display alternates between „P1” and „P2”. Release „+” button.
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Burner Pressure THERMOcompact 615/2 E Delivered gas Ignition 6.5 rate Output [kW] 8.0 10.0 12.0 14.0 15.0 Burner pressure and gas rate Burner pressure1) [mbar] Natural gas 2H Main burner jet mark2) 7/120 for G20 2.3 2.3 3.3 5.0 7.0 9.3 10.5 for G30 5.8 5.8 8.1 11.9 16.3 21.5 24.3 for G31 7.5 7.5 10.5 15.4 21.2 27.9 31.
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Gas Rate THERMOcompact 615/2 E Delivered gas Output [kW] 6.5 8.0 10.0 12.0 14.0 15.0 0.8 1.0 1.3 1.4 1.7 1.7 Gas Rate1) [m3/h] Natural gas 2H Main burner jet mark2) 7/120 for G20 Gas Rate THERMOcompact 620/2 E Delivered gas Output [kW] 7.7 8.0 10.0 12.0 14.0 16.0 18.0 20.0 0.9 1.0 1.2 1.4 1.7 1.9 2.1 2.
FUNCTIONAL CHECKS (COMMISSIONING PART III) Functional checks Procedure I Once the unit has been installed and the gas supply has been checked, operate the system to ensure that it is working correctly. 0 ● Operate the system, following the operating instructions supplied with the boiler. ● Check the system for water leaks and escaping gas. ● Check that the flue has been correctly installed, according to the fitting instructions supplied with the flue assembly.
Functional check of operation (TURBOmax Plus only) This boiler is fitted with indicator lights to display the operating status of the boiler. The status of the indicators in normal operation will be as follows. 1 Boiler in stand by mode 3 ● Red lock out indicator (1) OFF. 2 ● Yellow flame indicator (2) OFF. ● Green warmstart indicator (3). - ON – Warmstart ON - OFF – Warmstart OFF Hot water operation Fig. F.2: Functional check TURBOmax Plus Euro B/S 071/0 ● Fully open hot water tap.
FUNCTIONAL CHECKS (COMMISSIONING PART III) Functional check of operation (THERMOcompact only) This boiler is fitted with indicator lights to display the operating status of the boiler. The status of the indicators in normal operation will be as follows. 1 Boiler in stand by mode 3 ● Red lock out indicator (1) OFF. THERMOcompact 2 ● Yellow flame indicator (2) OFF. ● Green indicator (3) has no function. Central Heating/hot water operation ● Operate the heating/hot water Fig. F.
FUNCTIONAL CHECKS (COMMISSIONING PART III) ☞ Adjusting pump speed picture shows a TURBOmax Plus application The unit is fitted with a two-speed pump. The pump is delivered with the switch (1) set to position II.
FUNCTIONAL CHECKS (COMMISSIONING PART III) Handing over to the user Set the maximum radiator temperature control to the desired setting. Set the maximum hot water temperature control to the desired setting.
SERVICING 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).
SERVICING Cleaning the burner and primary heat exchanger ● Turn off the boiler. ● Isolate the electrical supply to the 2 boiler. ● Remove the boiler case as described on page 22. 1 ● Turn off the gas service valve. ● 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) and then remove the flue gas connector (2a) on the fan. ● Remove the retaining spring (3).
PARTS REPLACEMENT Safety instructions The following safety instructions are to be followed when installing replacement parts! Fig. E.1: General Euro B/S 006/0GB Ensure that ALL regulations are observed. After installing replacement parts, recommission and check boiler function as described in commissioning section.
PARTS REPLACEMENT Burner ● Refer to the important information and initial preparation on page 59. ● Remove combustion chamber cover by unclipping the three clamps. 1 2 ● Disconnect the ignition and flame sensing leads. 2 ● Remove electrode bracket supporting screw (1) and then remove the electrodes (2). ● Remove two screws (3) and pull burner (4) forwards to remove. ● Reassemble in reverse order. 3 Euro B/S 157/0 4 Fig. E.
PARTS REPLACEMENT Fan ● Refer to the important information and initial preparation on page 59. ● Remove combustion chamber cover by unclipping the three clamps (1). 2 ● Remove the screw (3) and push the flue connector (4) upwards until it clears the fan outlet (when the boiler is installed with a rear outlet flue system push the flue connector (4) towards the rear of the boiler until it clears the fan outlet). 1 ● Disconnect the electrical connections (5) and the air tubes (6 and 7) from the fan.
PARTS REPLACEMENT ☞ 2 Gas valve picture shows a TURBOmax Plus boiler ● Refer to the important information and initial preparation on page 59. 1 ● Loosen screw and pull electrical plug off the gas valve. ● Pull off the two modulating coil wires. 4 ● Disconnect air tube from gas valve. ● Undo nut (1) on the gas valve outlet connection. 3 ● Undo compression nut on the outlet of the gas service valve.
PARTS REPLACEMENT ☞ Temperature sensors (NTC’S) picture shows a TURBOmax Plus boiler ● Refer to the important information and initial preparation on page 59. ● Identify which sensor(s) is to be replaced. 2 ● If required remove combustion chamber cover by unclipping the three clamps. 1 ● Pull off connecting wire from sensor. ● Unscrew NTC sensor (1,2 or 3). ● Replace NTC sensor. ● Reassemble in reverse order. 3 NTC sensor 3 for TURBOmax Plus only. Euro B/S 163/0 ☞ Fig. E.
PARTS REPLACEMENT ☞ Expansion vessel picture shows a TURBOmax Plus boiler 1 2 3 Fig. E.9: Expansion vessel 64 Euro B/S 164/0 4 Please note: In the unlikely event of a failure of the CH expansion vessel follow procedure depending upon the installation circumstances. Boiler installed with top connection air/flue duct to left/right hand side, or vertical flue installation (where 500 mm clearance exists about the boiler). ● Refer to the important information and initial preparation on page 59.
PARTS REPLACEMENT 2 2 1 Electronic control board 1 ● Refer to the important information and initial preparation on page 59. ● Lower control box. ● Unclip the terminal box cover by releasing the cover retaining clips and lift to remove. ● Unclip the electronic board cover by releasing the clips (2) and lift to remove. 4 4 ● Disconnect both HT leads from electronic board. ● Unplug all leads from the board. ● Disconnect main power supply and any external controls.
PARTS REPLACEMENT ☞ Pump picture shows a TURBOmax Plus boiler ● Refer to the important information and initial preparation on page 59. ● Release central heating water pressure. 3 ● Unclip the terminal box cover by releasing the cover retaining clips and lift to remove. ● Unplug the pump wire (2) from the electronic board. ● Undo the three pump screws (3). ● Pull pump forward to remove. ● Fit new ‘O’ rings supplied to pump connections. 1 ● Re-assemble in reverse order. Euro B/S 167/1 2 Fig. E.
PARTS REPLACEMENT ☞ Automatic bypass picture shows a TURBOmax Plus boiler ● Refer to the important information and initial preparation on page 59. ● Release central heating water pressure. ● Remove spring clip (2) 2 3 ● Undo union (1), remove bypass/connecting pipe. 1 ● Pull apart bypass and connecting pipe. Euro B/S 169/0 ● Re-assemble in reverse order. Fig. E.
PARTS REPLACEMENT TURBOmax Plus Diverter valve (TURBOmax Plus only) 5 ● Refer to the important information and initial preparation on page 59. 4 ● Release central heating water pressure. ● Disconnect the plug (4) from the diverter valve. ● Remove the spring clip (5). ● Undo the unions (6) and remove the diverter valve. ● Re-assemble in reverse order. 6 Euro B/S 170/0 7 Fig. E.
DHW heat exchanger (TURBOmax Plus only) 1 ● Refer to the important information and initial preparation on page 59. ● Release central heating water pressure. 3 ● Remove the diverter valve and pump as previously described. 4 ● Disconnect wire from the NTC. 2 ● Remove the spring clips (3 and 4). ● Undo the bottom left hand union (2). ● Push the heat exchanger (5) backwards to disconnect. ● Re-assemble in reverse order. Euro B/S ???/0 5 Fig. E.
PARTS REPLACEMENT Checking functions Procedure I On completion operate the system run to ensure that the boiler is working correctly. 0 ● Operate the system, following the operating instructions supplied with the boiler. ● Check the system for water leaks and escaping gas. ● Check that the flue has been correctly installed, according to the separate flue instructions. ● Check the burner for correct ignition and flame picture. ● TURBOmax Plus only: Check the hot water system for correct operation. Fig.
FAULT FINDING 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.
FAULT FINDING TURBOmax Plus Indicator lights (TURBOmax Plus only) The boiler control panel also contains three indicator lights whose function is as follows: ● Red lock out indicator (1), when illuminated boiler is at lock out. 1 ● Yellow flame indicator (2), when illuminated main burner is ignited. 3 2 ● Green warmstart indicator (3) Illuminated = Warmstart switched ON Not illuminated = Warmstart is switched OFF and there is no demand for hot water Fig. St.
FAULT FINDING Logical fault finding procedure These checks must be carried out before attempting to use the fault finding guide. 1. Carry out electrical safety checks (See Section ‘Preliminary Electrical Checks’). 2. Check that the external electricity supply to the boiler is on, and a supply of 230 V~ is present between boiler terminals ‘L’ and ‘N’. 3. Check that the gas supply to the boiler is on, that it has been correctly purged and that an inlet pressure of 20 mbar is available at the gas valve.
FAULT FINDING Status Mode To display status mode proceed as follows: To cancel the status code mode proceed as follows: The status mode provides information about the current operating status of the boiler. ● 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). ● Press the„i” button below the display or Display Indication ● Do not press any key for approximately four minutes.
FAULT FINDING 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“. Display ● Use „+“ or „-“ buttons to scroll up or down to the desired diagnosic number. ● Press „i“ button to display the corresponding diagnosic information.
FAULT FINDING Display Indication Displayed values/adjustment values d.37 Modulator current mA d.40 Actual flow temperature °C d.45 Not applicable d.46 Not applicable d.47 Not applicable d.50 Maximum flow temperature d.53 Not applicable d.54 Not applicable d.60 Number over heat cut off operations d.61 Number of lock outs d.64 Average ignition time s d.65 Maximum ignition time s d.67 Remaining anti cycling period min d.68 Number of unsuccessful attempted 1st ignitions d.
FAULT FINDING Fault codes Fault memory To cancel fault error memory display mode, proceed as follows: 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. The fault memory stores details of the ten most recent faults. ● Press the „i“ and „-“ buttons simultaneously. ● Use the „+“ button to scroll back through the list of memorised errors.
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 switch on electronic board For test purposes, disconnect external controls fr
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.
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 pitot tube (in fan outlet) and air hoses are not obstructed and correctly aligned. Check or replace air pressure switch. Does the fan run now? Yes Yes No Check electrodes and electrode leads. Replace as necessary. Check status code (see page 52) is S.
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 running? Check water pressure in central heating system, refill and vent.
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.22 No No Yes Does burner flame modulate/ go out when radiator temperature control is turned left to the horizontal position at flow temperature of approx.
No No Check/replace hall sensor Does hot water indicator glow/flash now? Draw hot water at high rate Yes No Yes Yes Normal operation carry out electrical safety checks Check hot water flow rate and temperature. Compare with technical data, if flow is not sufficient check incoming main and cold water filter.
DIAGRAMS TURBOmax Plus Functional Flow diagram: TURBOmax Plus 824/2 E, 828/2 E CONTROL BOX MAIN SWITCH F2A L 1 2 N Burner lock out indicator (red) Ignition indicator MAIN TRANSFORMER Hot water/warmstart demand indicator 230V 20V POWER SUPPLY display F1,25A MAIN SWITCHBOARD AIR PRESSURE SWITCH gr gr plug in connector b FAN br y/g plus / minus buttons b br reset button PUMP info button DIVERTER VALVE p y/g p p t bl bl bl bl w NTC RETURN TEMPERATURE SENSOR br Legend b br y/g
DIAGRAMS Functional Flow diagram: THERMOcompact 615/2 E, 620/2 E, 624/2 E, 628/2 E CONTROL BOX MAIN SWITCH F2A L 1 2 N THERMOcompact 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 b 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 blue brown yellow/green red pink orange
Euro B/S 029/1_GB X2 T 1,25 X1 3 4 5 X3 X14 X13 U100 T2 Pressure warmstart X2 NTC return Pump TURBOmax Plus NTC return 1 NTC earth 2 NTC flow Lifting magnet Aqua sensor Bridge Ionisation electrode 3 13 9 8 20 7 19 6 18 NTC flow 5 17 4 3 15 2 14 1 13 Water sensor X12 4 14 16 X2 L N 5 15 7 8 9 6 16 X4 (VUV) X7 Accessories X8 7 17 21 Gas valve 8 18 Switchgear cabinet Diverter valve 9 19 Aqua sensor Pressure sensor 4 20 Ignition electrodes 22 10 Ionisation elect
Euro B/S_VC_018/1 T 1,25 X1 X3 X14 X13 U100 T2 NTC earth X2 NTC return Pressure sensor 1 NTC flow Lifting magnet Bridge Ionisation electrode 2 X12 3 13 22 10 X2 3 4 5 4 14 NTC flow 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1 13 X2 L N 5 15 9 21 7 8 9 6 16 X4 (VUV) X7 Accessories X8 7 17 Pump 22 10 Gas valve 8 18 Switchgear cabinet Pressure sensor 9 19 Ignition electrodes 4 20 Ionisation electrode EV1 21 Fig. D.
SHORT PARTS LIST Description Part No. Key No. Burner, natural gas Burner chamber group 615E: 031508 Burner chamber group 620E: 031509 Burner chamber group 624E/824E: 031500 Burner chamber group 628E/828E: 031501 Distributor tube 615E: 126762 Distributor tube 620E: 126751 Distributor tube 624E/824E: 126752 Distributor tube 628E/828E: 1267523 Er.1 Ignition electrode Flame sensing electrode 090724 Er.2 Fan 190215 Er.
Er.7 Er.10 90 * TURBOmax Plus only Euro B/S 144/0 Er.12 Euro B/S 151/0 Euro B/S 152/0 Er.9 Euro B/S 154/0 Euro B/S 142/1 Er.11 Euro B/S 177/1 Er.8 Er.6 Euro B/S 146/0 Er.5* Er.3 Euro B/S 156/0 Euro B/S 143/0 Er.2 Euro B/S VC 057/0 Er.4 Euro B/S 148/0 Er.
Er.14 Euro B/S 145/0 Er.17 Euro B/S 178/0 Er.16* Euro B/S 149/0 Er.13* Euro B/S 155/1 Er.
Service Solutions Technical Advice 0870 01634 6060 777 292392 83 37 86 GB10 · 05/2001 Mü · Printed on 100 % recycled paper · Subject to alteration Head Office Vaillant Ltd.
