Related Manuals for Vaillant turboMAX pro 24/2 E
Summary of Contents for Vaillant turboMAX pro 24/2 E
- Page 1 For the installer Instructions for Installation and Servicing turboMAX pro Wall hung room sealed fan assisted 24/2 E 28/2 E combination and system boilers...
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Page 2: Table Of Contents
Table of Contents List of Contents ..... Gas supply adjustments (Commissioning Part II) 21 Contents included with boiler (turboMAX pro)3 Gas inlet working pressure . -
Page 3: List Of Contents
List of contents 1 1 List of contents 1.1 Contents included with boiler Ensure that all contents are included before commen- cing installation. Note! DO NOT remove the boiler from the polystrene base at this stage. Fig. 1.1: Items supplied with unit (turboMAX pro) Item Quantity Description Boiler... -
Page 4: Introduction
The data badge is fitted on the rear of the control panel. See text of General Requirements for installation requi- 2.1 General Information rements or notes. Vaillant ltd. support the Benchmark initiative. Note! In this installation manual you will find the Benchmark This boiler must be installed and serviced by a gas boiler commissioning checklist. -
Page 5: Boiler Specification
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... -
Page 6: Boiler Connections
3 Boiler Specification 3.2 Boiler connections 3.3 Functional Diagram Fig. 3.1: Connection diameters turboMAX pro Key: Heating system return (22 mm tail) Cold water connection with shut off valve (15 mm tail) Gas connection (15 mm tail) Hot water connection (15 mm tail) Fig. -
Page 7: General Requirements
BS 6891. Preliminary remarks 4.4 Flue system This appliance should only be installed in conjunction with a Vaillant flue system. Note! Install the flue system as detailed in the separate flue The boilers are delivered ready for installation installation instructions supplied with this boiler. -
Page 8: Top Outlet Flue System
4 General Requirements 4.4.1 Top outlet flue system 4.4.2 Rear outlet flue system (100 mm outside diameter) (100 mm outside diameter) The top outlet horizontal flue system (Art. No. 303 807) The rear outlet horizontal flue system (Art. No. 303 817) is suitable for installations up to 720 mm measured from is suitable for installations up to 600 mm wall thickness. -
Page 9: Flue Termination
General Requirements 4 4.4.4 Flue termination Terminal position for fan-assisted flue The following details refer to both flue systems. (minimum distance) a. The terminal must be positioned such that the pro- Directly below an openable, above an opening ducts of combustion can disperse freely at all times. or horizontal to an opening i.e. -
Page 10: Guide To System Requirements
4 General Requirements Important! 4.8.4 Pressure gauge This appliance must be earthed. This is factory fitted to the boiler and indicates the primary circuit pressure to facilitate filling and testing. 4.8 Guide to system requirements 4.8.1 Water circulation system Detailed recommendations for the water circulation 4.8.5 Expansion vessel system are given in BS 6798 and BS 5449: Part 1 (for The 24 kW boiler incorporate a 6 litre expansion vessel... -
Page 11: Circulating Pump
General Requirements 4 4.8.6 Circulating pump The circulating pump is included in the boiler. The pump head available for the heating system is shown in fig. 4.6. setting III setting II 1000 1100 1200 1300 1400 Volume flow [l/h] Fig. 4.6: Pump specifications 4.8.7 System by-pass An automatic system by-pass is included within the boi- ler. -
Page 12: Boiler Installation Sequence
5 Boiler Installation Sequence 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 clearan- ces 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... -
Page 13: Using Boiler Template
Boiler Installation Sequence 5 5.2 Using boiler template Note! Fix the paper template to the wall ensuring that the cor- Use alternative fixing holes where necessary. rect flue exit point has been identified, ensure that the template is vertical. Identify correct flue exit The template shows Mark the centre of the selected air/flue duct and its cir- - The position of the fixing holes for the boiler moun-... -
Page 14: Install The Flue System
5 Boiler Installation Sequence 5.4 Install the flue system 5.7 Gas supply Install the flue system (refer to separate air/flue duct • Connect the 15 mm compression gas service cock (1) installation instructions). supplied with the appliance (2) and tighten. •... -
Page 15: Cold Water Mains Inlet And Hot Water Outlet
Boiler Installation Sequence 5 5.8 Cold water mains inlet and hot water outlet 5.9 Central heating flow and return pipework Flush all foreign matter from the mains supply before Before connecting the heating circuit to the boiler appli- connecting to the boiler. ance, all pipework and radiators must be thoroughly •... -
Page 16: Connect The Flue System To The Boiler
5 Boiler Installation Sequence 5.10 Connect the flue system to the boiler • Refer to separate air/flue duct installation instructions included with the boiler. 5.11 Electrical installation General requirements Important! All electrical work shall be carried out by a competent person and shall comply with BS7671 (IEE Regulations). -
Page 17: Electronic Board Layout
Boiler Installation Sequence 5 5.13 Electronic board layout Socket X2 for internal unit components Socket X4 for minority reversing Socket X7 for accessory box connection Socket X8 for VRC-VC connection Do not use! Mains power supply: connections L, N and earth Room thermostat, 230 V: connections 3, 4 and 5 Socket X12: pump connection Socket X14: gas valve connection... -
Page 18: Controls
Fig. 5.14). Fig. I.12 shows the connection details where a pro- grammable room thermostat (time switch with built in Vaillant optional plug in timer accessories room thermostat) is used to control the boiler. Refer to the instructions supplied with the optional accessories for connection details. - Page 19 Boiler Installation Sequence 5 Automatic pump spin control (APS) DO NOT USE IN UK! 20 VDC The boiler incorporates a built in control which will spin the built in circulating pump and operate the diverter valve (turboMAX only) once in a 24 hour period. This control helps to prevent seizure when the boiler is not MAINS SUPPLY...
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Page 20: Commissioning Part I
6 Commissioning Part I 6 Commissioning 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. 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. -
Page 21: Gas Supply Adjustments (Commissioning Part Ii)
Gas supply adjustments (Commissioning Part II) 7 7 Gas supply adjustments 7.2 Main burner pressure The burner pressure on this appliance has been factory 7.1 Gas inlet working pressure set and does not require adjustment. To check the main To check the gas inlet working pressure: burner pressure connect the U-Gauge as follows depen- •... -
Page 22: Adjusting The Central Heating Output (Range Rating)
7 Gas supply adjustments (Commissioning Part II) Set the DHW temperature control to maximum and fire the boiler at full rate by fully opening a hot water tap. Check that the burner pressure is as the maximum shown in table 7.1. Measure the domestic hot water mode burner operating pressure (mbar), the heat input (kW), the inlet and outlet domestic hot water temperatures (°C) and flow rate... -
Page 23: Burner Pressure And Gas Rate
Gas supply adjustments (Commissioning Part II) 7 7.4 Burner Pressure and gas rate Burner Pressure turboMAX pro 24/2 E Delivered gas Output[kW] Ignition rate 8.9 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 Natural gas 2H Burner pressure [mbar] Main burner jet mark... -
Page 24: Fit Combustion Chamber Cover
7 Gas supply adjustments (Commissioning Part II) 7.5 Fit combustion chamber cover Carefully re-fit the combustion chamber cover to the boiler ensuring it is correctly sealed. Secure cover with retaining clamps. 7.6 Fit boiler casing • Carefully push case (1) onto the boiler such that the locating points either side at the top of the boiler engage. -
Page 25: Functional Checks (Commissioning Part Iii) 8
8.2 Functional check of operation • Ensure external controls are calling for heat. The Vaillant turboMAX pro is equipped with a set of dia- • The central heating demand indicator will illuminate gnostic indicator lights to show the operational (3). -
Page 26: Adjusting Pump Speed
To ensure regular servicing, it is strongly recom- mended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details. • Ensure the Benchmark gas boiler commissioning checklist is fully completed. -
Page 27: Servicing
Servicing 9 9 Servicing 9.1 Initial Inspection To ensure the continued safe and efficient operation of the boiler it is recommended that it is checked and ser- viced 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. -
Page 28: Cleaning The Burner And Primary Heat Exchanger
9 Servicing 9.2 Cleaning the burner and primary heat exchanger • Turn off the boiler. • Isolate the electrical supply to the boiler. • Remove the boiler case as described. • Turn off the gas service valve. • Turn off the boiler CH service valves. •... -
Page 29: Fault Finding
Fault Finding 10 10 Fault Finding To reset the appliance after a lockout (either burner lockout illuminated or any other indicator light flas- 10.1 Introduction hing), turn the central heating control to the reset positi- The turboMAX pro has built in diagnostic indicator lights on and release. - Page 30 Check electrical supply, appliance fuses and on/off control Sheet A Ensure boiler main Does green power on ON/OFF control is set Go to sheet C indicator glow? to position "1" Boiler ON/OFF control defective, Is 230VAC present across Repair external fault change electronic terminals L and N? board...
- Page 31 Check operation of pump and fan Sheet B Turn off the main ON/OFF control to the "0" position Diconnect the power supply to the boiler Replace fuse F1 Turn the main ON/OFF control to the "1" position Check transformer 230 VAC primary (black/red) and approx.
- Page 32 Check central heating and controls Sheet C Ensure that radiator temperature control knob is set to vertical position and that any internal timer (if fitted) is calling for heat Does yellow central heating demand Does yellow flame indicator flash? Go to sheet D indicator glow? Does ignition Is 230 VAC present across terminals 4 and 5...
- Page 33 Check flue and ignition system Sheet D Does the boiler Are electrodes sparking at Does fan run after approx. 30 secs.? Go to sheet E commence ignition the burner? Check electrodes and Does yellow fan operation Does yellow fan electrode leads. indicator glow? operation indicator flash? Replace as necessary.
- Page 34 Check gas valve and central heating system pressure Sheet E Does burner light 1st Is burner indicator Does burner shut down after Go to sheet F attempt? illuminated? approx. 15 secs. Check flame Does burner light within 3 Reset boiler rectification lead and ignition attempts? Does yellow ignition indicator flash?
- Page 35 Check operation of burner and modulation Sheet F Does burner flame modulate/ go Does flame indicator glow and out when radiator temperature Does heating flow pipe flames increase in size to full gas control is turned left to the Go to sheet G temperature rise? rate after approx.
- Page 36 Check D.H.W operation Sheet G Check hot water flow rate and temperature. Does yellow hot water Compare with technical data, if flow is not Draw hot water at high rate demand indicator glow? sufficient check incoming main and cold water filter.
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Page 37: Diagrams 11
Diagrams 11 11.1 Functional Flow diagram: turboMAX pro 24 E and 28 E control box main switch main transformer 230V power supply F1,25A main switchboard Burner lock out indicator (red) pressure Flame indicator switch Ignition indicator Fan operation indicator Central heating demand indicator Hot water demand indicator... -
Page 38: Wiring Diagram
11 Diagrams 11.2. Wiring diagram: turboMAX pro 24 E, 28 E Instructions for Installation and Servicing turboMAX pro R3...