Related Manuals for Vaillant TURBOmax Pro 28
Summary of Contents for Vaillant TURBOmax Pro 28
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Page 1: Installation And Servicing
INSTRUCTIONS FOR INSTALLATION AND SERVICING TURBOmax Pro 28/2 E Wall hung room sealed fan assisted combination boilers The code of practice for the installation, commissioning & servicing of central heating systems... -
Page 2: Table Of Contents
TABLE OF CONTENTS List of Contents Contents included with boiler ....4 Introduction General information ......5 EC designation . - Page 3 TABLE OF CONTENTS Gas supply adjustments Gas inlet working pressure .....34 Main burner pressure ......35 (Commissioning Part II) Adjusting the central heating output (range rating) .
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Page 4: Contents Included With Boiler
LIST OF CONTENTS Contents included with boiler Instructions for Use Ensure that all contents are included BEDIENUNGSANLEITUNG before commencing installation. BEDIENUNGSANLEITUNG BEDIENUNGSANLEITUNG BEDIENUNGSANLEITUNG BEDIENUNGSANLEITUNG DO NOT remove the boiler from the Fig. L.1: Items supplied with unit polystrene base at this stage. Item Quantity Description... -
Page 5: Introduction
See text of General Requirements for installation requirements or notes. The boiler has been designed for use with a sealed central heating system, Vaillant ltd. support the Benchmark and comes fully tested and assembled initiative. Within the information with a built in circulating pump, pack, you will find a Benchmark Log expansion vessel and diverter valve. -
Page 6: Boiler Specification
BOILER SPECIFICATION Technical data TURBOmax Pro 28/2 E Units ( VUW GB 282/2-3) Maximum CH heat input (net) 31.1 (106 200) kW (Btu/h) 10.4 - 28 CH heat output range (80/60 °C) kW (Btu/h) (35 500 - 95 500) Maximum DHW heat input (net) 31.1 (106 200) -
Page 7: Boiler Connections
BOILER SPECIFICATION Boiler connections Key: Heating system return (22 mm compression) Cold water connection with shut off valve (15 mm compression) Gas connection (15 mm compression) Hot water connection (15 mm tail) Heating system flow (22 mm compression) Flue outlet (100 mm flue with turret) Hanging bracket Fig. -
Page 8: Functional Diagram
BOILER SPECIFICATION Functional Diagram 1 Air duct 2 Fan 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... -
Page 9: General Requirements
Preliminary remarks water supplies for domestic premises. This appliance should only be BS 6700: Services supplying water installed in conjunction with a Vaillant for domestic use within buildings and flue system. their curtilages. Install the flue system as detailed in... -
Page 10: Boiler Location
GENERAL REQUIREMENTS Boiler location Gas Supply The location chosen for the boiler The gas supplier should ensure the must permit the provision of a availability of an adequate supply of satisfactory flue termination. The gas. location must also provide adequate A gas meter may only be connected space for servicing and air circulation to the service pipe by the supplier of... -
Page 11: Flue System
GENERAL REQUIREMENTS Flue system Note: The TURBOmax Pro boiler is 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. -
Page 12: Flue Termination
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. b. In certain weather conditions a plume of water vapour may be visible from the flue terminal. -
Page 13: Air Supply
GENERAL REQUIREMENTS Air supply Cupboard or compartment Electrical supply ventilation Detailed recommendations for air A 230 V, ~ 50 Hz single phase supply are given in BS 5440: Part 2. electricity supply fused to 3 Amp. TURBOmax Pro combination boilers must be provided in accordance with are very high efficiency appliances. -
Page 14: Guide To System Requirements
GENERAL REQUIREMENTS Guide to system Water circulation system Filling and make up requirements Detailed recommendations for the The system should be filled with water water circulation system are given in via a seperate filling point at a BS 6798 and BS 5449: Part 1 (for convienient position on the heating small bore and micro bore central cicuit. -
Page 15: Expansion Vessel
GENERAL REQUIREMENTS Expansion vessel Vessel Volume [L] Initial system pressure (bar) The 28 kW boiler incorporates a Pressure relief valve setting (bar) 10 litre expansion vessel which is Total water content of system suitable for a sealed heating system litres with a maximum water content of 100 litres. -
Page 16: Circulating Pump
DHW expansion vessel accessory A DHW expansion vessel kit (Art.No 306 237) is available as an optional extra from Vaillant Ltd. This expansion vessel kit should be fitted to the boiler whenever, either a stop valve of the loose jumper type or a non return valve are present in the cold water mains supply to the boiler. -
Page 17: General
GENERAL REQUIREMENTS 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,... -
Page 18: Using Boiler Template
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). -
Page 19: Fitting The Boiler Hanging Bracket
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). 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... -
Page 20: Removing Boiler Casing
BOILER INSTALLATION SEQUENCE Removing boiler casing Turn both securing fasteners (1) anti-clockwise by 90° to release 90° 90° control panel. Lower 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. -
Page 21: Gas Supply
BOILER INSTALLATION SEQUENCE Gas supply Connect the 15 mm compression gas service cock (1) supplied with appliance and tighten. Connect a gas supply pipe of not less than 15 mm diameter to the inlet of 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... -
Page 22: Cold Water Mains Inlet And Hot Water Outlet
BOILER INSTALLATION SEQUENCE Cold water mains inlet and hot water outlet 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 of the appliance with the washer (2) provided and tigh- ten. -
Page 23: Central Heating Flow And Return Pipework
BOILER INSTALLATION SEQUENCE Central heating flow and return pipework 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 (4) and return (1) service valves to the appliance, tighten the nuts with the washers provided (5 and 2). -
Page 24: Electrical Installation General Requirements
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). The boiler is supplied for connection to 230 V, ~ 50 Hz supply fused at 3 A rating. - Page 25 BOILER INSTALLATION SEQUENCE Caution Connection to the main Mains connection terminals L supply and N remain live even when the boiler on/off control is Lower the control panel. switched off. Refit the terminal box cover by pushing into place until it clips Unclip the terminal box cover (1) back into position.
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Page 26: Connecting To The Main Supply
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 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 27: Thermostatic Radiator Valves
„ON“ terminal and boiler terminal 4 Fig. I.12 should be broken by the contacts of the room thermostat (see schematic layout, Fig. I.14). Vaillant optional plug in timer accessories Refer to the instructions supplied with the optional accessories for connection details. -
Page 28: Controls
BOILER INSTALLATION SEQUENCE For optimum fuel economy it is Connection details for time switch recommended that where TRV’s are used they are used in conjunction ACL Drayton with a programmable room Tempus 1, Tempus 2 thermostat or separate timer and Lyfestyle LP111, LP711 room thermostat to ensure complete ACL Drayton... -
Page 29: Fit Boiler Casing
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). -
Page 30: Commissioning Part I
COMMISSIONING PART I Preliminary electrical Gas supply Water supply checks The complete gas installation Open all domestic hot water taps including the gas meter must be supplied by the boiler, turn on the inspected, tested for soundness and mains water supply to the boiler and Check the electrical installation by purged in accordance with BS 6891. - Page 31 COMMISSIONING PART I...
- Page 32 COMMISSIONING PART I Fig. Com. 1: Draining the heating system...
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Page 33: Filling The Heating System
COMMISSIONING PART I Filling the heating Initial system flush system („cold“) The whole of the heating system must Proceed as follows to fill the system: be flushed out at least twice: once cold, and once hot as instructed later Open all radiator valves on the on page 41. -
Page 34: Gas Inlet Working Pressure
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Gas inlet working pressure To check the gas inlet working pressu- Lower the front panel of the boiler. Lower the control panel. Slacken the sealing screw (1) located at measuring point „MIN”. Attach U-gauge to the inlet test point on the gas valve (2). -
Page 35: Main Burner Pressure
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Main burner pressure U-Gauge connection points for Natural gas 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. -
Page 36: Adjusting The Central Heating Output (Range Rating)
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) This illustration shows the U-tube pressure gauge connected to a system Adjusting the central configured to run on natural gas. When connecting the U-tube pressure heating output gauge to a system running on LPG, please refer to Fig. G.2 on page 35. (range rating) The TURBOmax Pro is fully modulating for central heating, and it... -
Page 37: Burner Pressure And Gas Rate
GAS SUPPLY ADJUSTMENTS (COMMISSIONING PART II) Burner pressure and Gas Burner Pressure rate Ignition Delivered gas Output [kW] 10.4 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 28.0 rate Burner pressure [mbar] Natural gas 2H Main burner jet mark for G20 10.8 7/120 Burner pressure... -
Page 38: Functional Checks
FUNCTIONAL CHECKS (COMMISSIONING PART III) Functional checks Procedure Once the unit has been installed and the gas supply has been checked, operate the system to ensure that it is working correctly. Operate the system, following the operating instructions supplied with the boiler. -
Page 39: Operation
FUNCTIONAL CHECKS (COMMISSIONING PART III) Operation The Vaillant TURBOmax Pro is equipped with a set of diagnostic indicator lights to show the operational status of the boiler. A functional check of DHW and CH operation can be made using these indicator lights. - Page 40 FUNCTIONAL CHECKS (COMMISSIONING PART III) Heating system Ensure that the power on indicator is illuminated (1). Ensure that the maximum radiator temperature control is turned to the high position. Ensure external controls are calling for heat. The central heating demand indicator will illuminate (3).
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Page 41: Adjusting Pump Speed
FUNCTIONAL CHECKS (COMMISSIONING PART III) Adjusting pump speed The unit is fitted with a two-speed pump. The pump is delivered with the switch (1) set to position II. Important note: The boiler should only be operated at pump setting II because the heating capacity for hot water is reduced when operated at pump setting I! It is possible, however, to change the... -
Page 42: Handing Over To The User
To ensure regular servicing, it is strongly recommended that arrangements are made for a Maintenance Agreement. Please contact Vaillant Service Solutions (0870 6060 777) for further details. Ensure the boiler log book is fully completed and leave with the end user. -
Page 43: Initial Inspection
SERVICING Initial Inspection To ensure the continued safe and Before commencing any servicing or efficient operation of the boiler it is maintenance work, carry out an initial recommended that it is checked and inspection of the system as follows: serviced as necessary at regular Inspect the flue, pipework and intervals. -
Page 44: Cleaning The Burner And Primary Heat Exchanger
SERVICING Cleaning the burner and primary heat exchanger Turn off the boiler. Isolate the electrical supply to the boiler. Remove the boiler case as described on page 20. Turn off the gas service valve. Turn off the boiler CH service valves. -
Page 45: Safety Instructions
PARTS REPLACEMENT Safety instructions The following safety instructions are to be followed when installing replacement Ensure that ALL regulations parts! are observed. Important: Before starting any maintenance work: Isolate the mains electricity supply by disconnecting the plug at the socket outlet (if there is only an isolating switch remove the fuse from the switch). -
Page 46: Burner
PARTS REPLACEMENT Burner Refer to the important information and initial preparation on page 45. Remove combustion chamber cover by unclipping the three clamps. Disconnect the ignition and flame sensing leads. Remove electrode bracket supporting screw (1) and then remove the electrodes (2). Remove two screws (3) and pull burner (4) forwards to remove. -
Page 47: Fan
PARTS REPLACEMENT Refer to the important information and initial preparation on page 45. Remove combustion chamber cover by unclipping the three clamps (1). 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... -
Page 48: Gas Valve
PARTS REPLACEMENT Gas valve Refer to the important information and initial preparation on page 45. Loosen screw and pull electrical plug off the gas valve. Pull off the two modulating coil wires. Disconnect air tube from gas valve. Undo nut (1) on the gas valve outlet connection. -
Page 49: Temperature Sensors (Ntcs)
PARTS REPLACEMENT Temperature sensors (NTC’S) Refer to the important information and initial preparation on page 45. Identify which sensor(s) is to be replaced. If required remove combustion chamber cover by unclipping the three clamps. Pull off connecting wire from sen- sor. -
Page 50: Expansion Vessel
PARTS REPLACEMENT Expansion vessel 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). -
Page 51: Electronic Control Board
PARTS REPLACEMENT Electronic control board Refer to the important information and initial preparation on page 45. 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. -
Page 52: Pump
PARTS REPLACEMENT Pump picture shows a TURBOmax Plus boiler Refer to the important information and initial preparation on page 45. Release central heating water pressure. Unclip the terminal box cover by releasing the cover retaining clips and lift to remove. Unplug the pump wire (1) from the electronic board. -
Page 53: System Bypass
PARTS REPLACEMENT System bypass Refer to the important information and initial preparation on page 45. Release central heating water pressure. Remove spring clip (2) Undo union (1), remove bypass/connecting pipe. Pull apart bypass and connecting pipe. Re-assemble in reverse order. Fig. -
Page 54: Pressure Gauge
PARTS REPLACEMENT Pressure gauge Refer to the important information and initial preparation on page 45. Release central heating water pressure. Pull out the four retaining clips and remove the pressure gauge from fascia. Remove retaining clip and disconnect pressure gauge capillary tube. -
Page 55: Dhw Heat Exchanger
PARTS REPLACEMENT DHW heat exchanger Refer to the important information and initial preparation on page 45. Release central heating water pressure. Remove the diverter valve and pump as previously described. Disconnect wire from the NTC. Remove the spring clips (3 and 4). Undo the bottom left hand union (2). -
Page 56: Checking Functions
PARTS REPLACEMENT Checking functions Procedure On completion operate the system run to ensure that the boiler is working correctly. 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. -
Page 57: Introduction
FAULT FINDING Fault finding Flame indicator (yellow) 4) Ensure the heating system is full of water and charged to approx. Illuminates when flame is recognised by the flame monitoring system. 1 bar. If not refill the system and Introduction vent system. Ensure boiler flow and (A flashing indicator shows that an The TURBOmax Pro has built in NTC sensor is broken, not connected... -
Page 58: Fault Finding Charts
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Page 66: Functional Flow Diagram
DIAGRAMS Functional Flow diagram: TURBOmax Pro 28 E (VUW GB 282-3) 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... -
Page 67: Wiring Diagram
DIAGRAMS Wiring diagram TURBOmax Pro 28 E (VUW GB 282-3) Fig. D.2: Wiring diagram... -
Page 68: Short Parts List
SHORT PARTS LIST Description Part No. Key No. Burner chamber group: 031501 Burner, natural gas Distributor tube: 126753 Er.1 Ignition electrode 090724 Er.2 Flame sensing electrode 190215 Er.3 LPG: 053463 Gas valve Er.4 Natural gas: 053462 Flow-NTC 252805 Er.5 Return-NTC 065087 Main heat exchanger Er.6... - Page 69 SHORT PARTS LIST Er.1 Er.2 Er.3 Er.4 Er.5 Er.6 Er.7 Er.8 Er.9 Er.10 Er.11 Er.12...
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- Page 72 Head Office Service Solutions 0870 6060 777 Vaillant Ltd., Vaillant House, Technical Advice 01634 292392 Medway City Estate, Trident Close, Rochester, Kent ME 2 4 EZ...