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Vaillant TURBOmax VUW 242 E Instructions For Installation And Servicing

Wall hung room sealed fan assisted combination boilers
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INSTRUCTIONS FOR INSTALLATION AND SERVICING
Wall hung room sealed fan assisted
Supplied By www.heating spares.co Tel. 0161 620 6677
TURBOmax VUW 242 E
G.C. No 47-044-25
TURBOmax VUW 282 E
G.C. No 47-044-26
combination boilers
HEATING, CONTROLS, HOT WATER.

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  • Page 1 INSTRUCTIONS FOR INSTALLATION AND SERVICING TURBOmax VUW 242 E G.C. No 47-044-25 TURBOmax VUW 282 E G.C. No 47-044-26 Wall hung room sealed fan assisted combination boilers HEATING, CONTROLS, HOT WATER. Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 2: Table Of Contents

    Page Page 1. Introduction 6. Servicing 6.1 Initial inspection 2. Boiler Specification 6.2 Routine maintenance 2.1 Technical Data 6.3 Re-commissioning the boiler 2.2 Dimensions 2.3 Boiler connections Parts replacement 2.4 Function diagram 7.1 Initial preparation 7.2 Fan 3. General Requirements 7.3 Air pressure switch 3.1 Related documents 7.4 Burner...

  • Page 3: Introduction

    1. Introduction The TURBOmax range consists of Note: This boiler must be installed models with outputs for domestic hot and serviced by a competent person water of 24 and 28 kW. The boiler is in accordance with the Gas Safety easily sited on any internal wall and (Installation and Use) Regulations can be installed with either a horizontal...

  • Page 4: Boiler Specification

    2. Boiler specification 2.1 Technical data TURBOmax VUW 242 E VUW 282 E units Maximum CH heat input 29.3 34.2 (100,000) (116,600) (Btu/h) CH heat output range 9.6-24.0 11.2-28.0 (32,800-81,900) (38,200-95,500) (Btu/h) Maximum DHW heat input 29.3 34.2 (100,000) (116,600) (Btu/h) Maximum DHW heat output range 9.6-24.0...

  • Page 5: Dimensions

    2.2 Dimensions (All dimensions in mm) 1a Air/flue duct to the rear 1b Air/flue duct to the side Appliance bracket Heating system return (22 mm) Cold water connection (15 mm) Gas connection (15 mm) Hot water connection (15 mm) Heating system flow (22 mm) Pressure relief valve outlet in BSP) * with standard horizontal flue...

  • Page 6: Function Diagram

    2.4 Function diagram 1 Air duct 2 Air pressure switch 3 Combustion chamber 4 Temperature sensor (NTC) 5 Ignition electrodes 6 Modulating burner 7 Overheat thermostat 8 Fully modulating automatic gas valve 9 DHW heat exchanger 10 Indicator lights (LED’s) 11 Maximum radiator temperature control 12 Maximum hot water temperature...

  • Page 7: General Requirements

    3. General requirements 3.1 Related documents 3.2 Boiler location The installation of the boiler must be The location chosen for the boiler must in accordance with the relevant permit the provision of a satisfactory requirements of Gas Safety (Installation flue termination. The location must and Use) Regulations 1994, Health also provide adequate space for and Safety Document No.

  • Page 8: Gas Supply

    3.3 Gas supply The gas supplier should ensure the availability of an adequate supply of gas. A gas meter may only be connected to the service pipe by the supplier of gas or their contractor. An existing meter should be checked to ensure that it is capable of passing the rate of gas supply required.
  • Page 9 3.4.1 Flue Termination 1. The terminal must be positioned such that the combustion products can disperse freely at all times. 2. 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.

  • Page 10: Air Supply

    3.5 Air supply 3.6 Electricity supply 3.7 Guide to system requirements Detailed recommendations for air A 230 V~ 50Hz single phase supply are given in BS 5440: Part 2. electricity supply fused to 3 amps must 3.7.1 Water circulation system be provided in accordance with the It is not necessary to have an air vent Detailed recommendations for the...
  • Page 11 3.7.2 Filling and make up The system should be filled with water Heating via a separate filling point fitted at a circuit Double check Mains convenient position on the heating return Hose valve assembly water circuit. Where local Water Authority unions supply Regulation allows, a temporary...
  • Page 12 3.7.9 DHW expansion vessel accessory A DHW expansion vessel kit (Art. No. 8070) is available as an optional accessory from Vaillant Ltd. This fig. 8 expansion vessel kit should be fitted to the boiler whenever either a stop valve of the loose jumper type or a...

  • Page 13: Boiler Installation Sequence

    4. Boiler installation sequence 4.1 General The boiler should be mounted on a flat and vertical area of wall of sufficient area for the boiler plus the required minimum clearances for installation and servicing (fig. 10). These are shown on the installation template supplied with the boiler and are: 5 mm either side of the boiler...

  • Page 14: Preparation Of Boiler Location

    11. Pre - installation connecting group • fixing screws and wallplugs (includes 300 813) 8015 • installation and user instructions 12. Vaillant boiler replacement connection accessory 300 813 • flue restrictor • 13. Pipe cover accessory 8099 domestic hot and cold water connections and straddle bracket 14.
  • Page 15 Where an old existing Vaillant boiler is to be replaced, the boiler replacement accessory (Art. No. 300 813) can be fig. 12...

  • Page 16: Installing The Flue System

    4.4 Installing the flue system Note: To allow fitting of the bottom boiler cover, the left hand tab (2, fig. At this stage install the flue system 16) should be folded upwards where (refer to separate installation pipes are fitted in the left hand void. instructions supplied).

  • Page 17: Connecting The Flue Assembly To The Boiler

    4.5.3.4 Gas supply The boiler is supplied with a 20 x 15 mm gas service valve (10, fig. 14). Fit the 20mm compression fitting to the boiler gas inlet (11, fig. 14) and tighten. Install a gas supply pipe not less than 15mm diameter and connect to the gas service valve.
  • Page 18 Loosen screws on the 95 mm diameter Lower the flue assembly until a gap of x 55mm wide clamp (6, fig. 21) and about 25 mm exists between the air push over the air duct. duct of the air/flue duct and terminal assembly and the half rings on the Remove screws and sealing washer appliance.

  • Page 19: Electrical Installation

    IMPORTANT Ensure that all cords Drill two holes 3 mm diameter pass through the terminal box entrance through the air duct clamp (2. Fig 24) grommets and are securely fixed by ensuring that the drill does not pene- the cable clamps. Ensure that the trate the flue duct.

  • Page 20: Controls

    (see Schematic layout, fig. 30). If a frost thermostat is to be fitted it should be connected in parallel across terminals 3 and 4. 4.8.2.3 Vaillant optional Plug-in timer Accessories Refer to the instructions supplied with the optional plug in timer accessories for connection details.
  • Page 21 4.8.3 Thermostatic radiator valves 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). For optimum fuel economy it is recommended that where TRVs are used they are used in conjunction with a programmable roomstat or separate timer and room thermostat to ensure...

  • Page 22: Commissioning

    5. Commissioning 5.1 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. 5.2 Gas supply The complete gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with BS 6891.

  • Page 23: Filling The Heating System

    5.4 Filling the heating system The boiler primary circuit and the heating system should be filled using a filling method as described in Section 3.7.2. Ensure that the boiler CH service valves (3, fig. 31) are open. Partially open the filling valve and allow water to enter the system.

  • Page 24: Initial Lighting

    5.6 Initial lighting • Check that the boiler combustion chamber (5, fig. 33) is correctly fitted. • Ensure the cold water shut-off valve (4, fig. 34) is open by turning anti-clockwise. • Open the gas service valve (2, fig. • Check that the CH service valves (1 and 5, fig.

  • Page 25: Gas Inlet Working Pressure

    At this point the preset maximum tolerance shown, contact Vaillant fig. 35 Ltd. Technical Department). domestic hot water flow rate can be • Turn off the hot tap. adjusted if required. • Remove U gauge. Tighten the sea- Note: The water flow limiter built ling screw (1, fig.

  • Page 26: Adjusting Central Heating Output (Range Rating)

    5.9 Adjusting the central heating output (range rating) The TURBOmax is fully modulating for central heating, and it is therefore not necessary to range rate the central heating. However, if desired, it is possible to range rate the boiler, as follows: •...

  • Page 27: Functional Checks

    5.10 Functional Checks 5.10.1 Introduction The Vaillant TURBOmax 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 (fig. 41).

  • Page 28: Checking Flame Supervision Device

    5.11 Checking flame 5.13 Fitting case supervision device Attach top door panel by slotting side clips (1, fig. 42) into holes in side Operate the boiler and turn off the panel and sliding panel down to gas supply at the boiler gas service secure.

  • Page 29: Handing Over To User

    (7, fig. made for a Maintenance Agreement. 44). A suitable combustion analyser Please contact Vaillant Service can be connected to this point to Department (FREEPHONE 0800 establish the combustion performance 318076) for further details.

  • Page 30: Routine Maintenance

    6.2 Routine maintenance 6.2.1 Remove front case Remove bottom hinge screw (1, fig. 46) and pull lower door panel forward and down to release it from the top hinge pin (2, fig. 46). Slide the top panel up to release retaining clips (1, fig.

  • Page 31: Re-Commissioning The Boiler

    6.2.5 Inspect burner With the combustion chamber front cover and heat exchanger front panel removed it is possible to inspect the burner. Any deposits should be removed with a soft brush. Check the condition of the ignition and monitoring electrodes. 6.2.6.

  • Page 32: Parts Replacement

    7. Parts replacement 7.1.2 Releasing CH water pressure and draining the boiler (fig. 50) • Isolate electrical supply to boiler. IMPORTANT: • Before starting any maintenance Remove combustion chamber cover work: as in section 7.1.5. • • Turn off boiler CH service valves Isolate the mains electricity supply (2).
  • Page 33 7.1.3 Removal of front casing 7.1.7 Removal of heat exchanger front panel. 7.1.3.1 Door (fig. 52) • Remove bottom hinge screw (1) • Remove the five screws (1 and 3, and pull the bottom door panel fig. 47) securing the heat exchanger forwards and down to release it and remove the panel by gently from top hinge pin (2).

  • Page 34: Fan

    7.2 Replacement of fan (fig. 55) • Isolate the boiler from the electrical supply. • Remove front casing as in section 7.1.3, and remove combustion chamber cover as in section 7.1.5. • Disconnect the electrical connections from the fan. • Remove the 2 fan securing screws (4) and remove fan.

  • Page 35: Burner

    7.4 Replacement of burner fig. 57 • Isolate the boiler from the electrical supply. • Remove front casing as in section 7.1.3. • Remove combustion chamber cover as in section 7.1.5 • Disconnect the ignition and flame sensing electrode leads (1, fig. 57). •...

  • Page 36: Temperature Sensor (Ntc)

    7.6 Replacement of NTC temperature sensor Note: The NTC temperature sensor is an extremely reliable component and as such is unlikely to fail. Before changing the NTC please check that it is defective - see section 8 - fault finding. •...

  • Page 37: Main Heat Exchanger

    7.7.1 Replacement of main solenoid 7.7.3 Replacement of gas operator valve. • Isolate boiler from the electrical • Isolate the boiler from the electrical supply. supply. • Remove front casing as in section • Remove front casing as in section 7.1.3.

  • Page 38: Ch Expansion Vessel

    7.9 Replacement of CH 7.9.2 Boiler installed with air flue duct to the rear, or vertical flue expansion vessel installation (where less than In the unlikely event of a failure of the 300mm vertical clearance exists CH expansion vessel follow procedure above the boiler) 7.9.1 or 7.9.2 depending upon the EITHER...

  • Page 39: Transformer

    • Pull pump forward to remove. 7.10 Replacement of • Fit new '0' rings (supplied with transformer pump) to pump connections. • Isolate boiler from the electricity • Re-assemble in reverse order. supply. • Carry out electrical checks • Remove front casing as in section (see section 5.1).

  • Page 40: Automatic Air Release

    7.13 Replacement of automatic 7.15 Replacement of diverter air release valve • • Turn off boiler as in section 7.1.1. Turn off boiler as in section 7.1.1. • • Remove front casing as in section Remove front casing as in section 7.1.3.

  • Page 41: Pressure And Temperature Gauge

    7.15.1 Replacement of water section diaphragm (fig. 72). • Turn off boiler as in Section 7.1.1. • Remove bottom cover as in section 7.1.3.3. • Open hot water taps. • Remove clip (2), undo union (3) • Remove 6 screws (4). •...

  • Page 42: Dhw Microswitch

    7.18 Replacement of DHW microswitch. • Isolate appliance from electricity supply. • Remove front casing as in section 7.1.3. • Lower front control panel as in section 7.1.6. • Lift off microswitch retaining ’bow’ spring, • Pull microswitch forward to remove from mounting bracket and disconnect wires.

  • Page 43: Circuit Boards

    7.20 Removal of printed circuit boards (PCBs) Before commencing work on PCB replacements carry out the following:- • Diagnose which board requires changing using the fault finding guide (see section 8: Fault finding). • Turn off the boiler as in section 7.1.1.

  • Page 44: Fault Finding

    8. Fault finding 8.2 Logical fault finding 6) Set boiler central heating control to Heating and Hot Water position procedure 8.1 Introduction 8.2.1 Preliminary Checks 7) Ensure that the Maximum Radiator The TURBOmax has built in diagnostic These checks must be carried out Temperature and Maximum Hot indicator lights (fig.

  • Page 45: Fault Finding Charts

    Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 46 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 47 Supplied By www.heating spares.co Tel. 0161 620 6677...
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  • Page 50 Supplied By www.heating spares.co Tel. 0161 620 6677...
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  • Page 52 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 53 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 54: Electrical Diagrams

    9 Electrical diagrams 9.1 Functional Flow diagram: VUW 242 E / 282 E fig. 78 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 55: Wiring Diagram

    9.2 Wiring diagram: VUW 242 E / 282 E fig. 79 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 56: Schematic Appliance Circuit Diagram

    9.3 Schematic appliance circuit diagram: VUW 242 E / 282 E fig. 80 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 57: Short Parts List

    10. Short parts list Key No. Description Part No. GC No. 19 0162 Air pressure switch 05 0557 Main heat exchanger VUW 242 06 4951 Main heat exchanger VUW 282 06 4952 Burner VUW 242 04 1960 Burner VUW 282 04 1961 Diverter valve 01 1269...
  • Page 58 fig. 87 fig. 88 fig. 89 fig. 90 fig. 91 fig. 92 fig. 93 fig. 94 fig. 95 fig. 96 fig. 97 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 59: Information

    11. Supplementary L.P.G. Appliances: information for VUW 242 EB TURBOmax VUW 282 EB The appliance delivered is designed Related documents to be for use with LPG. supplemented by: Please read the instructions for BS 5482: CP for domestic butane installation therefore as follows: and propane gas burning installations Part 1:...
  • Page 60 HEATING, CONTROLS, HOT WATER Head Office Sales 01634 292310 Vaillant Ltd., Vaillant House, Service Freephone 0800 318076 Medway City Estate, Trident Close, Technical Advice 01634 292392 Rochester, Kent ME 2 4 EZ Training 01634 292370 Supplied By www.heating spares.co Tel. 0161 620 6677...

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