Vaillant TURBOmax Pro 28 Benutzerhandbuch

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

TABLE OF CONTENTS

Introduction

Boiler Specification

General Requirements

Boiler Installation Sequence

General information . . . . . . . . . . . . . . . . . . . . . . . . . .5

EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

List of Contents Contents included with boiler . . . . . . . . . . . . . . . . . . . .4

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Boiler connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Rear outlet flue system . . . . . . . . . . . . . . . . . . . .11

Top outlet flue system . . . . . . . . . . . . . . . . . . . .11

Extended top outlet flue system . . . . . . . . . . . . . .11

Flue termination . . . . . . . . . . . . . . . . . . . . . . . .12

Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Cupboard or compartment ventilation . . . . . . . . . . . . . .13

Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Guide to system requirements . . . . . . . . . . . . . . . . . . .14

Water circulation system . . . . . . . . . . . . . . . . . .14

Filling and make up . . . . . . . . . . . . . . . . . . . . .14

Pressure relief valve . . . . . . . . . . . . . . . . . . . . .14

Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . .14

Expansion vessel . . . . . . . . . . . . . . . . . . . . . . .15

Circulating pump . . . . . . . . . . . . . . . . . . . . . . .16

System by-pass . . . . . . . . . . . . . . . . . . . . . . . . .16

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

DHW expansion vessel accessory . . . . . . . . . . . .16

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Preparation of boiler location . . . . . . . . . . . . . . .17

Selecting position of boiler . . . . . . . . . . . . . . . . .17

Using boiler template . . . . . . . . . . . . . . . . . . . . . . . . .18

Fitting the boiler hanging bracket . . . . . . . . . . . . . . . . .19

Install the flue system . . . . . . . . . . . . . . . . . . . . . . . . .19

Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Removing boiler casing . . . . . . . . . . . . . . . . . . . . . . .20

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Cold water mains inlet and hot water outlet . . . . . . . . . .22

Central heating flow and return pipework . . . . . . . . . . .23

Connecting the flue system to the boiler . . . . . . . . . . . .24

Electrical installation general requirements . . . . . . . . . . .25

Connecting to the main supply . . . . . . . . . . . . . . . . . .26

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Fit boiler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Commissioning Part I Preliminary electrical checks . . . . . . . . . . . . . . . . . . . .31

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Filling the heating system . . . . . . . . . . . . . . . . . . . . . .33

Draining the heating system . . . . . . . . . . . . . . . . . . . .33

Initial system flush (`cold`) . . . . . . . . . . . . . . . . . . . . . .33

TABLE OF CONTENTS

Gas supply adjustments

(Commissioning Part II)

Servicing

Fault Finding Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Logical fault finding procedure . . . . . . . . . . . . . . . . . .57

Fault finding charts . . . . . . . . . . . . . . . . . . . . . . . . . .58

Diagrams Functional flow diagram . . . . . . . . . . . . . . . . . . . . . . .66

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Short parts list Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Cleaning the burner and primary heat exchanger . . . . . .44

Parts replacement Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Temperature sensors (NTCs) . . . . . . . . . . . . . . . . . . . .49

Main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . .49

Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Electronic control board . . . . . . . . . . . . . . . . . . . . . . .51

Main transformer . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . .52

System bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Aqua sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

DHW heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .55

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .55

Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . .56

Functional checks

(Commissioning Part III)

Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Adjusting pump speed . . . . . . . . . . . . . . . . . . . . . . . .41

Final system flush (hot) . . . . . . . . . . . . . . . . . . . .41

Handing over to the user . . . . . . . . . . . . . . . . . . . . . .42

Gas inlet working pressure . . . . . . . . . . . . . . . . . . . . .34

Main burner pressure . . . . . . . . . . . . . . . . . . . . . . . . .35

Adjusting the central heating output (range rating) . . . . .36

Burner pressure and gas rate . . . . . . . . . . . . . . . . . . .37

LIST OF CONTENTS

Contents included with

boiler

Ensure that all contents are included

before commencing installation.

DO NOT remove the boiler from the

polystrene base at this stage.

BEDIENUNGSANLEITUNG

Instructions for Use

Fig. L.1: Items supplied with unit

Table L.1: Items supplied with unit

Euro B/S 021/1 GB_Pro

Item Quantity Description

1 1 Boiler

2 1 Flue restriction rings

3 1 Cold water inlet valve

5 1 Copper tail for hot water outlet connection

6 1 Template

4 3 Flow and return service valve, gas service valve

7 1 Guarantee Card and Benchmark log book

8 1 Installation and connection accessories and

PRV packages incl. DHW outlet union nut

9 3 Installation and Servicing, Users and Flue Installation

Instructions

10 1Hanging bracket

INTRODUCTION

The TURBOmax Pro is a fully

automatic, wall mounted, room sealed

combination boiler for central heating

and domestic hot water. Domestic hot

water is supplied directly from the

boiler, without requiring a copper

cylinder, cold water tank, feed and

expansion tank and associated

pipework. Domestic hot water has

priority over central heating.

The boiler has been designed for use

with a sealed central heating system,

and comes fully tested and assembled

with a built in circulating pump,

expansion vessel and diverter valve.

The TURBOmax Pro has an output for

domestic hot water of 28 kW. The

boiler is easily sited on any internal

wall and can be installed with either

a horizontal or vertical RSF (room

sealed fan assisted) flue. Two types of

flue system are available, rear flue

outlet, top outlet (with turret)

concentric flue system (100 mm

outside diameter) and an extended

concentric flue system (125 mm

outside diameter). Flue extensions and

additional bends and elbows are

available for both flue systems to

increase the siting flexibility. The

boiler is not suitable for external

installation.

This boiler is available in Natural

Gas. An optional LPG conversion kit

is available.

If desired, an inhibitor may be used

in the system. Guidance on the use of

inhibitors is contained in these

instructions.

The boiler contains a domestic hot

water heat exchanger. The

temperature in the heat exchanger is

limited by the boiler control system

and it is not necessary to install a

scale reducer on the cold mains to the

boiler.

However, in exceptionally hard water

areas to prevent scale formation in

the property hot water system

pipework, a scale reducer may be

fitted.

TURBOmax Pro combination boilers

have a built in diagnostic system

which indicates the operational status

of the boiler. This feature provides key

information to aid commissioning and

fault finding.

The data badge is fitted on the rear

of the control panel.

See text of General Requirements for

installation requirements or notes.

Vaillant ltd. support the Benchmark

initiative. Within the information

pack, you will find a Benchmark Log

Book. It is very important that this is

completed correctly at the time of

installation, commisioning and hando-

ver to the user.

Note: This boiler must be installed

and service 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.

General Information

EC designation

TURBOmax Pro boilers (VUW GB

282/2-3) carry the „CE“ Mark. This

demonstrates that the boilers fulfil the

essential requirements of the Gas

Appliance Directive (90/396/EEC)

and the Gas Appliance (Safety)

Regulations 1992.

The „CE“ Mark also demonstrates that

the boilers comply with the

requirements of the Electromagnetic

Compatibility Directive

(89/336/EEC), the Low Voltage

Directive (72/23/EEC), the Boiler

Efficiency Directive (92/42/EEC) and

the Boiler (Efficiency) Regulations

1993.

BOILER SPECIFICATION

Technical data

TURBOmax Pro 28/2 E

( VUW GB 282/2-3) Units

CH heat output range (80/60 °C) 10.4 - 28

(35 500 - 95 500) kW (Btu/h)

DHW heat output 28 (95 500) kW (Btu/h)

DHW flow rate ∆T =35 °C rise 11.5 l/min

DHW flow rate at factory set temperature rise (∆T 42 °C) 9.5 l/min

Mains water pressure required for max. flow rate 0.5 bar

Minimum water flow rate 1.5 l/min

Mains water pressure required for min. flow rate 0.15 bar

Maximum inlet water pressure 10 bar

Inlet gas working pressure required (natural gas) 20 mbar

Gas burner pressure ignition rate 1.8 mbar

Gas rate max. (DHW) 3.3 m3/h

Weight 45 kg

Primary water content 2.0 l

Maximum CH heat input (net) 31.1 (106 200) kW (Btu/h)

Gas supply (G20) Gross CV (s.t.) 37.8 MJ/m3

Gas burner pressure max. rate 10.8 mbar

CH temperature flow range 35 - 82 °C

Minimum CH water flow (for 20 °C rise) 1203 l/h

Pump pressure available 0.25 (25) bar (kPa)

Expansion vessel pre-charge pressure 0.75 bar

Maximum CH system pressure 3 bar

Electrical supply 230/50 V~/Hz-

External fuse 3 A

Power input 150 W

Maximum DHW heat input (net) 31.1 (106 200) kW (Btu/h)

Case height 800 mm

Case width 440 mm

Case depth 338 mm

BOILER SPECIFICATION

Boiler connections

310

592

145

100

35 35

432

130 180

148

543 21

Fig. B.1: Connection diameters

Euro B/S 024/2

Key:

1Heating system return

(22 mm compression)

2Cold water connection with shut

off valve (15 mm compression)

3Gas connection (15 mm

compression)

4Hot water connection

(15 mm tail)

5Heating system flow

(22 mm compression)

6Flue outlet (100 mm flue with

turret)

7Hanging bracket

8Rear flue outlet

BOILER SPECIFICATION

Functional Diagram

1Air duct

2Fan

3Main heat exchanger

4Temperature sensor (NTC I)

5Flame sensing electrodes

6Modulating burner

7Fully modulating automatic gas

value

8Maximum hot water temperature

control

9Maximum radiator temperature

control

10 Diverter valve

11 DHW heat exchanger

12 Automatic bypass valve

13 CH flow service valve

14 Hot water outlet

15 Gas service valve

16 Service valve

17 Service valve

18 Pressure relief valve

19 Aqua sensor (DHW flow switch)

21 Main on/off control

22 Pressure gauge

23 Indicator lights

24 Expansion vessel

25 Expansion vessel charging valve

26 Circulating pump

27 Automatic air vent

28 Ignition electrode

29 Temperature sensor (NTC II)

30 Air pressure switch

31 Flue gas duct

Fig. B.2: Functional Diagram

Euro B/S 196/0

GENERAL REQUIREMENTS

Ensure that ALL regulations

are observed.

Fig. R.1

Euro B/S 006/0_GB

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. It should also be in

accordance with the relevant

requirements of the Local Authority,

Building Regulations, Building

Standards (Scotland) Regulations and

the relevant recommendations of the

following British Standards:

BS 5440: Flues and ventilation of

gas fired boilers not exceeding

70 kW net:

- Part 1: Flues

- Part 2: Ventilation

BS 5449: Specification for forced

circulation hot water for domestic

premises.

BS 5546: Specification for gas hot

water supplies for domestic premises.

BS 6700: Services supplying water

for domestic use within buildings and

their curtilages.

BS 6798: Specification for

installation of gas fired boilers not

exceeding 60 kW input.

BS 6891: Specification for

installation of low pressure gas

pipework up to 28 mm (R1) in

domestic premises (2nd family gas).

BS 7593: Treatment of water in

domestic hot water central heating

systems.

Institute of Gas Engineers Publication

IGE/UP/7/1998: Guide for

Installation in Timber Framed

Housing.

Important: The appliance must be

installed and serviced by a

competent person as stated in the

Gas Safety (Installation and Use)

Regulations 1998.

Preliminary remarks

This appliance should only be

installed in conjunction with a Vaillant

flue system.

Install the flue system as detailed in

the separate flue installation

instructions supplied with this boiler.

GENERAL REQUIREMENTS

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.

Installation pipes should be fitted in

accordance with BS 6891.

Pipework from the meter to the boiler

must be of an adequate size. Do not

use pipes of a smaller size than the

boiler gas connection (15 mm).

The complete installation must be

tested for soundness and purged as

described in BS 6891.

Boiler location

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. The boiler may be

installed in any room, although

particular attention is drawn to the

requirements of BS7671 (IEE

Regulations) and, in Scotland, the

electrical provisions of the Building

Standards (Scotland) Regulations, in

respect of the installation of a boiler

in a room containing a bath or

shower.

Where the installation of the boiler

will be in an unusual location, special

procedures may be necessary and BS

5546 and BS 6798 give detailed

guidance on this aspect. The boiler

must be mounted on a flat, vertical

wall, which must be sufficiently robust

to take the weight of the boiler. The

boiler may be installed on a

combustible wall, subject to the

requirements of the Local Authorities

and Building Regulations.

A compartment used to enclose the

boiler must be designed and

constructed specifically for this

purpose. (An existing cupboard or

compartment may be used provided

that it is modified for the purpose).

Details of essential features of

cupboard/compartment design

including airing cupboard

installations are given in BS 6798.

If the boiler is to be fitted in a timber

framed building, it should be fitted in

accordance with Institute of Gas

Engineers Publication

IGE/UP/7/1998 „Guide for Gas

Installation in Timber Framed

Housing“.

Note: Where a room sealed boiler

is installed in a room containing a

bath or shower, any electrical switch

or boiler control utilising mains

electricity should be so situated that

it cannot be touched by a person

using the bath or shower.

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