Vaillant TURBOmax VUW 282/1 E Benutzerhandbuch

TURBOmax VUW 242/1 E

TURBOmax VUW 282/1 E

Wall hung room sealed fan assisted

combination boilers

INSTRUCTIONS FOR INSTALLATION AND SERVICING

HEATING, CONTROLS, HOT WATER.

Page

1. Introduction 3

2. Boiler Specification 4

2.1 Technical Data 4

2.2 Dimensions 5

2.3 Boiler connections 5

2.4 Function diagram 6

3. General Requirements 7

3.1 Related documents 7

3.2 Boiler location 7

3.3 Gas supply 8

3.4 Flue system 8

3.5 Air supply 10

3.6 Electricity supply 10

3.7 Guide to system requirements 10

4. Boiler installation sequence 13

4.1 General 13

4.2 Boiler delivery 13

4.3 Preparation of boiler location 14

4.4 Installing the flue system 16

4.5 Mounting the boiler 16

4.6 Connecting the flue assembly

to the boiler 17

4.7 Electrical installation 19

4.8 Controls 20

5. Commissioning 22

5.1 Preliminary electrical checks 22

5.2 Gas supply 22

5.3 Water supply 22

5.4 Filling the heating system 23

5.5 Initial system flush ('cold') 23

5.6 Initial lighting 24

5.7 Gas inlet working pressure 25

5.8 Main burner pressure 25

5.9 Adjusting central heating

output (range rating) 26

5.10 Functional checks 27

5.11 Checking flame

supervision device 28

5.12 Final system flush ('hot') 28

5.13 Fitting case 28

5.14 Handing over to user 29

Page

6. Servicing 29

6.1 Initial inspection 29

6.2 Routine maintenance 30

6.3 Re-commissioning the boiler 31

7. Parts replacement 32

7.1 Initial preparation 32

7.2 Fan 34

7.3 Air pressure switch 34

7.4 Burner 35

7.5 Electrodes 35

7.6 Temperature sensor (NTC) 36

7.7 Gas valve 36

7.8 Main Heat exchanger 37

7.9 CH expansion vessel 38

7.10 Transformer 39

7.11 Overheat thermostat 39

7.12 Pump 39

7.13 Automatic air release 40

7.14 Automatic bypass 40

7.15 Diverter valve 40

7.16 Pressure and temperature

gauge 41

7.17 Differential pressure switch 41

7.18 DHW microswitch 42

7.19 DHW heat exchanger 42

7.20 Circuit boards 43

8. Fault finding 44

8.1 Introduction 44

8.2 Logical fault finding procedure 44

8.3 Fault finding charts 45

9. Electrical diagrams 54

9.1 Functional flow diagram 54

9.2 Wiring diagram 55

9.3 Schematic appliance

circuit diagram 56

10. Short parts list 57

11. Supplementary LPG

information 59

Leave these instructions with the user

when the installation is completed.

1. Introduction Note: This boiler must be installed

and serviced by a competent person

in accordance with the Gas Safety

(Installation and Use) Regulations

1994. In the UK 'CORGI' Registered

Installers undertake the work to a

safe and satisfactory standard.

The TURBOmax 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 or 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,

bypass, expansion vessel and diverter

valve.

TURBOmax boilers carry 'CE' Mark.

This demonstrates that the boilers fulfill

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 (Directive

89/336/EEC), the Low Voltage

Directive (73/23/EEC), the Boiler

Efficiency Directive (92/42/EEC) and

the Boiler (Efficiency) Regulations

1993.

TURBOmax meets the requirements of

Statutory Instrument ‘The Boiler (Effi-

ciency) Regulations 1993 and

therefore is deemed to meet the

requirements of Directive 92/42/EEC

on the efficiency requirements for new

hot-water boilers fired with liquid or

gaseous fuels.

The TURBOmax range consists of

models with outputs for domestic hot

water of 24 and 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. Flue extensions and

additional bends and elbows are

available for increased siting flexibility.

(The boiler is not suitable for external

installation).

If desired an inhibitor may be used in

the system. Guidance on the use

of inhibitors is contained in these

instructions.

Natural Gas and LPG versions of the

boiler are available.

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 inlet 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.

The TURBOmax has built-in diagnostic

indicator lights which illuminate in

sequence giving information on the

boiler status when operating and per-

formance of key components to aid in

commissioning and fault finding.

The data badge is fitted on the bottom

of the combustion chamber.

See text of General Requirements for

Installation Requirements or notes.

TURBOmax VUW 242/1 E VUW 282/1 E units

Countries of Destination GB, IE

Maximum CH heat input 29.3 34.2 kW

(100,000) (116,600) (Btu/h)

CH heat output range 9.6-24.0 11.2-28.0 kW

(32,800-81,900) (38,200-95,500) (Btu/h)

Maximum DHW heat input 29.3 34.2 kW

(100,000) (116,600) (Btu/h)

Maximum DHW heat output range 9.6-24.0 11.2-28.0 kW

(32,800-81,900) (38,200-95,500) (Btu/h)

DHW flow rate @ 35 °C rise 10 11.5 l/min

Mains water pressure required for max. flow rate 0.8 1.0 bar

Minimum water flow rate 2.7 2.7 l/min

Mains water pressure required for min flow rate 0.3 0.3 bar

Maximum inlet water pressure 10 10 bar

Inlet gas working pressure required (Natural Gas) 20 20 mbar

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

Gas burner pressure max. rate 10.0 10.6 mbar

Gas burner pressure ignition rate 2.0 2.0 mbar

Gas rate max (DHW) 2.79 3.26 m3/h

Main burner jet size 16 x 7/120 18 x 7/120 no. x size

CH flow temperature range 40-90 40-90 °C

Minimum CH water flow (for 20 °C rise) 1,032 1,204 l/h

Pump pressure available 0.25 0.25 bar

8l expansion vessel pre-charge pressure 0.75 0.75 bar

Maximum CH system pressure 3.0 3.0 bar

Connections

Heating flow / return 22 22 mm

Cold water inlet 15 15 mm

DHW outlet 15 15 mm

Gas inlet 15 15 mm

Pressure relief discharge pipework (min) 15 15 mm

Weight 47 48 kg

Primary water content 0.7 0.7 litres

Electrical supply

Voltage 230/50 230/50 V~/Hz

2 x internal fuses 2 2 A

1 x internal fuse 1.25 1.25 A

external fuse 3 3 A

Power input 130 130 W

2. Boiler specification

2.1 Technical data

Supplementary LPG information on page 59.

1021

880

95.5

480

120 max. 995* max. 995 *

190

765438

50 380

120

GW 547/1

fig. 1

2.3 Boiler connections

1 Compression union (flow of

heating system)

2 Service valve (flow of heating

system)

3 Domestic hot water connection

4 Compression Union (gas)

5 Gas service valve (supplied with

the boiler)

6 Cold water connection with

shut-off valve

7 Service valve (return of heating

system)

8 Compression union (return of

heating system)

9 Pressure relief valve

200

124

12 3456789

GW 546/1

fig. 2

2.2 Dimensions

(All dimensions in mm)

1a Air/flue duct to the rear

1b Air/flue duct to the side

2 Appliance bracket

3 Heating system return (22 mm)

4 Cold water connection (15 mm)

5 Gas connection (15 mm)

6 Hot water connection (15 mm)

7 Heating system flow (22 mm)

8 Pressure relief valve outlet

(3/4in BSP)

* with standard horizontal flue

accessory.

(max. = 2965 mm with extensions)

120

321

GW 573/2GB

fig. 3

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

control

13 Central heating control and

lockout reset

14 Main on/off control

15 CH flow service valve

16 Gas service valve

17 Flue gas duct

18 Fan

19 High efficiency heat exchanger

20 Flame sensing electrode

21 Differential pressure switch

22 Expansion vessel charging valve

23 Expansion vessel

24 Automatic air vent

25 Circulating pump

26 Diverter valve

27 Water switch (DHW)

28 Water section

29 Temperature and Pressure gauge

30 Automatic bypass valve

31 Pressure relief valve

32 CH return service valve

33 Cold water shut off valve

3. General requirements 3.1 Related documents

The installation of the boiler must be

in accordance with the relevant

requirements of Gas Safety (Installation

and Use) Regulations 1994, Health

and Safety Document No. 635 (The

Electricity at Work Regulations 1989),

BS7671 (IEE Wiring Regulations) and

the byelaws of the local Water

Undertaking. 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 60 kW:

- 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.

BRITISH GAS PUBLICATION DM2:

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 1994

3.2 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 (I.E.E. 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.

(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).

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

accordancewith British Gas Publication

DM2 'Guide for Gas Installations in

Timber Framed Housing'.

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.

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.

3.4 Flue system

The standard horizontal flue system

(Art. No. 300 807) is suitable for

installations up to 995 mm measured

from the centre of the boiler flue outlet

to the outside face of the wall (A, fig.

4). Flue extensions (Art. No. 300 802)

are available to extend this length up

to 2965 mm. Both 90°elbows

(Art. No. 300 808) and 45°bends

(Art. No. 300 809) are also available

to increase siting flexibility.

A vertical flue system is also available

(Art. No. 300 800).

TURBOmax boilers may also be used

in SE- duct applications (SE- duct flue

system available Art. No. 300810)

Refer to the flue installation instructions

for full details.

A max = 2965 mm

GW 579/2

fig. 4

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.

3. If the terminal is fitted less than 2m

above a balcony, above ground or

above a flat roof to which people

have access, then a suitable guard

must be provided and fitted (available

from Tower Flue Components,

Tonbridge, TN9 1TB: reference TFC

type K3).

Table 1:

Terminal position for fan-assisted flue

(minimum distance - see fig. 5)

A- Directly below an openable mm

window or other opening

(e.g. air brick) 300

B- Below gutters, soil pipes

or drain pipes 25

C- Below eaves 25

D- Below balconies 25

(below car port roof 200)

E- From vertical drain pipes

and soil pipes 25

F- From internal or external

corners 25

G-Above ground or balcony

level 300

H- From a surface facing a

terminal 600

I- From a terminal facing a

terminal 1200

J- From an opening in a

car port (e.g. door, window)

into a dwelling 1200

K- Vertically from a terminal

on the same wall 1500

L- Horizontally from a

terminal on the same wall 300

M-Distance from adjacent

wall for Vertical Flue 500

BCD

H, I

BFM

fig. 5

GW 595/1

Where a terminal is fitted less than

1m below a plastic gutter or less than

0.5 m below painted eaves or any

other painted surface then a suitable

shield at least 1m long should be

fitted to protect the surface.

Note: Vertical flues must not terminate

within 600 mm of an openable

window, air vent or any other

ventilation opening.

3.5 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.

3.5.1 Cupboard or compartment air

supply

TURBOmax Room Sealed Combination

Boilers are very high efficiency

appliances.

As a consequence the heat loss from

the appliance casing during operation

is very low. For cupboard and

compartment installations it is therefore

not necessary to provide any high or

low level permanent air vents for

cooling purposes.

3.6 Electricity supply

A 230 V~ 50Hz single phase

electricity supply fused to 3 amps must

be provided in accordance with the

latest edition of BS7671 (I.E.E. Wiring

Regulations) and any other local

regulations that may apply.

THIS APPLIANCE MUST BE EARTHED.

The method of connection to the mains

electricity supply must provide a

means of completely isolating the

boiler and its ancillary controls.

Isolation is preferably by the use of a

fused three pin plug and unswitched

shuttered socket outlet, both complying

with the requirements of BS 1363.

Alternatively, a 3 Amp fused

double-pole switch with a 3mm

contact separation on both poles may

be used.

3.7 Guide to system

requirements

3.7.1 Water circulation system

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).

Pipework not forming part of the useful

heating surface should be insulated to

help prevent heat loss and possible

freezing, particularly where pipes are

run through roof spaces and ventilated

underfloor spaces.

Draining taps must be located in

accessible positions which permit the

draining of the whole system including

the boiler and the hot water system.

Draining taps should be at least 1/2

in. BSP nominal size and be in

accordance with BS 2879.

The boiler is suitable for use with

minibore or microbore systems.

Copper tubing to BS 2871: Part 1

should be used for water carrying

pipework. All capillary joints in the

DHW pipework must be made with

lead free solder.

Particularly where a new boiler is to

be fitted to an existing system, it is

good practice that the system is

thoroughly cleansed. This cleasing

should take place prior to the fitting of

the new boiler and be in accordance

with BS 7593.

For advice on the application of

system cleansers contact Sentinel,

Grace Dearborn Ltd, Widnes,

Cheshire, WA8 8UD.

Tel: 0151 4951861.

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