Vaillant TURBOmax Plus 824/2 E User manual

INSTRUCTIONS FOR USE
TURBOmax Plus 824/2 E, 828/2 E
THERMOcompact 615/2 E, 620/2 E, 624/2 E, 628/2 E
The code of practice for the installation,
commissioning & servicing of central heating systems

2
TABLE OF CONTENTS
General information
Safety
For your information . . . . . . . . . . . . . . . . . . . . . . . . . .3
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . .3
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Specified use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
EC designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Factory Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Initial checks before turning ON . . . . . . . . . . . . . . . . . .9
Domestic hot water operation (TURBOmax Plus only) . . . .10
Heating operation . . . . . . . . . . . . . . . . . . . . . . . . . .13
Resetting the appliance . . . . . . . . . . . . . . . . . . . . . . .14
Turning the boiler OFF (TURBOmax Plus only) . . . . . . . .15
Turning the boiler OFF (THERMOcompact only) . . . . . . .16
Care and maintenance . . . . . . . . . . . . . . . . . . . . . . .17
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Important Note
☞This symbol is used to indicate
important instructions.
●This symbol is used to indicate
a required step.
3
GENERAL INFORMATION
We can accept no liability
whatsoever for damage or
injury resulting from failure to
observe these instructions.
Key to symbols
Liability
For your information Thank you for choosing a Vaillant
boiler. The information given in this
booklet will enable you to obtain the
best performance from your boiler.
TURBOmax Plus provides both central
heating and domestic hot water,
with the domestic hot water supplied
directly from the boiler. The boiler
will operate automatically to provide
domestic hot water whenever a hot
water tap is opened, and auto-
matically adjusts to meet the demand
for both central heating and domestic
hot water in the most economical way.
THERMOcompact provides central
heating and domestic hot water
where a separate indirect hot water
cylinder is also incorparated to the
system.
If, after reading these instructions,
you have any questions on the
operation of the boiler, please
contact either your installer or Vaillant
Technical Department.
The benchmark logbook should be
completed by the installer and/or the
commissioning engineer and handed
to the user.
All CORGI registered installers
carry a CORGI ID card, and have a
registration number.
Both should be recorded in your
Benchmark Log Book. You can check
your installer by calling CORGI direct
on 01256 372300.

4
GENERAL INFORMATION
Specified use
EC designation The purpose of EC designation is to
certify that the boiler complies with
the requirements of the directives
covering gasfired appliances
(Council directive 90/396/EEC) and
electromagnetic compatibility
(Council directive 89/336/EEC).
These appliances also comply with
the requirements of the directive on
operating efficiency (Council directive
92/42/EEC).
Vaillant TURBOmax Plus and
THERMOcompact boilers are made
to fulfil the latest technical specifica-
tions and official safety regulations.
These appliances are designed as
boilers for use in central heating and
hot water supply systems.
THERMOcompact boilers only supply
domestic hot water where a separate
indirect hot water cylinder is also
incorparated to the system.
If the appliances are used for purposes
other than or in excess of these
specifications, this shall be classed as
incorrect operation, and neither the
manufacturer nor supplier will accept
any liability for resulting damage or
injury.
Use of this type is entirely at the
owner’s risk.
The term „specified use” also covers
observance of the operating and
installation instructions, along with
adherence to the servicing schedules.

5
SAFETY
Safety instructions
Setup and adjustments
Installation and adjustment of the
boiler as well as service maintenance
and repair of the boiler may only be
carried out by a competent person in
accordance with the Gas Safety
(Installation and Use) Regulations
1998. (In the U.K. „CORGI“
Registered installers undertake the
work to a safe and satisfactory
standard).
If the boiler is installed in a
compartment do not obstruct any
purpose provided ventilation
openings, and do not use the
compartment for storage purposes.
Gas smell
If you smell gas or suspect a gas
leak:
- Turn off the boiler.
- Do not switch any electrical
switches in the hazardous area
ON or OFF.
- Do not smoke in the hazardous
area.
- Turn off the gas supply at the gas
meter.
- Ventilate the room.
- Consult your gas supplier, service
agent or other competent person.
Modifications in and around the
boiler
No modifications may be made to
the following items:
- The boiler.
- The gas, water and electrical
supply.
- The flue system.
- The safety valve for the heating
water.
- Any structural changes around the
appliance that could affect the
operational safety of the boiler.
Follow the safety instructions!
Fig. S.1
Euro B/S 002/0_GB

6
SAFETY
Explosive and flammable
materials
Do not use or store any explosive or
highly flammable materials (e.g.
gasoline, paper or paint) near to the
appliance.
Inspection
The boiler should be serviced
annually. We recommend that you
sign a service agreement with your
service agent or Vaillant Ltd.
Safety instructions

7
Two year guarantee!
Fig. W.1
Euro B/S 122/0_GB
Your guarantee
Vaillant undertakes to rectify any
manufacturing defect that occurs
within twenty four months of the
installation date.
Registering with us
Registration is simple. Just complete
the Guarantee Registration Card and
return to Vaillant within 30 days of
installation. Your details will then be
automatically registered within the
Vaillant scheme.
Note: No receipt will be issued.
Immediate help
If your Vaillant boiler develops a fault
your first action should be to contact
your installer, as his professional assess -
ment is needed under the terms of our
Guarantee. If you are unable to
contact your installer, phone Vaillant
Service Solutions:
0870 6060 777
FACTORY GUARANTEE

8
OPERATION
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32 10
758 4
1
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VRC-VC
Fig. B.1a: Operating elements TURBOmax Plus
Euro B/S 073/1
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32 9
758 4
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VRC-VC
THERMOcompact
A
Fig. B.1b: Operating elements THERMOcompact
Euro B/S_VC_086/1GB
Overview
TURBOmax Plus
Operating controls
For access to the controls press the
upper middle of the lower front panel
and drop it down.
The following can be seen:
1Maximum radiator temperature
control (page 13)
2The „+“ and „-“ buttons for the
display panel
3Main ON/OFF control (pages 10
and 15)
4Built in control/timer module (if
fitted)
5The „i“ information button
6Boiler display
7Indicator lights to display the
current operating mode
8„Reset“ button: (see page 14)
9Maximum hot water temperature
control and warmstart ON/OFF
control (page 11)
10 Pressure gauge displaying the
pressure in the heating system
THERMOcompact
You can identify a THERMOcompact
boiler by the sticker which is situated
at the top left hand side of the control
panel (see A, Fig. 1b)
Operating controls
For access to the controls press the
upper middle of the lower front panel
and drop it down.
The following can be seen:
1Maximum radiator temperature
control (page 13)
2The „+“ and „-“ buttons for the
display panel
3Main ON/OFF control (pages 10
and 16)
4Built in control/timer module (if
fitted)
5The „i“ information button
6Boiler display
7Indicator lights to display the
current operating mode
8„Reset“ button: (see page 14)
9Pressure gauge displaying the
pressure in the heating system

9
OPERATION
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1
2
3
4
Fig. B.2: LED displays
Euro B/S 074/1
Initial checks before
turning ON
Open the service valves
●Ensure the cold water service valve
is open. This can be checked by
opening a hot water tap and
ensuring water flows.
●Ensure that the service valves in
the heating flow and return (2and
1) and the gas service valve (3)
are open.
☞The flow, return and gas
service valves are open when
the line marking has the same
direction as the pipe.
●The pressure relief valve (4) is
provided for safety reasons and
must not be interfered with.
Note:
A bottom cover is fitted to the
appliance. The service valves can
be seen through the cover.
I
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Fig. B.3: Opening service valves
Euro B/S 009/0GB
☞picture shows a TURBOmax
Plus boiler
Indicator lights/boiler display
TURBOmax Plus and THERMOcompact
boilers have an advanced multi-
function boiler display (1). When the
main ON/OFF control is in the „ON“
position the display will normally
show the temperature of water in the
boiler circuit (45 °C in the example),
which confirms that the boiler is
functioning correctly.
1In the unlikely event of a fault
developing which prevents the
boiler from operating, the display
may show a fault code (page 14).
2Red indicator
Illuminated = Boiler has locked out
3Yellow indicator
Illuminated = Main burner ignited
4 TURBOmax Plus
Green warmstart indicator (3)
Illuminated = Warmstart switched
ON
Not illuminated = Warmstart is
switched OFF and there is no
demand for hot water
Flashing = There is either a
demand for hot water or
warmstart
4 THERMOcompact
Green indicator (3) is illuminated
but has no function.

10
OPERATION
Check the water contents
●Check the water contents of the
system on the pressure gauge (1).
The needle on the pressure gauge
should be within the green band
(between 1 and 1.5 bar). If the
needle displays a value below
0.8 bar when the appliance is
cold, follow the instructions left by
your installer to refill the system.
Alternatively, your installer should
be called to refill the system.
VRC-VC
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Fig. B.4: Checking the water level
Euro B/S 076/1
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3
Fig. B.5: Domestic hot water supply
Euro B/S 077/1
Domestic hot water
operation (TURBOmax
Plus only)
The boiler should only be used
when the heating system con-
tains water. Use of the boiler
without water may cause
damage to the boiler or its
components.
Setting the maximum domestic
hot water temperature control
●Turn the main switch (2) to the „l“
position.
●The display will show the boiler
flow temperature which indicates
electrical power to the boiler.
●The domestic hot water tempera-
ture can be adjusted using the hot
water temperature control (3).
● Turn the control clockwise to increa-
se the temperature and anti-clock-
wise to decrease the temperature.
As a guide for normal circumstances
set the knob to the one o´clock positi-
on.
Note:
This control adjusts the maximum
domestic hot water temperature. If
adjusting the control upwards
appears to have no effect on the
temperature, then the boiler is
already operating at full output for
the selected flow rate.
If you live in a hard water
area please do not set the
control knob above the mid
(12 o´clock) position to prevent
excessiv scale formation
(fig. B.5).

11
OPERATION
Warmstart operation (TURBOmax
Plus only)
The warmstart facility provides
instantaneous delivery of domestic
hot water from the TURBOmax Plus
boiler.
When the warmstart system is
switched ON the boiler will
automatically light periodically to
maintain the internal temperature of
the boiler at approximately 40 °C.
When the warmstart system is
switched OFF a short delay may be
experienced in obtaining hot water at
the tap.
●The warmstart system is activated
by turning the hot water tempera-
ture control knob (1) all the way to
the very right for a short time.
The green indicator light will now
illuminate. Reset the hot water
temperature control knob to the
desired setting. The boiler will now
provide instantaneous delivery
of hot water directly when a hot
water tap is turned ON.
●The warm start system is switched
OFF by turning the hot water
temperature control knob (1) all the
way to the very left for a short
time. The green indicator light is
NOT illuminated. Reset the hot
water temperature control knob to
the desired setting.
Note:
Irrespective of whether the warm-
start facility is switched ON or
OFF, the boiler will automatically
operate to provide hot water
whenever a hot water tap is
opened.
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b
a
b
Fig. B.6: Switching the warm start on and off
Euro B/S 078/1
TURBOmax Plus

12
OPERATION
1
Fig. B.7: Drawing off hot water
Euro B/S 079/0
Obtaining hot water (TURBOmax
Plus only)
On opening a hot water tap (1) at a
supply point (basin, shower, bath,
etc.) the TURBOmax PLus boiler will
automatically operate to deliver hot
water.
On closing the tap the boiler switches
OFF (or continues to operate for cen-
tral heating if required). The pump
and fan will continue to operate for a
short period.
TURBOmax Plus

13
OPERATION
VRC-VC
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Fig. B.8: Setting the flow temperature
Euro B/S 080/1
Setting the external controls
●Set the room thermostat (3) and/or
the thermostatic radiator valves (4)
according to the instructions
supplied with the control(s).
HINT! Vaillant offer room thermostat/
time control accessories which
give accurate and economic
room temperature control as
well as improved comfort.
Ask your installer!
The boiler will now operate
automatically to provide central
heating for the conditions selected on
the external controls (TURBOmax Plus
will also provide domestic hot water
on demand).
Whilst the boiler is operating, the
boiler display (1, fig. B.2) indicates
the temperature of the water within
the boiler circuit. After the boiler
stops operating the pump and fan
will continue to operate for a short
period to fully disperse the heat from
the boiler.
Note:
The boiler incorporates an anti-
cycling economiser control to
prevent energy wasteful ON and
OFF operation of the boiler for
short periods when in the central
heating mode. When turning the
room thermostat to a higher setting
there may therefore be a short
delay before the boiler operates.
34
Fig. B.9: Setting the external controller
Euro B/S 014/0
Heating operation
Setting the maximum radiator
temperature control
●Turn the main switch (1) to the „l“
position.
●Set the maximum radiator
temperature control to the desired
setting using the control knob (2).
We recommend the following
settings:
-Left setting during spring and
autumn,
-Middle setting during mild
winter,
-Right setting during cold winter.

14
OPERATION
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STOP
max. 3 x
Fig. B.11: Reset
Euro B/S 083/1
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Fig. B.10: Reset
Euro B/S 082/1
Resetting the appliance
When a hot water tap (TURBOmax
Plus only) or the central heating
system requires heat, the boiler auto-
matically ignites and starts to operate.
If the automatic ignition is not suc-
cessful within 10 seconds, then the
boiler does not go into operation and
switches to „Lock out“.
This is indicated visually by the red
indicator light (1) and the displaying
of fault code „F.28“ or „F.29“ (flame
extinguished during operation). A
new attempt to ignite the flame can
then only be performed after pressing
the „Reset“ button.
●Press the „Reset“ button (2) and
hold for approx. 1 second.
If the boiler still shuts off after
a third attempt, then please
consult your installer or
Vaillant Service Solutions.
The boiler also switches to „Fault“
when there is not enough water in the
system. This fault is indicated by fault
code „F 22“. The boiler can only be
placed back in operation after the
heating system has been properly
refilled with water (see page 10).
In the unlikely event of any other fault
developing, which prevents the boiler
from operating, the display will also
show other fault codes. If a fault code
is displayed please contact your
installer or Vaillant Service Solutions.
Note:
If contacting Vaillant Service
Solutions please remember to
quote the fault code, as this will
help to pinpoint the fault.

15
OPERATION
Turning the boiler OFF
(TURBOmax Plus only)
To turn OFF the central heating
only (Summer mode)
●Turn the maximum radiator
temperature control knob used to
control the heating supply
temperature (1) all the way to the
left.
HINT! You can switch off the heating
operation in summer, for
example, but the boiler will
continue to provide domestic
hot water whenever a hot water
tap is opened.
VRC-VC
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Fig. B.13: Shutting down the unit completely
Euro B/S 124/1
VRC-VC
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Fig. B.12: Setting the summer operating mode
Euro B/S 123/1
To turn OFF central heating and
hot water for short periods of
time
●Turn the main ON/OFF control (2)
to the „0“ position.
☞If you want to turn the
TURBOmax Plus boiler OFF
for a longer period of time
(e.g. holidays), and there is
no danger of frost, then you
should also turn off the gas
supply, the cold water service
valve (see page 9) and the
electrical supply. Please note
the frost protection hints in this
regard (page 17).
TURBOmax Plus

16
OPERATION
Turning the boiler OFF
(THERMOcompact only)
To turn OFF the central heating
●Turn the maximum radiator
temperature control knob used to
control the heating supply
temperature (1) all the way to the
left.
HINT! Do not turn the
THERMOcompact boiler OFF
if a hot water cylinder is also
incorporated in the system
unless there is no demand for
domestic hot water.
VRC-VC
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THERMOcompact
Fig. B.15: Shutting down the unit completely
Euro B/S_VC_088/1
VRC-VC
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THERMOcompact
Fig. B.14: Setting the summer operating mode
Euro B/S_VC_087/1
To turn boiler OFF for short
periods of time
●Turn the main ON/OFF control (2)
to the „0“ position.
☞Do not turn the
THERMOcompact boiler OFF
if a hot water cylinder is also
incorporated in the system
unless there is no demand for
domestic hot water.
THERMOcompact

17
OPERATION
Troubleshooting
In the unlikely event that a problem
occurs with the operation of the
TURBOmax Plus or THERMOcompact
boiler, the following points should be
checked:
1. Boiler fails to operate:
●Is the gas supply turned on? (see
page 9)
●Is the water supply turned on? (see
page 9)
●Is there enough water in the
heating system? (see page 10)
●Is the electrical supply switched
ON?
●Is the main ON/OFF control in the
„ON” position? (switch position
„I“) (see page 10)
●Is the burner lock out indicator
light illuminated? (see page 14)
2. Hot water operates but no central
heating (TURBOmax Plus only)
●Is the heating turned ON? (see
page 13).
●Are all external heating controls
ON? (see page 13)
If your boiler still does not operate
then please consult your installer or
Vaillant Service Solutions
(0870 6060 777).
Care and maintenance
Clean the outer casing of your boiler
with a damp cloth and a little soap.
Do not use abrasive or solvent
cleaning agents that may damage
the case or the plastic fittings.
The appliance should be serviced at
least once per year. To ensure regular
servicing, it is strongly recommended
that arrangements are made with
your service agent or Vaillant Ltd. For
further details please contact Vaillant
Service Solutions: (0870 6060777).
Frost protection
Your boiler is equipped with a frost
protection function:
If the heating water temperature
drops below 5 °C when the main
switch is ON, then the boiler goes
into operation and heats the boiler
circuit to approx. 30 °C.
It cannot be guaranteed that
water will circulate throughout
the entire heating system.
If the boiler is not operated for
several hours during very cold
weather there is therefore the
possibility of the system freezing.
Please ensure that if you are absent
during a period of frost the central
heating remains in operation and all
rooms are kept above freezing point.
It must be remembered, however, that
the boiler will be automatically
switched off by the built in monitoring
devices if certain faults occur, e.g.
interruption in the gas or electricity
supply or faults in the flue gas system.
To overcome this possibility you can
drain both the central heating system
and boiler.
Frost protection and
monitoring devices can only
function when the main switch
of the unit is set to the „I“
position and the boiler is
connected to the electrical
supply.

18
OPERATION
Status display
(For maintenance and service work
performed by your installer or service
agent)
The status displays are activated by
pressing the „i“ button (1). The
current status code, e.g. „S.34“ for
the frost protection mode, is shown
on the display (2).
Pressing the „i“ button again will
switch you back to the normal mode.
The „+“ and „-“ buttons will only be
used by your installer or service agent
during service and maintenance
work.
2
1
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Fig. B.16: Status displays
Table B.1: Status displays (A complete overview of the status codes can be found in the installation instructions).
* Heating operation
** Hot water operation (TURBOmax Plus only)
Euro B/S 081/1
Display Meaning
S.00* No heating required
S.01* Fan running
S.03* Ignition sequence
S.04* Burner ignited
S.05* Fan and water pump over run
S.07* Water pump over run
S.08* Anti cycling mode (after heating operation)
S.10** Hot water demand
S.34* Frost protection mode
S.14** Burner ignited

19

83 36 90 GB10 · 03/2001 Mü · Printed on 100 % recycled paper · Subject to alteration
Head Office
Vaillant Ltd., Vaillant House,
Medway City Estate, Trident Close,
Rochester, Kent ME 2 4EZ
Service Solutions 0870 6060 777
Technical Advice 01634 292392